Condensate Management System for Air Compressors

An Affordable Way to Treat Oily Air Compressor Condensate

As environmental standards increase, it becomes increasingly important to trap the oil within an air compressors waste discharge. Robust, deceptively simple, yet designed for the unexpected, you'll find that our F15AC can fit any budget, almost any size compressor system, and should be part of any condensate management system.

• Did you know it is unlawful to drain your air compressor condensate directly to the sewer without first treating it for harmful contaminants?
• The Clean Water Act of 1970 created the Environmental Protection Agency (EPA) which is currently enforcing its regulations to maintain a safe and green environment.
• Title 40, Part 279 of the Code of Federal Regulations dictates the Rules Governing Proper Handling and Disposal of Used Oil. These rules specify that there can be no more than 40 ppm oil in the waste water drained to sewers.
• Some local regulations are even stricter, depending upon a municipality's ability to treat the wastewater at the local level.
• Most compressor condensate contains a minimum of 300 ppm of oil, so dispensing it directly to your drain is a thing of the past, as you face large fines if your facility is inspected.

Why separate air compressor condensate yourself?

A compressed air system produces condensation, which is the moisture that drops out of a compressed air flow as it cools. This condensation will contain oil if the compressors uses lubrication in its compression chamber. These include oil-flooded rotary screw compressors and reciprocating compressors with lubricated cylinders. This oily water mixture causes an environmental concern, as there are local regulations limiting the amount of lubricants that can be drained into municipal sewer systems

Treating condensate waste on site is simple and effective utilizing the Muscle™ Compressor Coalescer's gravity separation method. This simple method of separation requires no fancy, expensive replacement filters, yet effectively treats most compressor condensate to comply with the EPA's standard as well as those of many local industrial treatment facilities.

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Zebra Muscle™ Lowers Air Compressor Waste Costs Up to 98% Versus Hauling It Off Site

Condensate is mostly water. Expect a 50:1 ratio, 50 parts water to 1 part oil (or just 1 gallon of oil in a 55 gallon drum of condensate).

Air systems can produce an enormous amount of condensate each day. A 100 HP compressor operating in a climate of 70°F with 80% humidity generates 2 gallons of condensate each hour.

Disposal companies charge between $150 to $250 to dispose of a 55 gallon drum of compressor condensate.

The savings are considerable if you separate your condensate on site, paying only to dispose of the oil:

• If you use the numbers above, a 100 HP compressor, operating 24 hours, will produce a minimum of 48 gallons of condensate a day and only 0.96 gallons of this is oil. It will take you 57 days to accumulate (1) 55 gallon drum of oil with a minimum disposal cost of $150.
• In that same 57 days, without separation, you will accumulate almost (50) 55 gallon drums of condensate with a minimum disposal cost of $7,500. The Muscle saves you over $7,000 in disposal cost during 2 months of operating!

Contact Zebra today for more information on the Muscle Compressor Coalescer and how it will minimize your condensate waste stream and treat it effectively to comply with EPA and local municipality regulations!

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Condensate Inlet Clean Water Discharge Waste Oil Discharge Coalescing Media

The Muscle™ Compressor Coalescer for Separating Oil from Air Compressor Condensate

Robust, yet simple, the Muscle Compressor Coalescer fits any budget, and almost any size compressor system, and should be part of any condensate management system.

Do not be fooled by expensive systems with filter elements that require frequent replacement. Although the elements capture dirt, rust, or scale, these are not commonly regulated contaminants or in abundance to pose environmental concern.

Contact Zebra today to determine if this system will meet your condensate management system needs, providing effective treatment to dispense direct to the drain!

Features Include:

• Durable, translucent barrel
• Spin-welded fittings to prevent leaks
• Coalescing media increases surface area for oils
  to readily collect and separate
• No consumable components
• Manual oil drain spigot
• Automatic air release vent
• Automatic de-oiled water drain port
• Will not overflow
• Limited three year warranty!

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How the Muscle Compressor Coalescer Works

Will the Muscle Compressor Coalescer Work for You?

Contact Zebra today to determine if this system will meet your needs, providing effective treatment to dispense direct to the drain! Please provide us the following information:

1. Who is the compressor manufacturer and/or model number?
2. What is the HP or cfm of your compressor?
3. What is the average room temperature in the location of the compressor?
4. What is the average relative humidity in that location?
5. How many hours per day does it operate?
6. What is the appearance of the separated water portion (clear or more milky in nature?)

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Specifications of the Muscle Compressor Coalescer for Air Compressor Condensate

Model Number: F15AC Tank Material: Polyethylene Tank Capacity: 8 gallons (30 liters) Tank Height: 20” (51cm) Tank Diameter: 17” (43cm) Tank Weight: 20 lbs. (9kg) Tank Fittings: Spin-welded Temperature: 41-95°F (5-35°C) Inlet Connection, max.: 1/2” (12.7mm) Inlet Pressure, max.: 150 psi (10.3 barg) Condensate, per release, max.: 1 gallon (3.78 liters) Release Interval, min.: 5 minutes Oil Volume Capacity, max.: 0.75 gallons (2.84 liters) Outlet Connection: 1/2” (12.7mm) Hoses: Not included Air Vent: Automatic Water Release: Automatic Oil Drain: Manual Drum Dolly: #FXDD15, Sold separately Dual Units: Available with manifold when condensate output greater than capacity of one unit

Download Literature F15AC Product Profile F15AC Specifications Sheet F15AC White Paper

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Important Note

This system utilizes the method of gravity separation to separate oil from water. In some cases where there are specialized detergents in a compressor lubricant, a stable oil/water emulsion may remain, and will appear more milky in nature. These emulsions are generally safe to dispose of, however, each municipality will have their own limit based upon oil contaminant content, volumes generated, and their ability to treat it.

Please contact Zebra for more information regarding these emulsions. You may also check with your local municipality to determine contaminant levels and volumes allowed for direct release. In most areas, free testing services are available to determine possible contaminant levels and if they are safe to dispose of without further treatment.

More Information regarding Air Compressor Maintenance

Air compressor maintenance, in regard to properly draining the system, depends upon the volume of air compressor condensate accumulated. The volume of condensate in a system will vary with weather conditions, depending upon the temperature of the air and its humidity.

For instance, a 100 HP compressor, taking in 400 cfm, will accumulate just over .5 gallons of condensate per hour when the air temperature is 50°F having 40% humidity. This same compressor, operating when the air temperature is 80°F with 60% humidity, will generate just under 3 gallons of condensate per hour.

Do not underestimate the possible damage caused by the accumulation of condensate within an air compressor. Left to build up, rust and scale will accumulate within the piping system and eventually ruin machinery reliant on the air supply.