Condensate Formation

Steam loses heat during transport condensing to water. Pressure reduction through control valves causes flash cooling condensing steam. Heat transfer equipment generates condensate. Separators remove liquid water before steam reaches turbines, process equipment, or distribution headers.

Separator Design

Vertical vessel with steam inlet, baffle separating liquid droplets, wire mesh mist eliminator, dry steam outlet, and condensate drain to recovery system. Internal design promotes gravity separation while maintaining low pressure drop.

Operating Pressure

Matches steam system pressure from low-pressure heating steam at 5-15 psig to process steam at 150-600 psig. Design accommodates pressure with appropriate safety factors. Materials handle saturated steam temperatures.

Separation Mechanism

Inlet momentum break allows gravity separation. Baffles create tortuous path forcing directional changes. Heavier water droplets fall while lighter steam rises. Mesh pad captures remaining moisture. Combined stages achieve dry steam quality.

Material Selection

Carbon steel construction for steam and condensate service. Design handles thermal cycling during startup and operation. Proper drainage prevents water hammer. Insulation maintains temperature reducing external condensation.

Steam Quality

Inlet steam may contain 5-10% moisture. Separator reduces moisture to under 1% delivering dry steam protecting equipment. Critical for turbines requiring dry steam preventing blade erosion. Process applications need specific steam quality.

Condensate Recovery

Separated water drains to condensate return system. Steam traps prevent steam loss while allowing liquid removal. Recovered condensate returns to boiler feedwater reducing makeup requirements and treatment costs.

Applications

Steam turbine inlet protection, process steam distribution headers, steam tracing systems, heating steam supply, and any application requiring dry steam. Found in power plants, refineries, chemical facilities, and industrial steam systems.

Level Control

Simple drain systems using float-operated steam traps. Automatic operation without external power. Reliable condensate removal maintaining separator performance. Backup drains handle upset conditions.

Performance Benefits

Protects turbines from water erosion extending blade life. Maintains process steam quality for consistent heat transfer. Prevents water hammer in distribution systems. Recovers condensate for boiler feedwater reducing costs.

Construction Standards

Design per ASME Section I for power boilers or ASME Section VIII for process applications. Materials suitable for steam service. Relief protection against overpressure. Complete documentation with capacity calculations.

ERGIL steam condensate separators deliver dry steam quality protecting equipment and improving system efficiency in industrial steam applications.