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PF-125 · Verified method

Aftercooler Condensate Calculator

Estimate condensate separated when compressed air cools to aftercooler outlet temperature.

Inputs

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ENGINEERING GUIDE

Use the Aftercooler Condensate Calculator to estimate condensate separated when compressed air cools to aftercooler outlet temperature. The calculator uses Compressed actual flow, Inlet temperature, Outlet temperature, Absolute pressure and Inlet RH and reports condensate rate.

How to interpret the result

Read the result in the context of the selected units and pressure basis. For this tool, the primary outputs are condensate rate. Change one input at a time when comparing scenarios so the effect of each variable remains clear.

Formula and methodology

PneumaForge applies this verified method: Moisture saturation difference at constant pressure. The functional engine is shared with related tools in the condensate family, while this page solves the specific intent represented by aftercooler condensate calculator.

Moisture saturation difference at constant pressure

Variables and inputs

  • Compressed actual flow
  • Inlet temperature
  • Outlet temperature
  • Absolute pressure
  • Inlet RH

Worked example

Reproducible example: start with the calculator's default values (Compressed actual flow = 5000; Inlet temperature = 45; Outlet temperature = 30; Absolute pressure = 8) and calculate the result. Then change the variable most relevant to your application and compare the new condensate rate against the baseline.

Assumptions and limits

Mass basis avoids the error of comparing g/m³ at different pressures directly. Water density only used to convert mass to liquid volume.

Engineering tips

  • Use absolute total pressure in psychrometric calculations.
  • Compare moisture on a dry-air mass basis when pressure changes significantly.
  • Use correction factors from the actual dryer manufacturer rather than universal tables.
  • Keep the inputs used for aftercooler condensate calculator on a consistent engineering basis before comparing alternatives.

Frequently asked questions

What does the Aftercooler Condensate Calculator calculate?

It is designed to estimate condensate separated when compressed air cools to aftercooler outlet temperature. The reported outputs are condensate rate.

What inputs does the Aftercooler Condensate Calculator use?

The calculator uses Compressed actual flow, Inlet temperature, Outlet temperature, Absolute pressure and Inlet RH. Only use values that represent the same operating condition or design case.

What formula or method is used?

The calculation follows: Moisture saturation difference at constant pressure. The page also states the assumptions that define where the method is valid.

Which assumptions can affect the result?

Mass basis avoids the error of comparing g/m³ at different pressures directly. Water density only used to convert mass to liquid volume.

Can I use different units?

Yes. PneumaForge converts supported units through canonical engineering units. For compressed-air reference flows and pressure bases, the reference pressure and temperature must also remain consistent.