The number of filter cartridges
and their size depends upon the separator size, fineness of droplets to remove
and the liquid removal rate required for your application. Whereas we’ll
use a 0.01 micron filter cartridge for 0.2 micron droplet removal, there are
other porosities used for coalescing droplets as large as 4 microns.
The body of a coalescing separator is more complex than
a standard vortex style centrifugal separator because internally media needs to
be secured and externally the vessel itself has to be designed to provide access
to the media for replacement.
While our standard centrifugal separators consist
of a fully welded body without need to access the internals, coalescing
separators need to have a flanged body and this adds to the cost of the vessel.
Internally there needs to be support structures to hold the media in-place and
in the case of filter cartridge coalescing, each cartridge needs to be properly
sealed and plumbed to drain to a common port which is then routed to the
exterior of the vessel and common drain line.
Coalescing separators differ from
standard centrifugal separators because they will require periodic maintenance
if the process gas or liquid separated contain solids. Such build-up of
solids will eventually reduce the open area (increase differential pressure) and
affect the coalescing efficiency. Whereas mesh pads are likely cleanable,
filter cartridges require replacement. Coalescing separators come standard
with differential pressure gauge ports so you can install a gauge and monitor
changes in differential pressure.
Applications for coalescing vortex
The vast majority of centrifugal separator applications involve
removing liquid condensate from steam or compressed air and the removal of
droplets larger than 10 microns with 99% efficiency is sufficient.
Coalescer separators can be used for steam and air systems if you have a
requirement for such fine droplet removal, but they are more often used in
refrigeration, petrochemical and fine chemical processing applications where the
droplets are considered the “product to be recovered” or higher removal
efficiencies benefit the downstream process, by either protecting piping
components or purifying the gas itself.
applications include removing water and hydrocarbon liquids from natural gas to
improve its quality and protect downstream compressors, turbines, absorbers,
heat exchangers and instrumentation from contamination or damage.
compressor systems often leak lubrication oil and coalescer separators maximize
the volume of such oils recovered. These large compressors are common for
many types of industrial manufacturing processes including plastics
manufacturing, fertilizer production and any type process using industrial gases
that are either used for production or result as a byproduct of the
CNC machining applications utilizing high pressure coolant
generate a high volume of fine oily mist from both heat transfer and high
velocity impingement between the tool and the part. Coalescing separators
are an important component of air scrubbing systems which ensure the vented air
is safe for the personnel and environment.
Custom fabricated design
our carbon steel, stainless steel and exotic alloy vortex separators are custom
fabricated, which enables us to adjust the nozzle size or orientation,
connection types and inspection ports to meet your specific application
requirements. All of our custom fabricated separators are designed and
engineered in accordance with ASME Code, Section VIII, Division 1 and can be
ASME U code stamped.
To properly size a coalescer separator for your application we need to