A coalescer is a specialized filtration device designed to separate immiscible liquids (e.g., oil and water) or remove liquid aerosols and fine particulate matter from gas streams. By merging tiny droplets into larger ones through coalescence, it enables efficient separation via gravity or mechanical means. Widely used in oil and gas, petrochemical, and industrial processing, coalescers enhance system efficiency, protect downstream equipment, and ensure compliance with environmental regulations.
Working Principle:
Coalescence Process: Microscopic liquid droplets or particles collide and merge within a multi-layered media (e.g., glass fiber, PTFE), forming larger droplets that settle or are drained.
Separation: Combined with gravity or centrifugal force, separated liquids are collected and removed.
Design Components:
Coalescing Media: Hydrophobic/oleophilic materials (e.g., glass fiber, polymer membranes) optimized for target contaminants.
Support Structure: Stainless steel mesh or sintered metal core for mechanical stability.
Drainage System: Automatic or manual drains to discharge separated liquids.
Applications:
Oil & Gas: Dehydration of natural gas, removal of lubricant aerosols in compressed air.
Aviation: Fuel polishing to eliminate water and particulates.
Chemical Processing: Recovery of solvents or acids from gas streams.
Pharmaceuticals: Sterile gas filtration for cleanroom environments.
Advantages:
High Efficiency: Removes 99.9% of droplets ≥0.3 µm.
Low Pressure Drop: Optimized flow paths minimize energy consumption.
Durability: Resistant to corrosion, high temperatures, and chemical exposure.
Liquid-Liquid Coalescers: Separate emulsified liquids (e.g., oil-water mixtures).
Gas-Liquid Coalescers: Remove liquid aerosols from gas or air streams.
Compact vs. Modular: Customizable for small-scale systems or large industrial plants.
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