Product basic parameters and core structure
1. Main structure: Horizontal or vertical pressure bearing shell, with a first stage coalescence filter element and a second stage separation filter element arranged in sequence along the flow direction inside. The bottom is equipped with a water collection bag (liquid storage chamber), a manual drain valve, and an automatic drain interface. The cylinder is equipped with a pressure difference gauge, a liquid level gauge, a maintenance manhole, and a vent.
2. Core filter element: The first stage aggregation filter element adopts a glass fiber aggregation layer and a stainless steel skeleton, responsible for aggregating and growing small droplets; The secondary separation filter adopts a hydrophobic (or oleophobic) aggregation network structure to block the penetration of polymerized droplets and only allow clean fluids to pass through.
3. Separation accuracy: It can separate droplets of 0.3 μ m or more in the fluid. After dehydration, the outlet water content of the oil can be controlled within 10ppm. The residual oil content of compressed air and natural gas after oil removal can reach the level of 0.01~0.1ppm.
4. Specification parameters: Design pressure of 0.1~1.6MPa, higher pressure levels can be customized as needed; Working temperature -20 ℃~120 ℃; A single unit can handle a flow rate of 1-100m ³/h, and multiple units can be connected in parallel to expand high flow conditions.
5. Material selection: The shell can be made of corrosion-resistant carbon steel, 304 stainless steel, or 316L stainless steel; The filter end cap and frame can be made of galvanized carbon steel or stainless steel; Seals can be selected from nitrile rubber, fluororubber PTFE， Suitable for oil products, solvents, and corrosive media.
6. Operating principle: After entering the shell, the liquid containing fluid first passes through a coalescence filter element. Micro sized water droplets (oil droplets) wet, collide, and aggregate on the fiber surface, gradually growing into millimeter sized liquid droplets; The fluid carrying large droplets enters the separation filter element, and the droplets are blocked by the hydrophobic network and settle to the bottom collection bag under the action of gravity; Clean fluid flows out from the outlet, and accumulated water (oil) is regularly discharged through the drain valve.
7. Drainage method: Manual drainage is standard, and automatic drainage valve and liquid level sensor can be selected to achieve automatic discharge of the water collection bag when the liquid level reaches the limit, reducing manual intervention.
8. Differential pressure monitoring: Install differential pressure gauges or transmitters at the inlet and outlet. When the filter element is clogged or the coalescence layer is saturated, if the differential pressure increases, it will prompt the replacement of the filter element.
9. Structural features: The filter element adopts a quick installation end cap or pull rod compression structure, which can be removed and replaced as a whole by opening the cap. Maintenance does not require cutting the pipeline.
10. Factory inspection: Each device completes shell hydrostatic testing, air tightness testing, filter assembly sealing inspection, supporting product drawings, material certificates, and qualification certificates to meet the acceptance requirements of petrochemical, power, and aviation projects.
Applicable industries and equipment operating conditions of the product
1. Aviation and oil storage and transportation: Jet A-1 aviation kerosene and jet fuel are deeply dehydrated to remove impurities. The airport oil depot and fuel truck filter separator are equipped with primary coalescence and secondary separation to ensure that the fuel cleanliness meets aviation standards.
2. Petroleum refining and oil fields: dehydration and impurity removal of diesel, gasoline, crude oil, lubricating oil, and transformer oil; Oil removal from oilfield reinjection water and pretreatment of oily wastewater to reduce oil content in water and meet reinjection and discharge standards.
3. Natural gas and gas transmission and distribution: Oil and water removal are carried out in front of natural gas long-distance pipelines, gate stations, and pressure regulating stations to remove pipeline condensate and compressor lubricating oil mist, and to protect pressure regulating valves, flow meters, and downstream combustion equipment.
4. Compressed air system: After the screw compressor is installed, it removes oil and water, and serves as a pre purification unit for freeze dryer and adsorption dryer, providing clean air source for pneumatic instruments, spraying, food and pharmaceutical use.
5. Hydraulic and lubrication system: Hydraulic oil, turbine oil, and gear oil are dehydrated and purified online to remove free water and emulsified water in the oil, preventing oil emulsification deterioration, bearing corrosion, and valve jamming.
6. Ships and engineering machinery: Purification of marine fuel and engine oil to adapt to high humidity conditions at sea and ensure stable operation of the main engine fuel system.
The positioning difference between the agglomeration separator and conventional basket, bag, and precision filters is clear. Conventional filters aim to intercept solid particles and remove impurities through the aperture of the filter screen; The coalescence separator solves the problem of liquid-liquid two-phase coexistence, relying on the emulsion breaking polymerization and density difference settling of coalescence materials to complete water oil separation. The two are often used in series - the front-end filter removes particles, and the back-end coalescence separator dehydrates, forming a complete fluid purification chain.
Core competitive advantages of the product
1. High separation accuracy and thorough dehydration. It can remove free water and emulsified water above 0.3 μ m, and the outlet water content is stable at ppm level, solving the root problems of oil turbidity, emulsification, and oxidation degradation.
2. The division of labor between the two-stage filter elements is clear, and the separation efficiency is stable. The aggregation layer is responsible for growing droplets, while the separation layer is responsible for intercepting droplets, each performing their own duties to avoid efficiency degradation caused by the "aggregation and separation" of single-stage filter elements.
3. Low pressure loss and high flow capacity. The effective filtering area of the filter element is sufficient, and the normal pressure difference is controlled at 0.02~0.05MPa, which does not affect the system flow and downstream equipment operation.
4. Drainage is visible and controllable. Equipped with a liquid level gauge and automatic drainage system, the liquid level in the collection tank is clear at a glance, avoiding secondary pollution caused by water accumulation and backflow.
5. The filter element is easy to replace and has low maintenance costs. Quick installation end cover with pull-out filter element, single replacement only takes about ten minutes, without the need for special tools, reducing downtime losses.
6. Wide range of material adaptability. Carbon steel anti-corrosion to 316L stainless steel full series shell, multiple sealing materials to choose from, balancing atmospheric oil and high-pressure corrosive medium working conditions.
Frequently Asked Questions (FAQ)
Q1: What is the working principle of the coalescence separator?
A: The liquid containing fluid first passes through a primary coalescence filter, where micrometer sized water droplets (or oil droplets) wet, collide, and merge on the surface of the glass fiber coalescence layer, gradually growing into millimeter sized large droplets; Subsequently, it enters the secondary separation filter element, and the large droplets are blocked by the hydrophobic (oil repellent) mesh surface, unable to penetrate. Under the action of gravity, they settle to the bottom water collection bag, and the clean fluid flows out from the outlet. After the accumulated water (oil) reaches a certain liquid level, it is discharged through the drain valve to complete the separation of oil and water phases.
Q2: What is the difference between a coalescing filter and a separating filter, and can they be used separately?
A: The function of the coalescence filter is to allow small droplets to grow, while the function of the separation filter is to block the already grown droplets. The two must be used in series. When using a coalescence filter element alone, droplets will be carried out with the fluid. When using a separation filter element alone, tiny droplets cannot be intercepted. Only a two-stage combination can achieve a ppm level dehydration effect.
Q3: What are the water and oil content indicators for export?
A: Under oil dehydration conditions, the free water content at the outlet can generally be controlled within 10ppm; Under compressed air and natural gas oil removal conditions, the residual oil content can reach 0.01~0.1ppm. The specific indicators are related to the selection of inlet moisture content, flow rate, and filter element accuracy.
Q4: How often is the filter replaced?
A: Based on the pressure difference. During normal operation, the pressure difference is 0.02~0.05MPa. When the pressure difference rises to 0.1~0.15MPa (or the upper limit set by the manufacturer), it should be replaced. The replacement cycle for working conditions with high liquid content and impurities is short, and the clean oil can last for more than six months.
Q5: Can a coalescence separator be used for natural gas and compressed air?
A: Okay. The removal of oil and water from natural gas and compressed air belongs to typical gas-liquid separation conditions. By selecting the corresponding gas phase coalescence separation filter element and combining it with automatic bottom drainage, the condensate and oil mist can be stably removed, protecting downstream pressure regulating valves, flow meters, dryers, and gas equipment.
Q6: What are the differences between regular precision filters and oil filters?
A: Precision filters only remove solid particles and are ineffective for emulsified water and dissolved water; Oil filters are mostly vacuum or heated dehydrators, with large equipment volume and high energy consumption. The coalescence separator completes dehydration by physically coalescing the filter element. It has a compact structure, low pressure loss, and can operate continuously online, making it suitable as an online purification unit for fuel and hydraulic systems.
