Repalcement PALL Separatpor Cartridge
Separator Cartridge is a key functional component for high-efficiency two-phase separation, the core matching part of coalescence separation equipment. It is specially designed for the separation of large droplets formed by coalescence, with high-precision liquid blocking and phase separation performance. It can effectively separate the coalesced large liquid droplets from the base medium, and intercept fine solid impurities at the same time.
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Product Introduction
Separator Cartridge is a key functional component for high-efficiency two-phase separation, the core matching part of coalescence separation equipment. It is specially designed for the separation of large droplets formed by coalescence, with high-precision liquid blocking and phase separation performance. It can effectively separate the coalesced large liquid droplets from the base medium, and intercept fine solid impurities at the same time. As a standard replaceable component, it is widely matched with vertical/horizontal coalescers in petroleum, chemical, natural gas, electric power and other industries, and is essential for the deep purification of industrial fluids.
Working principle
Pre-interception of large particles
The outer layer of the Separator Cartridge is designed with a coarse filtration layer, made of high-strength fiber and porous mesh materials. It can pre-intercept large solid particles and agglomerated impurity clusters in the fluid, avoid the blockage of the inner separation layer by large impurities, and prevent the coalesced large liquid droplets from being broken by impurity collision, laying a good foundation for the subsequent efficient separation.
Droplet blocking and separation
After the fluid with coalesced large droplets flows through the inner separation layer, the separation layer relies on its hydrophobic/oleophilic selective wettability and dense pore structure to form a liquid blocking barrier for the target droplets. The base medium can pass through the separation layer smoothly, while the large liquid droplets are completely blocked on the surface of the separation layer, realizing the rapid phase separation of the two immiscible media.
Droplet gathering and drainage
The blocked large liquid droplets continue to gather and merge on the surface of the separation layer to form larger liquid films or liquid beads. Driven by gravity and fluid shear force, these liquid aggregates slide down along the surface of the cartridge to the bottom liquid collection area of the matching coalescer equipment, and are then discharged through the drain valve of the equipment, while the purified base medium flows out through the cartridge to complete the whole separation and purification process.
Structural composition
Separation layer
The core functional layer of the cartridge, made of hydrophobic/oleophilic modified glass fiber, polypropylene or PTFE composite materials. It has the characteristics of high air permeability/liquid permeability of the base medium and strong blocking performance of the target liquid droplets, and the precise pore size design ensures the high efficiency and stability of phase separation, which is the key to realizing droplet separation.
Pre-filtration layer
Covered on the outer side of the separation layer, made of high-strength melt-blown fiber or metal mesh with gradient pore structure. It is responsible for pre-intercepting large solid particles and impurity clusters in the fluid, protecting the separation layer from blockage and damage, and avoiding the secondary breakage of coalesced large droplets.
Reinforcing support skeleton
The internal and external supporting structure of the cartridge, made of 304/316L stainless steel mesh or high-strength engineering plastic. It provides sufficient mechanical support for the separation layer and pre-filtration layer, effectively resisting the impact of fluid pressure, preventing the cartridge from deformation, collapse or damage during long-term operation, and ensuring the structural stability under high working pressure.
Sealing end cover assembly
Located at both ends of the cartridge, made of nitrile rubber, fluororubber or EPDM with excellent sealing performance and chemical corrosion resistance. It realizes the tight connection between the cartridge and the coalescer equipment cavity, completely avoiding the fluid short-circuit phenomenon (the fluid bypasses the functional layer directly), ensuring that all the fluid to be treated passes through the cartridge for effective separation and purification.
Product type
Liquid-liquid Separator Cartridge
Specialized for the separation of two immiscible liquid media, the core matching component of liquid-liquid coalescers (mainly oil-water separation). It is designed for the characteristics of liquid phase fluid, with high liquid permeability of the base liquid and strong blocking performance of the target liquid droplets (water droplets or oil droplets). It is widely used in the dehydration of petroleum products such as aviation kerosene, diesel oil and lubricating oil, the separation of chemical solvent emulsions, and the oil-water separation of industrial wastewater, with common matching precision of 1μm, 3μm and 5μm.
Gas-liquid Separator Cartridge
Specially designed for the separation of liquid droplets in gaseous fluids, the key part of gas-liquid coalescers. It has the characteristics of high gas permeability and ultra-strong liquid droplet blocking performance, which can effectively block the coalesced liquid droplets (≥0.3μm) in the gas phase and prevent the liquid droplets from being carried with the gas flow. It is widely used in the purification of natural gas, compressed air, industrial process gas and waste gas, such as the removal of liquid hydrocarbons and water droplets in natural gas, and the dehydration and deoiling of compressed air in industrial production.
Product Features
High-efficiency phase separation
Adopt high-quality modified separation materials and precise pore size gradient design, the separation efficiency of coalesced large droplets is as high as 99.99%. It can completely block the target liquid droplets while ensuring the unimpeded flow of the base medium, realizing the deep separation of two immiscible media, and the purified medium can meet the high-precision process requirements of various industries.
Stable and corrosion-resistant
The separation layer and pre-filtration layer are made of chemical corrosion-resistant fiber materials, which can resist the erosion of acidic, alkaline, organic solvents and other harsh media, and are not easy to age, deform or break. The stainless steel support skeleton has high pressure resistance and temperature resistance, and the cartridge can stably operate under the working pressure of 0.6-10MPa and the temperature of -20℃~120℃, with a long service life and low failure rate.
Standard modular design
Follow the industrial universal specification design, with unified outer diameter, length and interface size, which can be perfectly matched with various mainstream coalescer equipment on the market (Pall, Parker, Liffilt and other brands). It is compatible with vertical and horizontal coalescers, and there is no need to modify the equipment during replacement, which is highly universal.
Easy maintenance and replacement
The overall structure is simple, and the disassembly and replacement do not require complex professional tools and technical personnel. On-site operators can complete the replacement operation in a short time, effectively reducing the equipment shutdown time and maintenance workload, and ensuring the continuous and stable operation of the production line.
Low comprehensive operating cost
The product has high cost performance, with long service life under normal working conditions, which reduces the frequency of replacement and the consumption of spare parts. The replacement process does not need additional auxiliary materials, the daily maintenance is only simple pressure difference monitoring, and the whole life cycle operating cost is low, which effectively reduces the enterprise's fluid purification cost.
Application area
Petrochemical industry
As the core consumable of petrochemical coalescence separation equipment, it is widely used in crude oil dehydration and desalination, deep purification of aviation kerosene, diesel oil and lubricating oil, and separation of chemical solvent emulsions. It can effectively separate water and solid impurities in oil products and chemical raw materials, improve product purity and quality, and avoid the corrosion and blockage of downstream refining, transportation and storage equipment.
Natural gas industry
Matched with natural gas coalescers, it is used in the whole process of natural gas extraction, gathering and transportation, processing and purification. It can efficiently separate liquid hydrocarbons, water droplets and solid particle impurities in natural gas, prevent the formation of hydrates in natural gas pipelines, avoid pipeline corrosion and blockage, improve the calorific value and purity of natural gas, and ensure the safe and efficient transportation and use of natural gas.
Electric power industry
It is matched with oil coalescers for the dehydration and impurity removal of industrial oil such as turbine oil, hydraulic oil and transformer oil in thermal power, hydropower and wind power plants. It can separate micro water droplets and fine solid impurities in the oil, ensure the good lubrication, insulation and cooling performance of the oil, protect steam turbines, transformers and other key equipment from wear and short circuit, and ensure the safe and stable operation of the power system.
Water treatment industry
Matched with industrial wastewater coalescers, it is used for the oil-water separation of oil-containing sewage, the purification of industrial wastewater and the pretreatment of seawater desalination. It can efficiently separate oil droplets and suspended solid pollutants in water, reduce the pollutant content in water, make the treated water meet the environmental protection emission standards or industrial recycling requirements, and improve the utilization rate of water resources.
General industrial field
It is widely used in the compressed air purification, process gas dehydration and deoiling of machinery, electronics, pharmaceutical and food processing industries. It can remove liquid droplets and fine impurities in the gas phase, ensure the cleanliness of the gas used in production, avoid the impact of liquid and impurity on product quality and production equipment, and meet the clean production requirements of various industries.
FAQ (Top 5 Concerns of Customers)
1. What is the general service life of the Separator Cartridge?
The service life is mainly determined by the medium impurity content, working flow and operating pressure, generally 3-6 months under normal working conditions (medium solid content ≤10ppm, flow and pressure matching equipment design). For media with high impurity content and high working pressure, the service life is about 1-2 months. It is recommended to judge the replacement time by monitoring the pressure difference at both ends of the cartridge in real time.
2. How to select the suitable Separator Cartridge for the existing coalescer equipment?
The selection is based on three core factors: separation type (liquid-liquid/gas-liquid), equipment model and specification (cartridge outer diameter, length and interface size), and process requirements (matching filtration precision, working temperature and pressure). We can provide professional matching schemes according to your equipment brand, model and production process parameters, and support non-standard specification customization.
3. What materials are the Separator Cartridges made of, and how to select them according to the medium?
The main core materials are modified glass fiber, polypropylene (PP) and polytetrafluoroethylene (PTFE). Modified glass fiber is suitable for general oil-water separation and gas-liquid separation under normal conditions; PP is food-grade non-toxic material, suitable for food, beverage and aqueous medium separation; PTFE has super strong corrosion resistance, suitable for acidic, alkaline and strong corrosive chemical medium separation.
4. What are the judgment criteria for timely replacement of the Separator Cartridge?
There are three clear judgment criteria: ① The pressure difference at both ends of the cartridge exceeds the rated value (generally 0.15-0.2MPa), and the pressure difference cannot be reduced after cleaning; ② The purification separation effect is significantly reduced, and the water content/impurity content of the treated medium fails to meet the process quality requirements; ③ The cartridge is deformed, damaged, aged or the sealing part is invalid, resulting in fluid short-circuit and separation failure.
5. Can the Separator Cartridge be customized for special working conditions such as high temperature and high pressure?
Yes, we support full-customized production for various special working conditions, including non-standard specifications (outer diameter, length, interface), high-temperature resistant (≤200℃) and high-pressure resistant (≥10MPa) material customization, special corrosion-resistant coating treatment and ultra-high precision separation layer design. You only need to provide specific process parameters and working condition requirements, and we will design and produce matching products.
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