Maximum Operating Pressure Coalescer: Unmatched Performance Under Extreme Pressures
Product Introduction
The Maximum Operating Pressure Coalescer is a cutting-edge industrial filtration system engineered to deliver exceptional liquid-gas separation and liquid-liquid coalescence under the highest operational pressures. Designed for demanding environments such as high-pressure natural gas pipelines, aviation fuel systems, and hydraulic machinery, this coalescer operates reliably at pressures exceeding 150 bar (2175 psi) while maintaining 99.99% efficiency in removing submicron contaminants. Its robust construction and advanced coalescing media ensure optimal performance in critical applications where safety, efficiency, and longevity are paramount.
Key Features & Advantages
1. Extreme Pressure Resistance
Rated for 150+ bar: Engineered to withstand pressures beyond industry standards, making it ideal for high-stress environments like deep-sea oil extraction or high-pressure gas transmission.
Burst-Proof Design: Reinforced housing and rupture discs prevent catastrophic failure, ensuring operator safety.
2. Ultra-High Filtration Efficiency
Beta Ratio (β) > 20,000: Removes 99.99% of droplets ≥0.05 μm, including ultrafine aerosols and emulsions that standard filters miss.
Multi-Layer Media: Combines glass microfibers, hydrophobic coatings, and nanofiber layers for superior droplet capture and coalescence.
3. Corrosion Resistance
Materials: 316L stainless steel, duplex stainless steel, or Hastelloy® for resistance to acids (H₂S, CO₂), saltwater, and harsh chemicals.
PTFE-Based Coatings: Non-stick surfaces prevent fouling from hydrocarbons or organic compounds.
4. Energy Efficiency
Low Pressure Drop: Optimized flow paths and large-diameter channels maintain pressure drops below 0.08 bar, reducing pumping costs.
High Turndown Ratio: Maintains efficiency across 20–100% of rated flow rates.
5. Compact & Modular Design
Space-Saving: Up to 40% smaller footprint than traditional separators, ideal for offshore platforms or retrofit projects.
Hot-Swappable Cartridges: Replace media modules without shutting down the entire system.
Working Principle
The Maximum Operating Pressure Coalescer combines advanced fluid dynamics with precision-engineered media to achieve superior separation:
1. Droplet Capture
Fluid (gas or liquid) enters the coalescer and flows through a dense bed of nanostructured fibers. Submicron droplets collide with fibers and aggregate into larger droplets (50–500 μm) due to electrostatic attraction and surface tension.
2. Separation
3. Clean Fluid Discharge
Purified gas/liquid exits through the upper outlet, while collected liquid is drained via an automated valve or manual port.
Application Scenarios
1. High-Pressure Natural Gas Processing
Challenge: Remove water, hydrocarbon condensates, and corrosive acids (H₂S/CO₂) from raw gas at pressures up to 150 bar.
Solution: Ensures compliance with pipeline specifications (ISO 13678) and prevents hydrate formation in subsea pipelines.
2. Aviation Fuel Purification
Challenge: Meet aerospace standards (DEF STAN 91-91) by eliminating free water, surfactants, and particulates at pressures up to 50 bar.
Solution: Delivers <1 ppm free water and <0.3 μm particulate removal for safe turbine operation.
3. Hydraulic Systems
Challenge: Protect pumps and valves from water contamination and emulsions in high-pressure systems (up to 350 bar).
Solution: Breaks emulsions, removes water to <10 ppm, and extends oil life by 50% or more.
Technical Data
Parameter | Specification |
|---|
Model | MPC-300 (Single-Stage), MPC-500 (Multi-Stage) |
Fluid Type | Natural gas, aviation fuel, hydraulic oil, sour gas |
Operating Pressure | 15–150 bar (217–2175 psi) |
Temperature Range | -60°C to +200°C (-76°F to +392°F) |
Flow Rate | 100–100,000 Nm³/h (gas); 50–5000 GPM (liquid) |
Beta Ratio (β) | β≥20,000 @ 0.05 μm; β≥50,000 @ 0.1 μm |
Removal Efficiency | 99.99% for 0.05–3 μm droplets; 99.999% for >3 μm |
Pressure Drop | <0.05 bar @ rated flow |
Lifespan | 24–36 months (depending on contamination levels) |
Certifications | API 618, ISO 16889, ASTM D1655, ASME BPVC |
Maintenance Guidelines
1. Routine Monitoring
2. Cartridge Replacement
3. Cleaning Procedures
Gas Service: Flush with dry nitrogen or compressed air to remove residual moisture.
Liquid Service: Soak in a mild detergent solution (e.g., isopropyl alcohol for aviation fuel), then rinse with deionized water.
4. Troubleshooting
Low Efficiency: Check for media fouling, incorrect installation, or exceeded β-ratio limits.
High ΔP: Clean or replace clogged pre-filters, or inspect for upstream equipment failure.
8 Frequently Asked Questions (FAQs)
1. What sets the Maximum Operating Pressure Coalescer apart from standard separators?
It operates safely at pressures up to 150 bar, uses advanced nanostructured media, and achieves β-ratios >20,000—far exceeding conventional systems.
2. Can it handle sour gas (H₂S/CO₂) at extreme pressures?
Yes. Materials like Hastelloy® C276 resist corrosion, ensuring reliable performance in H₂S-rich environments.
3. How does it perform in high-temperature applications?
Specialized PTFE coatings and thermal-resistant alloys allow operation up to 200°C without degradation.
4. Is it suitable for offshore oil platforms?
Absolutely. Compact design, corrosion resistance, and explosion-proof features make it ideal for harsh marine environments.
5. What is the maximum flow rate for hydraulic systems?
Up to 5000 GPM for multi-stage configurations, with pressure drops <0.08 bar.
6. Does it meet aerospace industry standards?
Yes. Certified to DEF STAN 91-91 and IATA requirements for jet fuel purity.
7. Can it be used for cryogenic LNG applications?
Specialized cryogenic models operate down to -162°C, ensuring efficient separation of water and hydrocarbons in liquefied natural gas systems.
8. What is the ROI of upgrading to a High-Pressure Coalescer?
Customers typically achieve payback in 6–12 months through reduced maintenance, extended equipment life, and improved process efficiency.
Conclusion
The Maximum Operating Pressure Coalescer redefines reliability under extreme conditions. Whether purifying natural gas, protecting jet engines, or optimizing hydraulic systems, its unmatched pressure tolerance, efficiency, and durability ensure peak performance. By investing in this technology, operators safeguard their assets and maximize profitability in the most demanding environments.
Need a custom solution? Contact our engineers today to design a coalescer tailored to your exact needs.
