Hydrocarbon Resistant Coalescer: Reliable Separation in Hydrocarbon-Rich Environments
Product Introduction
The Hydrocarbon Resistant Coalescer is a specialized filtration system engineered to deliver uncompromised gas-liquid and liquid-liquid separation in environments dominated by hydrocarbons—including natural gas, crude oil, aviation fuel, and hydraulic oils. Unlike conventional coalescers, which degrade rapidly when exposed to hydrocarbon solvents (causing material swelling, seal failure, or efficiency loss), this coalescer combines hydrocarbon-inert materials, chemically stabilized media, and robust structural design to maintain 99.9%+ contaminant removal efficiency.
Industries such as oil and gas production, aviation fuel handling, and industrial lubrication face unique challenges in hydrocarbon-rich settings: emulsified oil-water mixtures, entrained hydrocarbon droplets in gas streams, and corrosive condensates (e.g., naphthenic acids in crude oil). The Hydrocarbon Resistant Coalescer eliminates these risks, protecting downstream equipment (compressors, turbines, pumps), ensuring product purity, and reducing operational costs.
Key Features & Advantages
1. Superior Hydrocarbon Resistance
Inert Material Construction: Housing made from 316L stainless steel with electropolished surfaces or Hastelloy® C-276 resists hydrocarbon-induced corrosion (e.g., naphthenic acid corrosion in crude oil).
Hydrocarbon-Resistant Media: Proprietary fluoropolymer-coated glass microfibers or PTFE-impregnated polymer composites prevent swelling, dissolution, or degradation when exposed to alkanes, aromatics, or crude oil fractions.
Seal Integrity: FFKM (perfluoroelastomer) seals withstand hydrocarbon permeation, avoiding leaks even in high-solvent environments.
2. High-Efficiency Coalescence in Hydrocarbon Streams
Beta Ratio (β) > 25,000: Removes 99.9% of droplets ≥0.1 μm, including emulsified hydrocarbon-water mixtures and entrained oil mist in gas streams.
Multi-Stage Design: Optional pre-coalescers (for bulk hydrocarbon removal) and fine coalescers (for submicron droplets) ensure tailored performance in complex streams.
3. Extreme Environmental Tolerance
Temperature Range: -60°C to +200°C (-76°F to +392°F), with cryogenic variants for LNG (liquefied natural gas) and high-temperature models for refinery off-gases.
Pressure Resistance: Rated for up to 250 bar (3625 psi), suitable for high-pressure oil/gas pipelines and hydraulic systems.
4. Longevity & Cost Efficiency
Extended Lifespan: 36–60 months in hydrocarbon-rich environments (vs. 6–12 months for standard coalescers), driven by inert materials and anti-fouling media.
Low Maintenance: Hot-swappable cartridges and self-cleaning media reduce downtime by 50% during oil changeouts.
5. Compliance with Industry Standards
Certifications: API 618 (gas processing), ISO 16889 (hydraulic fluids), ASTM D1655 (aviation fuel), and NACE MR0175 (sour hydrocarbon service).
Working Principle
The Hydrocarbon Resistant Coalescer integrates hydrocarbon inertness with proven coalescence mechanics to ensure stable separation:
1. Hydrocarbon-Resistant Media Interaction
Fluid (gas or liquid) enters the coalescer and flows through the fluoropolymer-coated microfibers. Hydrocarbons (e.g., crude oil, jet fuel) do not degrade the media, as the inert coating repels absorption and prevents swelling.
2. Droplet Capture & Coalescence
Capture: Submicron droplets (0.1–5 μm) of water, emulsified oil, or contaminants collide with media fibers via turbulent flow and electrostatic attraction.
Merging: Captured droplets merge into larger aggregates (50–1000 μm) due to the media’s tortuous pathways and hydrophobic/hydrophilic coatings. The hydrocarbon-resistant design ensures consistent fiber spacing, even in oil-saturated streams.
3. Separation & Discharge
Gravity Separation: Enlarged droplets settle at the bottom of the housing (e.g., water in crude oil, free water in jet fuel).
Clean Fluid Exit: Purified gas/liquid exits through the upper outlet, while collected hydrocarbon/water mixture is drained via a heated valve (prevents freezing in cold climates).
Application Scenarios
1. Natural Gas/Oil & Gas Hydrocarbon Separation
Challenge: Raw natural gas contains entrained hydrocarbon condensates (C2–C5 alkanes) and water, which form emulsions that foul compressors and reduce pipeline efficiency. Sour gas (H₂S + hydrocarbons) exacerbates corrosion.
Solution: Removes 99.9% of hydrocarbon droplets ≥0.1 μm and water, meeting ISO 13678 pipeline specs. Hastelloy® C-276 housing resists sour hydrocarbon corrosion, protecting compressors and extending pipeline life.
2. Aviation Fuel Hydrocarbon Purity
Challenge: Jet fuel (Jet A-1) may contain trace hydrocarbons (e.g., from storage tank contamination) and emulsified water, risking icing in fuel lines or engine injector clogging.
Solution: FFKM seals and fluoropolymer media prevent hydrocarbon absorption, ensuring <1 ppm free water and <0.3 μm particulate removal (compliant with ASTM D1655 and DEF STAN 91-91).
3. Hydraulic Oil/Lubricant Hydrocarbon Protection
Challenge: Hydraulic systems in heavy machinery (e.g., excavators, refineries) face hydrocarbon contamination from seal leaks or cross-contamination, leading to emulsion formation and pump wear.
Solution: Breaks hydrocarbon-water emulsions, reduces water content to <10 ppm, and extends oil life by 50% in hydrocarbon-rich environments.
Technical Data
Parameter | Specification |
|---|
Model | HRC-700 (Single-Stage), HRC-900 (Multi-Stage) |
Fluid Type | Natural gas, crude oil, aviation fuel, hydraulic oil, sour hydrocarbon gas |
Operating Pressure | 1–250 bar (14.5–3625 psi) |
Temperature Range | -60°C to +200°C (-76°F to +392°F); cryogenic variant: -162°C (LNG) |
Flow Rate | 100–100,000 Nm³/h (gas); 50–5000 GPM (liquid) |
Beta Ratio (β) | β≥25,000 @ 0.1 μm; β≥50,000 @ 0.5 μm |
Removal Efficiency | 99.9% for 0.1–5 μm droplets; 99.99% for >5 μm (hydrocarbon/water emulsions) |
Pressure Drop | <0.04 bar @ rated flow (stable in hydrocarbon streams) |
Hydrocarbon Resistance | Alkanes (C1–C10), aromatics (benzene, toluene), crude oil, jet fuel, naphthenic acids |
Lifespan | 36–60 months (hydrocarbon-rich environments) |
Certifications | API 618, ISO 16889, ASTM D1655, NACE MR0175, PED 2014/68/EU |
Maintenance Guidelines
1. Routine Inspection
Differential Pressure (ΔP): Monitor weekly; replace media if ΔP exceeds 0.1 bar (initial ΔP: 0.02–0.05 bar), indicating hydrocarbon-induced fouling.
Visual Checks: Inspect housing for hydrocarbon-induced pitting (quarterly) and seals for swelling (biannual).
2. Media Replacement
Use OEM-certified fluoropolymer-coated media to maintain hydrocarbon resistance.
For multi-stage systems, replace all media simultaneously to avoid flow imbalances.
3. Cleaning Protocols
Gas Service: Flush with dry nitrogen to remove residual hydrocarbons.
Liquid Service: Soak in a mild alkaline detergent (pH 9–10) to dissolve hydrocarbon residues, then rinse with deionized water.
4. Troubleshooting
Efficiency Drop: Check for media swelling (incorrect material selection) or hydrocarbon breakthrough (exceeding β-ratio limits).
Leakage: Replace FFKM seals if swollen; retorque flange bolts to hydrocarbon-specific torque specs.
8 Frequently Asked Questions (FAQs)
1. What makes this coalescer “hydrocarbon resistant”?
It uses fluoropolymer-coated media (prevents swelling) and inert alloys (Hastelloy® C-276) that resist hydrocarbon-induced corrosion, unlike standard materials (e.g., carbon steel) that degrade in oil/alkane environments.
2. Can it handle crude oil with high naphthenic acid content?
Yes. The NACE MR0175-certified design resists naphthenic acid corrosion, making it ideal for sour crude oil processing.
3. How does it differ from standard coalescers in aviation fuel systems?
Standard coalescers absorb jet fuel hydrocarbons, leading to swelling and efficiency loss. This model’s fluoropolymer media repels fuel, maintaining <1 ppm water removal efficiency.
4. What is the maximum hydrocarbon concentration it can process?
Handles up to 30% emulsified hydrocarbon-water mixtures (e.g., crude oil-in-water) and 10,000 ppm entrained oil in gas streams.
5. Is it suitable for LNG (liquefied natural gas) applications?
Yes. Cryogenic variants operate at -162°C, resisting methane/ethane condensation while maintaining separation efficiency.
6. How often should maintenance be performed in hydrocarbon environments?
Inspect ΔP weekly, replace media every 3–5 years (or when ΔP >0.1 bar), and replace seals biannually.
7. Does it comply with offshore oil rig standards?
Yes. Certified to API RP 14E (offshore equipment) and ABS (American Bureau of Shipping) for marine hydrocarbon service.
8. What is the ROI for oil refineries?
Reduces compressor downtime by 70%, cuts media replacement costs by 60%, and prevents hydrocarbon-induced corrosion—payback in 8–12 months.
Conclusion
The Hydrocarbon Resistant Coalescer is the definitive solution for industries operating in hydrocarbon-rich environments. By combining inert materials, stabilized media, and high-efficiency separation, it ensures reliable performance in natural gas processing, aviation fuel purification, and hydraulic systems—even when exposed to crude oil, jet fuel, or sour gas. Whether preventing compressor fouling or extending oil life, this coalescer delivers unmatched durability and efficiency, safeguarding assets and maximizing profitability.
Ready to optimize your hydrocarbon separation? Contact our engineers today for a customized solution.
