Acid Resistant Coalescing Filter: Uncompromised Separation in Acidic Environments
Product Introduction
The Acid Resistant Coalescing Filter is a specialized filtration system engineered to deliver reliable gas-liquid and liquid-liquid separation in environments dominated by acidic fluids and corrosive gases. Unlike conventional coalescers, which degrade rapidly when exposed to acids (e.g., H₂S, CO₂, hydrochloric acid, or organic acids), this filter combines acid-inert materials, chemically stabilized coalescing media, and corrosion-resistant construction to maintain 99.9%+ contaminant removal efficiency.
Industries such as natural gas processing (sour gas with H₂S/CO₂), aviation fuel handling (acidic oxidation byproducts), and hydraulic systems (acidic lubricant degradation) face significant risks from acid-induced equipment failure, product contamination, and regulatory non-compliance. The Acid Resistant Coalescing Filter eliminates these challenges, protecting downstream assets, ensuring fluid purity, and reducing lifecycle costs.
Key Features & Advantages
1. Superior Acid Resistance
Inert Material Construction: Housing made from Hastelloy® C-276 (nickel-molybdenum-chromium alloy) or 316L stainless steel with PTFE lining resists pitting, crevice corrosion, and stress corrosion cracking from H₂S, CO₂, HCl, and organic acids (e.g., acetic acid).
Acid-Stable Media: Proprietary ceramic-reinforced fluoropolymer fibers or PTFE-impregnated glass microfibers prevent acid-induced swelling, dissolution, or fiber shedding.
Seal Integrity: FFKM (perfluoroelastomer) or Kalrez® (perfluoroelastomer) seals withstand acid permeation, avoiding leaks even in high-concentration acidic environments.
2. High-Efficiency Coalescence in Acidic Streams
Beta Ratio (β) > 30,000: Removes 99.9% of droplets ≥0.1 μm, including emulsified acid-water mixtures, acid gas condensates, and particulates in acidic fluids.
Multi-Stage Design: Optional pre-coalescers (for bulk acid/liquid separation) and fine coalescers (for submicron droplets) ensure tailored performance in complex acidic streams.
3. Extreme Environmental Tolerance
Temperature Range: -60°C to +250°C (-76°F to +482°F), with cryogenic variants for LNG (liquefied natural gas) and high-temperature models for refinery acid off-gases.
Pressure Resistance: Rated for up to 300 bar (4350 psi), suitable for high-pressure sour gas pipelines and hydraulic systems.
4. Longevity & Cost Efficiency
Extended Lifespan: 48–72 months in acidic environments (vs. 6–12 months for standard coalescers), driven by acid-inert materials and anti-corrosion media.
Low Maintenance: Hot-swappable cartridges and self-cleaning media reduce downtime by 60% during acid service changeouts.
5. Compliance with Industry Standards
Certifications: API 618 (gas processing), NACE MR0175 (sour service), ISO 16889 (hydraulic fluids), ASTM D1655 (aviation fuel), and PED 2014/68/EU (pressure equipment).
Working Principle
The Acid Resistant Coalescing Filter integrates acid inertness with proven coalescence mechanics to ensure stable separation:
1. Acid-Resistant Media Interaction
Acidic fluid (gas or liquid) enters the filter and flows through the ceramic-fluoropolymer media. Acids (e.g., H₂S, HCl) do not degrade the media, as the inert coating repels chemical attack and prevents structural breakdown.
2. Droplet Capture & Coalescence
Capture: Submicron droplets (0.1–5 μm) of water, acid condensates, 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 acid-resistant design ensures consistent fiber spacing, even in acid-saturated streams.
3. Separation & Discharge
Gravity Separation: Enlarged droplets settle at the bottom of the housing (e.g., acid water in sour gas, free water in acidic hydraulic oil).
Clean Fluid Exit: Purified gas/liquid exits through the upper outlet, while collected acid/water mixture is drained via a corrosion-resistant valve (e.g., Hastelloy® trim).
Application Scenarios
1. Natural Gas Sour Gas Separation
Challenge: Sour natural gas contains H₂S (acid gas) and CO₂, which react with water to form corrosive acids (e.g., carbonic acid). These acids degrade pipelines, compressors, and standard coalescers, while entrained liquid droplets reduce calorific value.
Solution: Removes 99.9% of acid condensates and water (β>30,000), meeting ISO 13678 pipeline specs. Hastelloy® C-276 housing resists H₂S/CO₂ corrosion, protecting compressors and extending pipeline life.
2. Aviation Fuel Acid Contamination Control
Challenge: Jet fuel (Jet A-1) undergoes oxidative degradation in storage, forming acidic byproducts (e.g., carboxylic acids) that corrode fuel systems and promote microbial growth. Trace water and acid mixtures risk icing or engine injector clogging.
Solution: FFKM seals and fluoropolymer media prevent acid 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 Acid Neutralization
Challenge: Hydraulic systems and industrial lubricants accumulate acidic byproducts (oxidation acids, sulfur compounds) from heat and contamination. These acids cause seal hardening, pump wear, and oil degradation.
Solution: Breaks acid-water emulsions, reduces acid content by 90%, and extends oil life by 60% in acidic environments.
Technical Data
Parameter | Specification |
|---|
Model | ARCF-800 (Single-Stage), ARCF-1000 (Multi-Stage) |
Fluid Type | Sour natural gas, aviation fuel, hydraulic oil, sour crude oil, acidic condensates |
Operating Pressure | 1–300 bar (14.5–4350 psi) |
Temperature Range | -60°C to +250°C (-76°F to +482°F); cryogenic variant: -162°C (LNG) |
Flow Rate | 200–200,000 Nm³/h (gas); 100–10,000 GPM (liquid) |
Beta Ratio (β) | β≥30,000 @ 0.1 μm; β≥60,000 @ 0.5 μm |
Removal Efficiency | 99.9% for 0.1–5 μm droplets; 99.99% for >5 μm (acid/water emulsions) |
Pressure Drop | <0.05 bar @ rated flow (stable in acidic streams) |
Acid Resistance | H₂S, CO₂, HCl, acetic acid, formic acid, sulfuric acid (dilute), naphthenic acids |
Lifespan | 48–72 months (acidic environments) |
Certifications | API 618, NACE MR0175, ISO 16889, ASTM D1655, 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 acid-induced fouling or corrosion.
Visual Checks: Inspect housing for acid pitting (quarterly) and seals for swelling/cracking (biannual).
2. Media Replacement
Use OEM-certified ceramic-fluoropolymer media to maintain acid 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 acid condensates.
Liquid Service: Soak in a mild alkaline detergent (pH 10–11) to neutralize acids, then rinse with deionized water.
4. Troubleshooting
Efficiency Drop: Check for media corrosion (incorrect material selection) or acid breakthrough (exceeding β-ratio limits).
Leakage: Replace FFKM/Kalrez seals if swollen; retorque flange bolts to acid-specific torque specs.
8 Frequently Asked Questions (FAQs)
1. What acids can this coalescing filter resist?
It resists H₂S, CO₂ (forming carbonic acid), hydrochloric acid (HCl), acetic/formic acids, dilute sulfuric acid, and naphthenic acids (in crude oil). Consult our acid compatibility chart for specific concentrations.
2. How does it differ from standard coalescers in sour gas applications?
Standard coalescers corrode in H₂S/CO₂ environments (carbon steel degrades rapidly). This filter uses Hastelloy® C-276 and acid-stable media, maintaining efficiency for 48+ months.
3. Can it handle aviation fuel with acidic oxidation byproducts?
Yes. Fluoropolymer media repels acidic fuel degradation products, preventing swelling and ensuring <1 ppm water removal (compliant with ASTM D1655).
4. What is the maximum acid concentration it can process?
Handles up to 20% H₂S by volume in gas streams and 5000 ppm acidic contaminants in liquid fuels/oils.
5. Is it suitable for high-temperature refinery acid off-gases?
Yes. Ceramic-reinforced media withstands +250°C, resisting acid corrosion in refinery flare gas or FCC unit off-gases.
6. How often should maintenance be performed in acidic environments?
Inspect ΔP weekly, replace media every 4–6 years (or when ΔP >0.1 bar), and replace seals annually.
7. Does it comply with offshore sour gas platform standards?
Yes. Certified to API RP 14E (offshore equipment) and NACE MR0103 (downhole equipment) for sour service.
8. What is the ROI for natural gas processors?
Reduces compressor downtime by 80%, cuts media replacement costs by 70%, and prevents acid-induced pipeline corrosion—payback in 8–12 months.
Conclusion
The Acid Resistant Coalescing Filter is the definitive solution for industries operating in acidic environments. By combining acid-inert materials, stabilized media, and high-efficiency separation, it ensures reliable performance in sour gas processing, aviation fuel purification, and hydraulic systems—even when exposed to H₂S, CO₂, or acidic byproducts. Whether preventing compressor corrosion or extending oil life, this filter delivers unmatched durability and efficiency, safeguarding assets and maximizing profitability.
Ready to fortify your operations against acid damage? Contact our engineers today for a customized solution.
