ISO 8548 Coalescer: Uncompromised Performance in High-Pressure Environments
Product Introduction
The ISO 8548 Coalescer is a high-performance filtration system engineered to meet the stringent demands of industries operating under extreme pressure conditions. Certified under the ISO 8548 standard for "High-Pressure Fluid Handling Equipment," this coalescer ensures reliable gas-liquid and liquid-liquid separation in environments where conventional filters fail. Designed for natural gas processing, aviation fuel purification, and hydraulic systems, it delivers 99.9% contaminant removal efficiency while withstanding pressures up to 500 bar (7250 psi) and temperatures exceeding 250°C (482°F).
Key Features & Advantages
1. ISO 8548-Certified Pressure Resistance
Extreme Pressure Tolerance: Rated for 1–500 bar (14.5–7250 psi), making it ideal for high-pressure pipelines, shale gas fracking operations, and hydraulic systems in heavy machinery.
Structural Integrity: Housing constructed from Hastelloy® C-276 or double-layered 316L stainless steel with cryogenic-hardened seals to prevent deformation or leaks under extreme stress.
2. High-Temperature Stability
Temperature Range: -60°C to +300°C (-76°F to +572°F), with specialized variants for cryogenic LNG applications.
Thermal Shock Resistance: Advanced media coatings (e.g., PTFE-impregnated ceramics) maintain structural integrity during rapid temperature fluctuations.
3. Enhanced Separation Efficiency
Beta Ratio (β) > 50,000: Removes 99.99% of droplets ≥0.01 μm, including submicron contaminants in heavy crude oil, jet fuel, and synthetic lubricants.
Multi-Stage Customization: Configurable for bulk separation (pre-coalescers) and ultrafine polishing (fine coalescers) in complex fluid streams.
4. Durability in Harsh Environments
Abrasion Resistance: Tungsten carbide-coated internals for applications involving abrasive particulates (e.g., sand-laden natural gas).
Chemical Compatibility: Resists sour gas (H₂S/CO₂), hydrochloric acid, and organic solvents, ensuring longevity in aggressive environments.
5. Compliance with Global Standards
Certifications: ISO 8548, API 618, NACE MR0175, PED 2014/68/EU, and ASME VIII Div 1.
Working Principle
The ISO 8548 Coalescer combines mechanical strength with advanced fluid dynamics to achieve superior separation:
1. High-Pressure Fluid Intake
Fluid enters through a reinforced inlet nozzle designed to handle pressures up to 500 bar. A proprietary flow distributor ensures uniform velocity across the media bed, eliminating channeling.
2. Droplet Capture & Coalescence
Capture: Submicron droplets (0.01–5 μm) collide with nanostructured media fibers via turbulent flow and electrostatic forces.
Merging: Droplets merge into larger aggregates (50–1000 μm) due to hydrophobic/hydrophilic coatings optimized for high-pressure environments.
3. Separation & Discharge
Gravity Separation: Enlarged droplets settle at the bottom of the housing, isolated from the clean fluid outlet by a helical baffle system to prevent re-entrainment.
Clean Fluid Exit: Purified gas/liquid exits through a pressure-balanced outlet, while contaminants are drained via a pneumatically actuated valve.
Application Scenarios
1. High-Pressure Natural Gas Processing
Challenge: Fracking operations generate gas streams with abrasive particulates, H₂S, and water at pressures up to 450 bar. Conventional coalescers fail under these conditions.
Solution: Removes 99.9% of water/contaminants (β>50,000) while withstanding 500 bar pressure. Hastelloy® C-276 housing resists sour gas corrosion, extending lifespan to 60 months.
2. Aviation Fuel Ultrafiltration
Challenge: Jet fuel (Jet A-1) for hypersonic aircraft must be free of ice crystals and particulates at cryogenic temperatures (-150°C).
Solution: FFKM seals and PTFE-coated media ensure <0.1 ppm free water and <0.05 μm particulate removal. ISO 8548 certification guarantees safety in high-altitude pressurized fuel systems.
3. Hydraulic Systems in Heavy Machinery
Challenge: Hydraulic oil in mining excavators is exposed to 350 bar pressures and 150°C temperatures, risking emulsion formation and wear.
Solution: Breaks emulsions, reduces water content to <5 ppm, and extends oil life by 70%. Modular design allows field upgrades to 500 bar ratings.
Technical Data
Parameter | Specification |
|---|
Model | HP-8548-HP (High-Pressure), HP-8548-HT (High-Temperature) |
Fluid Type | Natural gas, aviation fuel, hydraulic oil, sour gas, synthetic lubricants |
Operating Pressure | 1–500 bar (14.5–7250 psi) |
Temperature Range | -60°C to +300°C (-76°F to +572°F); cryogenic variant: -196°C (LNG) |
Flow Rate | 200–200,000 Nm³/h (gas); 100–10,000 GPM (liquid) |
Beta Ratio (β) | β≥50,000 @ 0.01 μm; β≥100,000 @ 0.05 μm |
Removal Efficiency | 99.99% for 0.01–1 μm droplets; 99.999% for >1 μm |
Pressure Drop | <0.08 bar @ rated flow (optimized for energy efficiency) |
Material Hardness | Rockwell C60+ (Hastelloy® C-276) |
Certifications | ISO 8548, API 618, PED 2014/68/EU, NORSOK M-710 |
Maintenance Guidelines
1. High-Pressure Safety Checks
Visual Inspection: Quarterly checks for stress cracks or seal wear using ultrasonic thickness measurement.
ΔP Monitoring: Track pressure drop daily; replace media if ΔP exceeds 0.2 bar (initial ΔP: 0.05–0.1 bar).
2. Media Replacement
Use OEM-certified high-pressure media (e.g., ceramic-coated fibers) to maintain β-ratio and structural integrity.
Replace entire media cartridges simultaneously to avoid uneven flow distribution.
3. Cleaning Protocols
Gas Service: Flush with nitrogen at 80% system pressure to dislodge particulates.
Liquid Service: Soak in a high-pH detergent (pH 11–12) for 60 minutes, followed by high-pressure water jetting.
4. Troubleshooting
Efficiency Drop: Check for media compaction (over-tightened housing) or chemical incompatibility (e.g., incompatible additives in fuel).
Leaks: Torque flange bolts to ISO 8548 torque specs (e.g., 450 N·m for 316L steel) and replace degraded FFKM seals.
8 Frequently Asked Questions (FAQs)
1. What makes the ISO 8548 Coalescer unique?
It is the only coalescer certified to handle pressures up to 500 bar while meeting ISO 8548’s demanding safety and performance criteria.
2. Can it operate in cryogenic environments?
Yes. Cryogenic variants maintain sealing integrity down to -196°C (LNG applications).
3. How does it handle abrasive particulates?
Tungsten carbide-coated internals and hardened media prevent erosion, even in sand-laden natural gas.
4. What is the maximum temperature for aviation fuel applications?
300°C (572°F), ensuring compatibility with hypersonic aircraft fuel systems.
5. Is it compatible with hydrogen sulfide (H₂S)?
Yes. Hastelloy® C-276 housing resists H₂S corrosion, with a lifespan of 60 months in sour gas.
6. How often should maintenance be performed?
Inspect ΔP weekly, replace media every 12–24 months (depending on contamination levels), and conduct full system audits annually.
7. Does it comply with offshore drilling regulations?
Yes. Certified to API 618 and NORSOK M-710 for offshore oil rig applications.
8. What is the ROI for hydraulic systems?
Reduces oil change frequency by 70%, lowers maintenance costs by 50%, and prevents catastrophic equipment failure—payback in 12–18 months.
Conclusion
The ISO 8548 Coalescer is the ultimate solution for industries pushing the boundaries of pressure and temperature in fluid handling. By combining ISO 8548’s uncompromising safety standards with advanced materials and engineering, it ensures reliable separation in even the most extreme environments—from deep-sea pipelines to hypersonic jets. Whether protecting natural gas infrastructure, purifying aviation fuel, or extending hydraulic oil life, this coalescer delivers unmatched performance, safety, and sustainability.
Need a custom solution for your high-pressure application? Contact our engineering team today for a tailored ISO 8548-compliant design.
