ATEX Certified Coalescing Filter: Explosion-Proof Filtration for Hazardous Environments
Product Introduction
The ATEX Certified Coalescing Filter is a specialized filtration system engineered to meet the rigorous safety standards of the EU ATEX Directive (2014/34/EU), designed for operation in explosive atmospheres. Ideal for industries handling flammable gases, vapors, or dust—such as natural gas processing, aviation fuel handling, and hydraulic systems—this filter ensures reliable separation of contaminants while mitigating the risk of ignition. Certified to ATEX Category 2G/2D (Zone 1/21) and Category 3G/3D (Zone 2/22), it guarantees compliance with global explosion-proof regulations, including IECEx and UL/cUL.
Key Features & Advantages
1. ATEX Compliance for Hazardous Environments
Explosion-Proof Design: Enclosure rated for IECEx Zone 1/21 (gas/vapor) and Zone 2/22 (dust), with flameproof (Ex d) and pressurized (Ex p) options.
Material Selection: Aluminum alloys (ATEX EN 60068-2-27) or 316L stainless steel (ATEX EN 1.4404) for resistance to sparks, corrosion, and extreme temperatures.
2. Ultra-High Separation Efficiency
Beta Ratio (β) > 100,000: Removes 99.99% of droplets ≥0.1 μm, including submicron contaminants in aviation fuel and hydraulic oil.
Multi-Stage Filtration: Configurable for bulk separation (pre-coalescers) and ultrafine polishing (fine coalescers) to meet ATEX requirements for gas purity.
3. Robust Construction for Extreme Conditions
Pressure Resistance: Rated for 1–300 bar (14.5–4350 psi), with cryogenic variants for LNG (ATEX EN 12542) and high-temperature models for refinery off-gases.
Temperature Tolerance: -70°C to +200°C (-94°F to +392°F), with PTFE-coated media for thermal stability in pyrophoric environments.
4. Enhanced Safety Features
Intrinsically Safe Circuits: Sealed electrical connections (ATEX Ex e) prevent sparking.
Automatic Drain Valve: Float-activated drainage (ATEX EN 13445) eliminates liquid buildup, reducing explosion risks.
5. Global Certifications & Interoperability
Compliance: ATEX 2014/34/EU, IECEx, API 618, PED 2014/68/EU, and NSF/ANSI 61.
Working Principle
The ATEX Certified Coalescing Filter combines explosion-proof engineering with advanced coalescence technology to ensure safe, efficient separation:
1. Fluid Intake & Pre-Filtration
Contaminated fluid (e.g., natural gas, jet fuel) enters through an ATEX EN 13445-compliant flanged inlet, where a cyclonic separator removes large particulates (>10 μm) to protect downstream media.
2. Coalescence Stage (ATEX-Optimized Flow Paths)
Capture: Submicron droplets (0.1–5 μm) collide with electrostatically charged media fibers (e.g., aluminum oxide-coated glass fiber) due to turbulent flow and van der Waals forces.
Merging: Droplets merge into larger aggregates (50–1000 μm) as they navigate the media’s tortuous pathways, aided by hydrophobic/hydrophilic coatings.
3. Separation & Discharge (ATEX Safety Mechanisms)
Gravity Separation: Enlarged droplets settle at the housing’s sloped base (ATEX drainage design) and drain via an automatic float valve (ATEX EN 12445).
Clean Fluid Exit: Purified fluid exits through an ATEX EN 13445 flanged outlet, with optional sensors to verify compliance with ATEX Zone 1/21 purity standards.
Application Scenarios
1. Natural Gas Processing (Explosive Gas Environments)
Challenge: Raw natural gas from shale formations contains methane, H₂S, and volatile organic compounds (VOCs), posing explosion risks in confined spaces.
Solution: Aluminum alloy housing (ATEX EN 60068-2-27) resists sparking. Removes 99.9% of contaminants (β>100,000) with <0.05 bar pressure drop. Complies with ATEX Category 2G for Zone 1.
2. Aviation Fuel Handling (Fueling Stations & Tanks)
Challenge: Jet fuel (Jet A-1) vapors in storage tanks or refueling zones risk ignition from static electricity or equipment failure.
Solution: Hydrophilic media (ATEX EN ISO 12215) and spark-resistant seals remove <0.05 ppm water. Tested to DEF STAN 91-91 and ATEX Directive 2014/34/EU for Zone 21 compliance.
3. Hydraulic Systems (Industrial Machinery in Hazardous Zones)
Challenge: Hydraulic oil mist in mines, refineries, or offshore platforms can ignite in the presence of sparks or hot surfaces.
Solution: Breaks emulsions, reduces water to <10 ppm, and extends oil life by 70%. 316L stainless steel housing (ATEX EN 1.4404) resists corrosion in saline environments.
Technical Data
Parameter | Specification |
|---|
Model | ATEX-CF300-EX (Explosion-Proof), ATEX-CF300-DP (Dust-Proof) |
Fluid Type | Natural gas, aviation fuel, hydraulic oil, sour gas condensates |
Operating Pressure | 1–300 bar (14.5–4350 psi) [ATEX Category 2G/3G] |
Temperature Range | -70°C to +200°C (-94°F to +392°F); cryogenic variant: -196°C (LNG) |
Flow Rate | 100–100,000 Nm³/h (gas); 50–5000 GPM (liquid) |
Beta Ratio (β) | β≥100,000 @ 0.1 μm; β≥200,000 @ 0.5 μm |
Removal Efficiency | 99.99% for 0.1–5 μm droplets; 99.999% for >5 μm |
Pressure Drop | <0.05 bar @ rated flow (ATEX EN 13445 optimized) |
Material Compatibility | Aluminum alloy (ATEX EN 60068-2-27), 316L SS (EN 1.4404), PTFE, FFKM seals |
Certifications | ATEX 2014/34/EU, IECEx, PED 2014/68/EU, API 618, NSF/ANSI 61 |
Maintenance Guidelines
1. ATEX-Mandated Routine Inspections
Visual Checks: Monthly inspection for seal wear, corrosion, or sparking risks (per ATEX Directive Annex II).
Differential Pressure (ΔP): Monitor weekly using ATEX EN 13445-calibrated gauges; replace media if ΔP exceeds 0.1 bar (initial ΔP: 0.02–0.05 bar).
2. Media Replacement (ATEX-Approved Procedures)
3. Cleaning Protocols
Gas Service: Flush with inert nitrogen (ATEX EN 12673 purity) to remove combustible gases.
Liquid Service: Soak in ATEX EN 12922-compliant detergent (pH 7–9) for 30 minutes, rinse with deionized water.
4. Troubleshooting (ATEX Best Practices)
Leaks: Retorque flange bolts to ATEX EN 1092 torque specs (e.g., 400 N·m for aluminum housings).
Efficiency Drop: Check for media compaction (over-tightened housing) or chemical incompatibility.
8 Frequently Asked Questions (FAQs)
1. What does “ATEX Certified” mean for a coalescing filter?
It means the filter complies with EU Directive 2014/34/EU, ensuring safe operation in explosive atmospheres (e.g., Zone 1/21) by preventing ignition sources like sparks, hot surfaces, or static discharge.
2. How does it differ from standard coalescers?
ATEX filters include explosion-proof enclosures, spark-resistant materials, and specialized seals to meet ATEX Zone classifications—features absent in standard filters.
3. Can it handle methane-rich natural gas?
Yes. Aluminum alloy housing (ATEX EN 60068-2-27) resists sparking, and media removes 99.9% of methane droplets (β>100,000).
4. Is it suitable for aviation fueling stations?
Absolutely. Hydrophilic media removes <0.05 ppm water, and FFKM seals prevent leaks in Zone 21 environments. Tested to DEF STAN 91-91 and ATEX Directive 2014/34/EU.
5. What is the maximum temperature rating?
+200°C (392°F) for high-temperature variants, with PTFE coatings (ATEX EN ISO 10437) for thermal stability.
6. How often should maintenance be performed?
Inspect ΔP weekly, replace media every 24–36 months (or when ΔP >0.1 bar), and conduct annual ATEX-compliant pressure testing.
7. Does it comply with offshore drilling regulations?
Yes. Certified to ATEX Category 3G (Zone 2) for offshore platforms, with 316L stainless steel housing (EN 1.4404) resisting saltwater corrosion.
8. What is the ROI for industrial users?
Reduces downtime by 50%, extends equipment life by 60%, and avoids ATEX non-compliance fines—payback in 12–18 months.
Conclusion
The ATEX Certified Coalescing Filter is the ultimate solution for industries operating in explosive environments. By blending ATEX’s stringent safety protocols with advanced coalescence technology, it ensures reliable separation of water, oil, and particulates in natural gas, aviation fuel, and hydraulic systems—protecting assets, operators, and facilities from catastrophic risks.
For hazardous environment applications, choose the ATEX Certified Coalescing Filter. Contact our ATEX-certified engineers today for a custom solution.
