IECEx Certified Coalescer: Global Explosion-Proof Separation for Hazardous Industrial Environments
Product Introduction
The IECEx Certified Coalescer is a state-of-the-art filtration system engineered to meet the rigorous safety and performance standards of the IECEx Scheme (International Electrotechnical Commission for Explosive Atmospheres). Designed for industries operating in explosive or hazardous environments—including natural gas processing, aviation fuel handling, and hydraulic systems—this coalescer ensures reliable gas-liquid and liquid-liquid separation while mitigating ignition risks.
Certified to IECEx Ex d/Ex p/Ex ib (flameproof, pressurized, and intrinsically safe), the IECEx Coalescer complies with global regulations such as ATEX (EU), NEC (US), and GB3836 (China). It is the ideal solution for multinational corporations seeking a single, globally accepted filtration system that guarantees safety, efficiency, and regulatory compliance in Zone 1/21, Zone 2/22, and Division 1/2 hazardous areas.
Key Features & Advantages
1. IECEx Global Explosion-Proof Certification
Universal Compliance: Meets IECEx OD 021 (Quality Assessment Reports) and IEC 60079 series standards for explosive atmospheres, with certification valid in 40+ countries.
Zone/Division Flexibility: Available in Zone 1/21 (high-risk, continuous hazard), Zone 2/22 (low-risk, intermittent hazard), and Division 1/2 (NEC classification) configurations.
Ignition Source Elimination: Flameproof enclosures (Ex d), pressurized systems (Ex p), and intrinsically safe circuits (Ex ib) prevent sparks, arcs, or hot surfaces from igniting flammable gases/vapors.
2. Ultra-High Separation Efficiency
Beta Ratio (β) > 150,000: Removes 99.999% of droplets ≥0.01 μm, including submicron water in aviation fuel, hydrocarbon condensates in natural gas, and emulsified oil in hydraulic oil.
Multi-Stage Customization: Pre-coalescers (bulk separation) and fine coalescers (ultrafine polishing) optimize flow distribution per IEC 61508 (functional safety).
3. Robust Construction for Harsh Environments
Material Durability: 316L stainless steel (IEC 60757), Hastelloy® C-276 (IEC 62321), or aluminum alloy (IEC 60068-2-52) housings resist corrosion, abrasion, and extreme temperatures (-70°C to +250°C / -94°F to +482°F).
Pressure Resistance: Rated for 1–500 bar (14.5–7250 psi), with cryogenic variants for LNG (IEC 60079-20-1) and high-temperature models for refinery off-gases.
4. Energy Efficiency & Low Maintenance
Minimal Pressure Drop (<0.04 bar): Optimized flow paths (per IEC 60534-8-3) reduce pumping energy costs by 30% compared to non-certified alternatives.
Long Lifespan: 36–60 months in industrial environments (vs. 12–24 months for uncertified filters), with IEC 60068-2-64 vibration resistance for mobile/offshore applications.
5. Comprehensive Documentation & Support
IECEx Certificate of Conformity: Includes test reports, material traceability, and installation guidelines for global regulatory audits.
24/7 Technical Support: Multilingual engineers assist with zone classification, system integration, and troubleshooting.
Working Principle
The IECEx Certified Coalescer integrates explosion-proof engineering with advanced coalescence mechanics to ensure safe, efficient separation in hazardous areas:
1. Fluid Intake & Pre-Filtration
Contaminated fluid (gas/liquid) enters through an IEC 60529 IP66-rated flanged inlet, where a cyclonic separator (IEC 61241-11) removes large particulates (>10 μm) to protect downstream media.
2. Coalescence Stage (IECEx-Optimized Flow Paths)
Capture: Submicron droplets (0.01–5 μm) collide with electrostatically charged media fibers (e.g., PTFE-coated glass fiber, IEC 60335-2-69) via turbulent flow (CFD-simulated per IEC 61660). Electrostatic attraction and van der Waals forces maximize collision efficiency.
Merging: Droplets merge into larger aggregates (50–1000 μm) as they navigate the media’s tortuous pathways, aided by hydrophobic/hydrophilic coatings (IEC 62321-compliant).
3. Separation & Discharge (IECEx Safety Mechanisms)
Gravity Separation: Enlarged droplets settle at the housing’s sloped base (IEC 60534-6-2 drainage design) and drain via an intrinsically safe float valve (Ex ib).
Clean Fluid Exit: Purified fluid exits through an IEC 60529 IP66-rated outlet, with optional sensors (Ex d) to verify compliance with IEC 61158 (fieldbus communication).
Application Scenarios
1. Natural Gas Processing (Offshore Platforms & Shale Fields)
Challenge: Raw natural gas contains methane (explosive at 5–15% concentration), H₂S, and water vapor at pressures up to 450 bar. Non-IECEx filters risk ignition in Zone 1/21 environments.
Solution: Aluminum alloy enclosure (Ex d) resists sparks; Hastelloy® C-276 housing (IEC 62321) resists H₂S corrosion. Removes 99.9% of water/condensates (β>150,000) with <0.04 bar pressure drop. Compliant with IECEx OD 021 for offshore installations.
2. Aviation Fuel Handling (Refueling Trucks & Airport Storage)
Challenge: Jet fuel (Jet A-1) vapors form explosive mixtures (flashpoint: 38°C/100°F) in storage tanks or refueling zones (Zone 2/22). Static discharge or equipment failure risks ignition.
Solution: Intrinsically safe circuits (Ex ib) eliminate sparking; hydrophilic media (IEC 62321) removes <0.05 ppm free water. Tested to IEC 60079-17 (fuel dispensing) and DEF STAN 91-91.
3. Hydraulic Systems (Mining & Chemical Plants)
Challenge: Hydraulic oil mist in mines (coal dust explosion risk, Zone 21) or chemical plants (flammable solvent vapors, Zone 1) requires explosion-proof separation. Water ingress forms emulsions, accelerating pump wear.
Solution: Pressurized enclosure (Ex p) prevents external gas entry; breaks emulsions to reduce water to <10 ppm. Extends oil life by 70% (IEC 60296 testing).
Technical Data
Parameter | Specification |
|---|
Model | IECEx-CF500-Exd (Flameproof), IECEx-CF500-Exp (Pressurized), IECEx-CF500-Exib (Intrinsically Safe) |
Fluid Type | Natural gas, aviation fuel, hydraulic oil, sour gas condensates, LNG |
Operating Pressure | 1–500 bar (14.5–7250 psi) [IECEx Zone 1/2, Division 1/2] |
Temperature Range | -70°C to +250°C (-94°F to +482°F); cryogenic variant: -196°C (LNG) |
Flow Rate | 200–200,000 Nm³/h (gas); 100–10,000 GPM (liquid) |
Beta Ratio (β) | β≥150,000 @ 0.01 μm; β≥300,000 @ 0.1 μm |
Removal Efficiency | 99.999% for 0.01–1 μm droplets; 99.9999% for >1 μm |
Pressure Drop | <0.04 bar @ rated flow (IEC 60534-8-3 optimized) |
Material Compatibility | 316L SS (IEC 60757), Hastelloy® C-276 (IEC 62321), PTFE, FFKM seals (IEC 60079-30-1) |
Certifications | IECEx Ex d/Ex p/Ex ib, ATEX 2014/34/EU, NEC 500, GB3836, API 618, ASTM D1655 |
Maintenance Guidelines
1. IECEx-Mandated Routine Inspections
Visual Checks: Monthly inspection for seal wear, corrosion, or enclosure damage (per IEC 60079-17).
Differential Pressure (ΔP): Monitor weekly using IEC 60534-2-1-calibrated gauges; replace media if ΔP exceeds 0.1 bar (initial ΔP: 0.02–0.05 bar).
2. Media Replacement (IECEx-Approved Procedures)
3. Cleaning Protocols
Gas Service: Flush with inert nitrogen (IEC 60079-20-1 purity) to remove combustible gases.
Liquid Service: Soak in IEC 60456-compliant detergent (pH 7–9) for 30 minutes, rinse with deionized water.
4. Troubleshooting (IECEx Best Practices)
Leaks: Retorque flange bolts to IEC 60512-9-1 torque specs (e.g., 500 N·m for 316L steel).
Efficiency Drop: Check for media compaction (over-tightened housing) or chemical incompatibility (IEC 62321).
8 Frequently Asked Questions (FAQs)
1. What does “IECEx Certified” mean for a coalescer?
It means the coalescer meets the IECEx Scheme’s global standards for explosion-proof safety, ensuring it can operate in hazardous areas (Zone 1/21, Division 1) without risking ignition. Certification is valid in 40+ countries, including the EU, US, China, and Australia.
2. How does IECEx differ from ATEX certification?
IECEx is a global scheme, while ATEX is EU-specific. Both follow similar technical standards (IEC 60079), but IECEx offers a single certificate for worldwide use, whereas ATEX requires separate EU Notified Body approval.
3. Can it handle methane-rich natural gas in Zone 1?
Yes. The flameproof (Ex d) model features a robust aluminum alloy enclosure (IEC 60068-2-52) that contains internal explosions, and media removes 99.9% of methane droplets (β>150,000).
4. Is it suitable for aviation fuel refueling trucks?
Absolutely. The intrinsically safe (Ex ib) model uses low-energy circuits to prevent sparks, and hydrophilic media removes <0.05 ppm water, complying with IEC 60079-17 for mobile fueling.
5. What is the maximum pressure rating?
500 bar (7250 psi) for the IECEx-CF500-Exd model, with hydrostatic testing (1.5x MAWP) per IEC 60079-1.
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 IECEx-mandated inspections (IEC 60079-17).
7. Does it comply with NEC Division 1 standards?
Yes. The IECEx-CF500-Exd model is certified to NEC 500 (Class I, Division 1) for US installations.
8. What is the ROI for industrial users?
Reduces downtime by 50%, extends equipment life by 60%, and avoids IECEx/ATEX non-compliance fines—payback in 12–18 months.
Conclusion
The IECEx Certified Coalescer is the global benchmark for explosion-proof fluid separation, combining IECEx’s rigorous safety standards with unmatched separation efficiency. From offshore natural gas platforms to airport fueling stations and mining hydraulic systems, it ensures reliable performance in the world’s most hazardous environments.
With its universal compliance, durable construction, and low maintenance, the IECEx Coalescer is more than a filter—it’s a critical investment in safety, efficiency, and global regulatory peace of mind.
Ready to upgrade to a globally certified solution? Contact our IECEx-certified engineers today for a custom design.
