Product Overview
Separation filter elements are precision-engineered components designed to isolate immiscible liquids (e.g., oil-water mixtures) or remove liquid droplets from gas streams in industrial systems. Unlike standard filters, these elements leverage phase separation principles to achieve ultra-low residual liquid content (<5 ppm) while maintaining high flow rates.
Widely used in oil/gas processing, compressed air systems, and chemical manufacturing, separation filters protect downstream equipment from corrosion, contamination, and operational failures. Their robust construction ensures reliable performance in extreme pressures (up to 100 bar) and temperatures (-60°C to 150°C).
Working Principle
Separation filters operate through a three-stage mechanism:
1. Inertial Impaction
High-velocity fluid enters the element, where directional baffles force sudden flow redirection. Heavy droplets (≥3 μm) lose momentum and collide with the filter media due to inertia.
2. Coalescence & Agglomeration
Captured droplets merge into larger masses via:
Surface Tension: Hydrophobic/hydrophilic media selectively attract target liquids.
Centrifugal Force: Spiral vanes generate rotational motion (up to 1,500 rpm in vortex designs).
3. Gravitational Drainage
Coalesced liquids fall into a collection sump, while purified media exits through the core. A secondary mesh layer prevents re-entrainment of separated phases.
Efficiency: Achieves 99.9% removal of free liquids and 95% emulsified contaminants.
Structural Composition
| Layer | Material | Function |
|---|
| 1. Inlet Diffuser | Perforated SS316 | Even flow distribution |
| 2. Primary Media | Sintered stainless steel | Captures droplets ≥10 μm |
| 3. Separation Matrix | PTFE-coated glass fiber | Breaks emulsions via surface chemistry |
| 4. Drainage Mesh | 200-μm SS304 wire mesh | Phase isolation and drainage |
| 5. Support Cage | Laser-welded SS316L | Withstands 10 bar backflush pressure |
Seals: Viton® gaskets (standard) / Kalrez® (high-temperature).
Technical Specifications
| Parameter | Specification |
|---|
| Filtration Rating | 0.1 μm (absolute) for solids, 3 μm for liquids |
| Max Pressure | 100 bar (1,450 psi) |
| Temperature Range | -60°C to 150°C (-76°F to 302°F) |
| Flow Rate | 10–2,000 L/min (liquid) / 50–10,000 Nm³/h (gas) |
| Burst Pressure | 150 bar (2,175 psi) |
| Differential Pressure | ≤0.3 bar (4.35 psi) at 20°C |
| Material Compliance | NACE MR0175 (H₂S environments), FDA 21 CFR 177 |
| Certifications | ISO 2942 (integrity test), API 614 (oil/gas) |
Application Theory
1. Phase Separation Dynamics
Separation filters exploit differences in:
Density: Heavier liquids (e.g., water) settle faster than lighter phases (e.g., oil).
Surface Energy: Hydrophobic media repel water but allow hydrocarbons to pass.
Viscosity: High-viscosity fluids require lower flow velocities (0.1–0.5 m/s).
2. Industry-Specific Designs
3. Efficiency Optimization
Flow Control: Maintain Reynolds number <2,000 to ensure laminar flow.
Pre-Filtration: Install 25-μm strainers upstream to protect separation media.
Monitoring: Use capacitive sensors to detect phase boundaries in real time.
Operational Advantages
Zero Cross-Contamination: PTFE barriers prevent remixing of separated phases.
Maintenance-Free Design: Auto-drain valves enable continuous operation for 12–24 months.
Energy Savings: Reduces compressor energy consumption by 15–25% (CAGI performance data).
Industry Applications
Oil & Gas
Pharmaceuticals
Food & Beverage
Conclusion
Separation filter elements combine advanced material science with multiphase flow engineering to deliver unmatched performance in critical industrial processes. Their ability to handle extreme operating conditions while minimizing lifecycle costs makes them indispensable for modern filtration systems.
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