Coalescing Filter Element Technical Specifications

1. Product Overview

Coalescing filter elements are high-performance filtration components designed to separate liquid aerosols, fine particulates, and immiscible fluids from gas or liquid streams. As critical components in industrial filtration systems, these elements play a vital role in ensuring process efficiency, equipment protection, and compliance with environmental standards.

Constructed with advanced porous media and engineered materials, coalescing filters excel in applications requiring ultra-clean output, such as compressed air systems, fuel processing, natural gas dehydration, and pharmaceutical manufacturing. Their unique design enables the simultaneous removal of submicron contaminants and liquid droplets through coalescence, making them superior to conventional filters in handling challenging multiphase flows.

2. Working Principle

Coalescing filters operate on three fundamental mechanisms:

‌1. Interception & Diffusion‌
As contaminated fluid passes through the multi-layered filter media, microscopic particles (0.01–1 μm) are captured via direct interception or Brownian motion.

‌2. Coalescence Phase‌
Captured liquid droplets merge into larger masses through the following stages:

• ‌Stage 1‌: Droplets adhere to fiber surfaces

• ‌Stage 2‌: Capillary action draws droplets into larger bodies

• ‌Stage 3‌: Gravity separates coalesced liquid from the medium

‌3. Drainage‌
Aggregated liquids drain into collection chambers via hydrophobic/hydrophilic separation layers, while purified gas/liquid exits the system.

This process achieves >99.99% efficiency in removing oil aerosols, water mist, and particulate matter down to 0.1 μm.

3. Structural Composition

A coalescing filter element comprises four functional layers:

The layered construction ensures progressive filtration while maintaining low pressure drop (typically <3 psi at rated flow).

4. Technical Specifications

Key Performance Metrics

• ‌Filtration Efficiency‌: 99.99% @ 0.3 μm (EN1822 H13 standard)

• ‌Max Operating Pressure‌: 16 bar (232 psi)

• ‌Temperature Range‌: -40°C to 120°C (-40°F to 248°F)

• ‌Flow Capacity‌: 50–5,000 Nm³/h (configurable)

• ‌Differential Pressure‌: ≤0.15 bar (2.17 psi)

• ‌Moisture Removal‌: ≤0.003 ppm(w) residual liquid

Material Compatibility

• ‌Housing‌: Aluminum/Stainless Steel

• ‌Seals‌: Fluorocarbon rubber (FKM)/Ethylene Propylene (EPDM)

• ‌Media‌: Hydrophobic glass fiber with nano-coating

Certifications

• ISO 16890:2016 (Particulate filtration)

• ASME BPE (Bio-processing compliant)

• ATEX Directive 2014/34/EU (Explosive environments)

5. Application Theory

Industrial Implementation Logic

Coalescing filters function as phase-separation enhancers in systems where:

1. Liquid contaminants degrade process quality (e.g., instrument air)

2. Particulates cause equipment abrasion (e.g., pneumatic tools)

3. Moisture induces corrosion (e.g., gas pipelines)

Application-Specific Design Variations

1. ‌Compressed Air Systems‌

• Multi-stage coalescers with activated carbon beds

• Auto-drainage valves for condensate removal

2. ‌Aviation Fuel (Jet A-1) Treatment‌

• Conductive media to prevent static ignition

• Dual-gradient density media for water/fuel separation

3. ‌CNG/LNG Processing‌

• Cryogenic-rated elements (-100°C/-148°F)

• Methane-compatible elastomers

4. ‌Pharmaceutical Air‌

• Sterilizable gamma-grade materials

• Integrity-testable designs per FDA 21 CFR Part 11

Performance Optimization Factors

• ‌Viscosity Matching‌: Media pore size adjusted to fluid viscosity (Stokes' law adaptation)

• ‌Velocity Control‌: Optimal flow velocity maintained at 0.15–0.3 m/s to prevent re-entrainment

• ‌Differential Monitoring‌: Smart sensors track ΔP to schedule maintenance

6. Operational Advantages

• ‌Energy Efficiency‌: 30–50% lower energy consumption vs. centrifugal separators

• ‌Maintenance Interval‌: 8,000–12,000 operating hours (3–5× conventional filters)

• ‌Environmental Compliance‌: Achieves <5 mg/Nm³ hydrocarbon emissions (EPA Method 25A)

7. Industry Applications

• ‌Oil & Gas‌: Glycol dehydration, scrubber systems

• ‌Power Generation‌: Turbine inlet air filtration

• ‌Chemicals‌: Catalyst protection, vapor recovery

• ‌Food & Beverage‌: Process air sterilization

This coalescing filter element combines advanced materials science with fluid dynamics optimization to deliver unmatched separation performance across industries. Its engineered design ensures reliable operation in extreme conditions while reducing lifecycle costs through extended service intervals and energy-efficient operation.