Filson Coalescing Filter Element
Filson coalescing filter element is also called coalescer element or coalescing filter cartridge. It mainly has two kinds. One is to remove water and oil from compressed air while another coalescing filter element is used to separate water from fuels and oils.
Filson coalescing filter element come in many shapes and designs. We are happy to custom coalescer elements based on your detailed applications. Also, we offer a complete line of replacement coalescing filter element for your present coalescing filter housing, such as Peco coalescing filters, Parker coalescing filter elements.
Coalescing Filter Element
Advantages of Filson Coalescing Filter Element
- High dewatering efficiency and lower pressure drop
- Low maintenance cost and replacement cost.
- Removal of sub-micron particle contaminants
- Suitable for gas or fluids application
- Custom design flexibility to fit your OEM requirements
- Complete replacement coalescing filter elements database
Your Reliable Coalescing Filter Element Supplier
Usually, Filson coalescing elements filters air from the inside to the outside. The inner hydrophilic core capture and collect liquid aerosols into large droplets, finally drain away by gravity. Whether for natural gas or fuel oil, Filson coalescer element is a perfect choice to help you achieve high dewater efficiency up to 99.99%.
Filson has been supplying coalescing filter element for more than a decade and has accumulated a great amount of experience in design and manufacturing as well as reliable partnerships with other specialized suppliers. Our specific filtration media, advanced production process ensures dry and clean air, oil for your system.
Compare to other coalescing filter element manufacturers, Filson coalescer elements have less pressure drop, offering you longer service life and reduced replacement costs, even for high pressure natural gas or high viscosity oil.
For Filson gas coalescers, it usually consists of two layers of filtration material, one is to remove particles that may exist in the gas stream, while the second layer, liquid droplets are separated after gathering into the big droplets.
Filson have wide range of brand replacement gas/liquid coalescer and liquid/liquid coalescing filter cartridges for your choices. Like SepraSol Liquid/Gas Coalescerwith double open end, AquaSep liquid/liquid coalescers, Peco Series XP coalescing filter elements.
Note: Even though coalescing filter cartridges have function of remove solid contaminates from the compressed air system as well as liquids. From the economic point of view, it is better to use coalescer cartridges in submicron level, like 0.3 to 25 microns.
Since large particles are easily blocking off coalescing filter disposable media and result in a shorter useful life. Coalescing filter elements perform better at the highest pressure and low temperature environment.
Talk to our technical team for custom made and OEM partnership for coalescing filter element.
Filson Coalescing Filter Element Specification:
- Working pressure up to 5000 PSIG
- Temperatures to 350°
- Coalescing efficiency up to 99.99%
- Filtration accuracy: from 0.01 to 25 um
- Clean pressure drop lower than 1.25 PSIG
- Air Flow: inside to outside
Filson Coalescing Filter ElementApplication:
- Compressed air filtration
- Refrigeration systems
- Air/oil separation
- Oil filtration
- Compressed natural gas filtration
- Corrosive Gas Filtration
Coalescing Filter Elements: The Ultimate FAQ Guide
I know you’re probably looking for a coalescing filter element.
Or, you would like to learn more about coalescing filters.
Whichever the case, this guide has all information you’re looking.
So, keep reading if you want to be an expert in the coalescing filtration process.
- What is a Coalescing Filter Element?
- How do you Choose Coalescing Filter Element Housing?
- What Material is Coalescing Filter Element made of?
- Which Material Options are available for Coalescing Filter Housing?
- What are the Functions of Coalescing Filter Element?
- How does Coalescing Filter Elements work?
- What are the Applications of Coalescing Filter Element?
- How does Coalescing Filter Elements compare to other Filter Element?
- What are the Benefits of using Coalescing Filter Element?
- What are the Features of a Good Coalescing Filter Element?
- Which Contaminants does Coalescing Filter Element Remove?
- What are the Risks of Using Ineffective Coalescing Filter Elements?
- How do you Determine the Efficiency of Coalescing Filter Element?
- What Types of Coalescing Filter Elements are there?
- What are the Components of Coalescing Filter Element?
- What are the Characteristics of High-Quality Coalescing Filter Media?
- How do you Test the Quality of Coalescing Filter Element?
- How can you Rate Coalescing Filter Element?
- What Factors Determine the Effectiveness of Coalescing Filter Element?
- How long will Coalescing Filter Element Last?
- When should you Replace Coalescing Filter Element?
- What should you consider when Selecting Coalescing Filter Element?
- Can you Clean Coalescing Filter Element?
- How much does Coalescing Filter Element Cost?
- How can you Determine the Surface Area of Coalescing Filter Element?
- How do you Maintain Coalescing Filter Element?
- What are the Quality Standards for Coalescing Filter Elements?
- What are the Safety Precautions when Replacing Coalescing Filter Elements?
- How can you Increase the Filtration Efficiency of Coalescer Filter Element?
- How do you Determine Pressure Drop Across Coalescing Filter Element?
- Why Import Coalescer Filter Element from China?
What is a Coalescing Filter Element?
A coalescing filter element is a device constructed using a porous material.
You can use it to remove liquids droplets, aerosols, suspended particles, and vapor impurities from the process fluid through coalescing effect.
Coalescing filter element
The coalescing filter elements have progressive layers that perform different functions.
The inner layers consist of fine mesh for restraining particulate contaminants while the outer section has course mesh and helps coalesce liquids into large droplets.
A coalescing filter element can also remove suspended and dissolved solid contaminants at the same level of efficacy as particulate filters.
How do you Choose Coalescing Filter Element Housing?
Selecting the correct filter housing that is compatible with the coalescing element model is very important for achieving maximum filtration performance.
Consequently, you need to consider the following fundamental aspects of the coalescing filter housing:
Coalescing filter housing
· Type of Material for Coalescing Filter Element
The choice of construction material depends on three main factors:
· Operating Pressure
The material you select must be able to withstand the system pressure and flow rate.
For instance, you cannot use materials like plastic and aluminum in systems which operate under very high pressure because they will easily rapture.
· Operating Temperature
Similarly, select a material that can withstand the operating and maximum process temperatures.
Some materials like PTFT can only operate under limited temperature ranges and are therefore less suitable for applications that operate at high temperatures.
The construction material must be chemically compatible with the process fluid and contaminants.
Selecting material which is resistant to corrosion like plastic and stainless steel will help you avoid possible housing degradation due to corrosion.
You can select the filter housing from a wide range of standard and exotic materials to ensure you meet your special filtration requirements.
Suitable Housing Configuration for Process Application
Different housings have different configurations based on the intended use.
Whereas you can select housing with only two ports for a particulate filter, the coalescing filter must have at least three ports.
The decision whether to use a vertical or horizontal design will depend on the system flow rates, application, and available installation space.
Vertical designs will help you save on floor installation space while the horizontal design will support higher flow rates and confer lower pressure drop.
Vertical housing design
Horizontal housing design
Size of the Coalescing Filter Element Housing
You will size your housing as determined by the system pressure, flow rates, type and quantity of contaminants to remove, line size, and port size.
You should also consider the relative importance of service intervals and life, desired level of filtration, and the response time.
Generally, bigger filter housing and elements will offer you longer service life, higher dirt holding capacity, extended service life, and lower pressure drop.
On the other hand, smaller filters have a faster response time, require smaller space for installation, and have a lower purchase price.
What Material is Coalescing Filter Element made of?
You can construct coalescing filter elements using diverse types of materials.
You can construct the medium using a natural, synthetic, or combination of both materials.
You can also impregnate the media using custom made or synthetic material to enhance its durability and mechanical strength.
Depending on your requirements, you can choose a single-layered or multi-layered medium that has varying filtration efficiency for each layer.
You can also consider pleated media which have a higher surface area and dirt holding capacity for effective filtration.
Some of the best materials for constructing housing include:
Coalescing filter element
This material is a natural product for the construction of a disposable coalescing filter element.
Besides, the majority of the cellulose media are constructed as pleats to increase the filtration surface area.
The elements made from cellulose are usually lower in price compared to other types of material.
Microfiber is an inert material that you can randomly arrange to form a multi-layered composite bound by resins.
They offer a higher filtration efficiency and dirt holding capacity compared to natural material.
The material is highly suitable for gas-liquid coalescing filtration and can also construct specialty configurations.
You can co-pleat the element with extra support layers made from diverse materials for stability and longevity.
iii. Stainless Steel
You can construct a durable media using stainless steel wire cloth strands subjected to diverse mesh patterns through weaving.
This material is suitable for constructing media for filtration under hostile environmental conditions.
Further, stainless steel elements are easy to clean and reuse and will significantly reduce the cost of disposal.
You can also use other types of synthetic materials such as polypropylene, polyester, and nylon.
However, these materials are sensitive to high temperatures and are less suitable for use under severe filtration conditions.
Which Material Options are available for Coalescing Filter Housing?
You can construct a coalescing filter housing from a wide range of common, exotic, and diverse mix of metal alloys.
The choice of housing material varies to the requirements of the filtration process.
Some of the most common materials include:
Coalescing filter system
- Carbon steel
- Stainless steel
- PTFT membranes
- Iron alloys
- Chromium etc.
What are the Functions of Coalescing Filter Element?
The primary functioning of a coalescing filter element is to remove liquid contaminants from the process fluid.
However, they are dual performance devices and will also remove particulate impurities in the process fluid.
Depending on the application, you can use gas-liquid coalesce for removing liquid contaminants from a gas stream.
You can use a gas-liquid coalescing filter to dry natural gas, seal gas, compressed air, etc.
You can also use liquid-liquid coalescing elements to separate a non-continuous phase (contaminating liquid) from the continuous phase (process liquid).
You can use these types of coalescing filters to remove water contaminants from fuel jets, diesel fuel, turbine fuels, lubricating oil et.
For both types of coalescing filter elements, the main aim is to protect the system components from degradation.
It also helps in the provision of process fluids and products that meet the industry’s cleanliness requirements.
In short, whether you go for oil coalescing filters or diesel coalescing filters, the primary function will remain the same.
Even though, they are designed for different liquids.
How does Coalescing Filter Elements work?
Coalescing filter elements remove contaminants from inside to outside flow.
The depth filters have two layers.
Also, the inner layer consists of finer mesh and the outer layer comprises a coarse mesh.
When pressurized fluid passes through the element, the finer mesh on the inside retains solid contaminants.
The fine mesh media amalgamate the tiny liquid droplets in the fluid as it forces its way through the element.
The drag force of the fluid carries the droplets towards the outside of the element where they combine into larger drops.
The large drops are susceptible to force of gravity and flow into the sump located at the bottom of the vessel.
The elements use three different mechanisms to clean the process fluid.
Diffusion is responsible for the removal of particles and droplets sized 0.1 microns and below.
The particles collide with each other and get trapped on the medium due to random Brownian motion.
Particles and droplets between 0.1 and 1 microns are removed through interception due to turbulent flow force which drives the contaminants into the fibers.
· Direct Impaction
It helps remove particles above 1 micron.
The large particles collide and stick to the medium fibers
What are the Applications of Coalescing Filter Element?
Coalescing filters are mandatory for numerous applications and industries which require removal of liquid contaminants from the main process fluid.
Some of the applications which require coalescing filter elements for smooth operation include:
- Filtration of compressed air
- Filtration of natural gas and seal gas
- Pre-filtration of sterile air
- Protection of desiccants/Refrigerators
- Elimination of mists
- Oil and water separation
- Protection of pneumatic valves and cylinders
- Equipment for food packaging
- Paint processes
- Automotive and electrical processes
- Air purification for instrumentation on and process control
- Pneumatic tool protection
- Vacuum pumps
- Petrochemical industries
- Filtration of oxygen, nitrogen and hydrogen sulfide gases
- Oil filtration
How does Coalescing Filter Elements compare to other Filter Element?
The main difference between the coalescing filter element and particulate filter elements is the function and principle of operation.
While the coalescing filter element can remove both solid and liquid contaminants, particulate filters elements can only remove solid contaminants.
Coalescing filter elements filter from inside to outside while particulate filter elements remove contaminants from outside to inside.
In comparison to adsorption filters, the difference comes in both structural components and function.
The adsorption filters cannot remove both solid and liquid contaminants but will remove oil vapor which the coalescing filter cannot remove.
What are the Benefits of using Coalescing Filter Element?
Using coalescing filters offers numerous advantages including:
- Efficient removal of liquid and solid contaminants at various micron rating by up to 99.99%
- Reduction in the concentration of liquid aerosols contaminants to below 5 ppm
- You can easily upgrade or customize the filter elements and housing to meet the special requirements of your filtration system.
- Provision of high surface area for removal of impurities
- Dual application, that is, solid and liquid contaminants filtration
- Lower costs of operation and maintenance
- Protection of downstream system components from corrosion
- Reduction of wear and tear of sensitive equipment in the system
- Provision of process fluids that meet the cleanliness standards required by end-users and different OEM specifications.
- Reduced downtime costs
- Extended fluid life in hydraulic systems
- Improved system reliability and durability
What are the Features of a Good Coalescing Filter Element?
A high quality coalescing filter elements should possess the following qualities:
- Meet the industry and regulatory codes and standards
- Lower pressure drop
- Higher dirt holding capacity
- High filtration efficiency
- Oleophilic or hydrophilic medium
- Easy to install and/or clean
- Fully bonded sleeves to avoid contamination of downstream fluids
- Allow zero bypassing
- Able to withstand high pressure and temperature
- High mechanical strength
- Quality sealing to avoid bypassing
- Compatible with multiple standard housing designs and models
- The end caps should be reinforced with a suitable fiber to ensure trouble-free operation
Which Contaminants does Coalescing Filter Element Remove?
The presence of contaminants in the process fluid threatens precision application requiring critical workplace cleanliness and product purity.
There are four classes of impurities common in industrial process fluids.
They include solid particles, water, Oil, microbes, and unwanted gases such as carbon dioxide, methane, ethane, etc.
Coalescing filters remove the first three classes of contaminants which are mainly found as suspended aerosols, vapor, emulsions, or dissolved impurities.
Coalescing filter element filtration
Water contaminants can be introduced as emulsions, vapor, and condensate.
Three main classes of water contaminants include free water, entrained water, and dissolved water.
Free water is large water droplets that remain after the process fluid has dissolved maximum water content.
You can remove free water using a mechanical barrier because they easily drop to the sump when you reduce the velocity of process gas.
Dissolved water is not visible and the quantities will depend on the temperature and chemical properties of the process fluid.
A warmer fluid is capable of holding higher quantities of dissolved water.
Entrained water is free water droplets that exist on the fluid flow as emulsification and is visible to the naked eye as a haze.
The particles can merge to form free water droplets.
Entrained water is the most problematic type in most applications as it can cause damage to several system components.
Coalescing filter elements are the only viable option for removing entrained water
Oil can contaminate the process fluid through numerous routes.
Some of the most common contamination occurs through leakage or oil spillage of oil and gas production facilities.
Other possible contamination sources include oil, volatile solvent and paint vapors, condensed or lube oil, and carbonized oils.
In the case of applications that deal with gas or air compression, then contamination can originate from lubricated joints of the compressor.
The type of compressor used will significantly determine the amount of oil introduced into the process of gas/air.
Even though you can use oil-less compressors, oil contamination is still a problem as natural air and gas contain destructive levels of oil that you must remove.
· Solid Contaminants
The source of particulate contaminants will vary from one application to the other.
They can originate from external sources or from within the system.
Possible contaminants can include rocks, sand, dust, rust and pipe scales, pollen, yeast cells and spores, mold, welding flash, airborne carbon, corroded metals, and pipes, etc.
The size of contaminants will vary greatly depending on the type of pre-filters installed on the upstream.
To enhance the performance and long service life of a coalescing filter element, you can install strainers and particulate filters upstream to remove the majority of the particles.
Using pre-filters can extend the service life a coalescing filter element by between four to ten times compared to no installation of any pre-filter.
Coalescing filter element traps the particulate contaminants on the inside surfaces made from fine meshes.
Continuous retention leads to clogging of pores in the long run hence you will need to conduct regular inspections to replace the elements appropriately.
Other important contaminants include molds, sulfur, and wax.
What are the Risks of Using Ineffective Coalescing Filter Elements?
An ineffective coalescing filter is an element which for one reason or the other fails to meet the filtration efficiency expected of it.
The poor performance can be due to the manufacture of low-quality elements that cannot achieve the required level of filtration or easily raptures and allows for bypass.
An ineffective coalescing filter element will cause the following problems:
- Solid contaminants can damage the system components including valves, pumps, seals, and plug injectors.
- Consecutive bombardment of the inner walls of piping and other equipment also accelerates the wear and tear processes.
- Contamination of final product which drastically reduces the quality of the product
- Water will corrode the system, especially if it saline in nature. It will also cause rusting of system components and deterioration in the quality of filtration.
- It reduces the lifespan or damages sensitive components in the systems like the gas turbine, injectors, pumps, etc.
- If the water is present in high quantities, it may crystallize when temperatures fall below freezing point and block the system pipelines and other components.
In extreme scenarios, the freezing can even explode the nozzles of injectors.
- Furthermore, microbial contaminants which feed on hydrocarbons and degrade the quality of fuel can only proliferate in the presence of water
- Water can also lead to the formation of varnish and acids in engines if it is present in a very high quantity in the fuel.
How do you Determine the Efficiency of Coalescing Filter Element?
You can conduct efficiency tests as described under ISO 12500-1 standards for testing the performance of compressed air filter elements in removing oil aerosols.
Accordingly, you will supply oil aerosol measuring between 0.1 and 0.3 microns using a nozzle to a clean stream of incoming fluid.
You should maintain a fluid inlet pressure of 101.5 psi and temperature at 20°C.
Use a photometer to count the amount of supplied aerosols until element wetting and the corresponding amount of aerosols that pass through the element.
Also, record the pressured drop across the element before and after the provision of aerosols.
Average a minimum of three readings, work out the beta ration, and present results on percentage removal efficiency, pressure drop, and percentage oil penetration.
What Types of Coalescing Filter Elements are there?
There are two main types of coalescing filter elements which are classified depending on types of application.
Types of coalescing filter element
· Liquid-liquid Coalescing Filter Elements
You will use these types of coalescing filter elements to remove the liquid contaminants that are suspended on the continuous phase of the process liquid.
The two liquids you are separating must be immiscible and have different densities for the filter elements to work appropriately.
As the continuous phase liquid passes through the coalescing element, the fibers amalgamate the non-continuous droplets into large drops which are acted upon by gravity.
These devices are suitable for diverse applications such as removal of water from hydrocarbons, oil, strong solvents.
You can also use them to separate hydrocarbons from different contaminants including amines, caustic, water, etc.
These coalescing elements can remove 99.9% of liquid contaminants from the continuous phase at different rated microns.
The coalescing element should have sufficient surface area for the removal of liquid contaminants.
Where two or more elements are mandatory, use a coupler to fit them together in the housing to increase the surface area for efficient filtration.
Also, ensure that you select housing with sufficient sump depth to avoid recombination of the two liquids once the elements break the emulsion.
· Gas-liquid Coalesce Filter Element
Liquid-gas coalescing elements remove liquid contaminants from gas or air process fluid.
Because of the high velocity characterizing gas processes, the filter element should be able to withstand high dirt holding capacity and high flow rates.
The contaminated gas will pass through the element from inside to outside.
Consequently, the filter will retain solid contaminants on the inside and releasing large liquid droplets on the outside.
You can use these types of coalescing filter elements in many industries to provide clean gases or compressed air.
You can use the elements to remove water and oil contaminants from compressed air systems. For optimum performance, use high pressure and low temperature.
You can also use coalescing filter elements to recover lube oil from compressor systems downstream.
Similarly, they will remove hydrocarbon and water contaminants down to 0.3 microns at 99.99% effectiveness.
Consequently, some of the special types of coalescing filter elements manufactured for specific application include:
- Natural gas coalescing
- Seal gas coalescing elements
- Oil coalescing elements
- Fuel gas coalescing elements
- Diesel coalescing elements
- Condensate coalescing elements
- Compressed air coalescing elements
- Water coalescing elements, etc
What are the Components of Coalescing Filter Element?
The design of a coalescing filter element significantly varies from one manufacturer to the other.
However, standard coalescing filter elements consist of the following parts:
Parts of coalescing filter element
Double O-ring: The gasket provides sealing to avoid bypass of the process fluid.
Stainless steel support: The support core is constructed using stainless steel and provides mechanical strength against the system pressure to avoid rupture.
You can have an internal and external support core.
The internal support core is located on the innermost side of the element and the external support after the external media retainer.
Media retainer: The media retainer contains the medium material. You can construct the retainer using different materials but fiberglass is the most common.
It protects the medium on both sides and provides it with enhanced mechanical strength.
Filter media: The medium is made using diverse materials. It retrains the particulate contaminants and initiates the coalescing process.
Drain layer: Also known as the anti-re-entrainment layer. It facilitates the collection and drainage of coalesced liquid to the sump to avoid carry-over effects.
End caps: You can fit end caps at both ends of the filter element. The material for constructing the end cap should be non-corrosive.
Some end caps are color-coded and provide an accurate and easy indication of the filtration grade.
The end cap ribs will guide to install the element centrally inside the housing.
Air distribution duct: It allows for uniform distribution of the airflow through the medium.
Annular location ring: The device is located on the lower end cap and prevents the vibration of the coalescing element while enhancing stability.
What are the Characteristics of High-Quality Coalescing Filter Media?
Understanding the technical characteristics of any coalescing filter is mandatory before attempting to configure it in your operations.
Some of the best technical characteristics may include:
- The filtration efficiency of liquid removal should range from 95% to 99%.
- The elements must remove more than 98% of solid and droplets larger than 1 micron
- Depending on the application, the coalescing filters elements can handle up to 250 m3 per hour or 50 million m3 per day.
- The residual volume of contaminants in filtered gas should be less than 1 mg/m3
- The elements can withstand operating temperatures of up to 150°C for filtration of solids and up to 90°C for the removal of liquid contaminants.
How do you Test the Quality of Coalescing Filter Element?
You can test the quality of a coalescing filter element through performing a series of tests.
The test will depend on the type of a coalescing filter element and the application which you are using it on.
Some of the tests you can perform on the coalescing element include:
- DOP test
- NaCI test
- LASE test
- ANSI/CAGI test
- Bubble points test
- Flow test
- Dirt loading test
- Contaminated pressure test
How can you Rate Coalescing Filter Element?
Filter rating indicates the efficiency of a filter element to remove and retain contaminants of a particular size.
You should define both the particle size and the removal efficiency when rating a coalescing element.
Different types of coalescing filter element
· Micron Rating
You can rate coalescing filters through a nominal rating scale.
The rating indicates the size of particles the element is capable of retaining.
The percentage of contaminant removal efficiency can also be indicated.
· Beta Ratio
This type of rating indicates both the size of the particle element is capable of retaining and the beta ratio.
The beta ratio is derived from a multi-pass filter element test.
To derive the ratio, challenge the elements with a known amount of contaminants of a particular size then detect how many have gone through the element.
Divide the number of particles that have gone through the element to those you fed in.
The provision of both the micron rating and beta ratio provides a comprehensive description of the effectiveness of a coalescing filter element.
What Factors Determine the Effectiveness of Coalescing Filter Element?
The filtration efficiency of a coalescing filter element depends on numerous factors.
Some of the key considerations include:
- Upstream installation of pre-filter: Though primarily considered for cost reduction, a pre-filter will also help extend the service life of a coalescing filter element.
- The nature, type, and characteristics of the contaminants: Viscosity and stickiness of the liquid being removed play a major role in settling time of the droplets.
- The size of droplets: Fine size droplets are more difficult to coalesce and require more settling time to drop out of the continuous phase/process fluid.
- The pore size in the fiber and thickness of the media: Elements with smaller pore sizes and thicker medium offer greater resistance to fluid flow although they capture more contaminants.
- The velocity of the process fluid: Increasing the phase velocity to optimal levels also increases the momentum of contaminants thus increasing the probability of contaminants striking and sticking on the medium.
- The level of contamination of the process fluid
- Pressure drop: As the pressure drop towards the change out pressure, the filtration efficiency starts to decline.
- Medium porosity/void volume: Selecting a medium having a higher void volume to construct elements lowers the clean pressure drop, extends the service life, and effective filtration area.
How long will Coalescing Filter Element Last?
The service life of a coalescing filtration system greatly varies from one application to the other and one process to the next.
Some of the factors which will affect the service life of coalescing filter elements include:
- The dirt-holding capacity of the elements
- The nature and size of contaminants
- The type of material used to construct the medium
- The amount of dirt in the incoming process fluid
- The flow rate of the process fluid
- The type of medium
Depending on these factors, the coalescing filter element can last from a few days to several months.
Consequently, most manufacturers recommend that you should change the filter elements at least once per year even if it has not depleted its dirt holding capacity.
When should you Replace Coalescing Filter Element?
You should replace the coalescing filter element when it reaches the designated change-out pressure drop.
As the element retains more and more dirt, the pores of the medium get blocked until a given differential pressure drop level where the elements will reduce the effectiveness.
At this level, you should change the coalescing filter element to avoid risks of bypass contaminants that will affect the flow of process operation.
Usually, coalescing filter assemblies come with attached differential pressure devices that measure and present the pressure drop across the elements.
You should inspect these devices daily and record the readings.
Automatic differential pressure devices will signal the alarm to indicate when the coalescing filter element is due for replacement.
Different manufactures recommend different change-out pressure drops for coalescing filter elements.
The initial pressure drop of a new element range between 1-2 psi.
Depending on the manufacturer’s recommendation, you should change the filter elements somewhere between 8 to 15 psi pressure drop.
Remember, filter replacement is an important process that determined efficiency and reliability.
What should you consider when Selecting Coalescing Filter Element?
The selection of the most appropriate coalescing filter element depends on different factors influencing filtration efficiency. Some of the most important factors include:
· Nature of the Process Fluid
The nature and characteristic of your process fluid will significantly influence the type of material you choose to construct the element.
The material for constructing the element must be compatible with the process fluid, that is, the process fluid must not corrode the elements.
You should determine the characteristic of your fluid beforehand to know whether it is acidic, oil-based, basic, aqueous, oxidative, or solvent-based.
· Flow Rate
The flow rate of the fluid directly depends on the applied pressure and system resistance.
However, the viscosity of a fluid directly affects the resistance and is inversely proportional to the flow rate.
You should, therefore, select a filter element that has the same flow rate rating as the system rating.
Choosing an element with a lower flow rate rating will significantly impose a very high-pressure drop and reduce the filtration speed.
Similarly, an element with a higher flow rate rating will affect the coalescing efficiency of the element.
· Operating Temperature
The operating temperature directly influences the rate of element corrosion, fluid viscosity, medium compatibility, and extractible.
The choice of medium material is important as most disposable elements constructed using natural material like cellulose cannot withstand very high temperatures.
The condition is even worsened when the high temperatures coincide with high-pressure differentials for prolonged periods.
· Pressure Drop
Pressure drop is a result of resistance imposed on fluid flow by the filter element.
The amount of pressure loss directly depends on pore size, medium porosity, thickness, and effective filtration area.
When selecting an element, you should understand how the depth, pore size, and thickness relate to resistance against fluid flow.
You should consider both the dry pressure drop or the differential pressure on a new coalescing filter element as well as the incremental pressure drop.
The dry pressure drop should not exceed 2 psi.
· Effective Filtration Area and Dirt Holding Capacity
The effective filtration area of a coalescing filter element is the face surface area and is directly proportional to the dirt holding capacity of the element.
The dirt-holding capacity of the element determines its service life.
It also has a direct effect on element replacement intervals and associated costs such as downtime and maintenance costs.
The larger the dirt holding capacity of an element, the lower the costs of filter replacement and downtime.
· The Required Degree of Filtration/Filtration Efficiency
The performance of a coalescing filter element is the most important factor to consider when selecting the element.
Also, the element has to remove the fluid contaminants at the desired level of cleanliness.
You should not select a filter with a lower pore size than required because it will add to the unnecessary cost of element replacement due to fast clogging.
You will also incur a higher cost of energy consumption because of the consumption of more energy in pushing process fluid across the element due to higher resistance.
You should also consider other factors such as effective filter area, thickness, porosity/void, and pleating which can significantly influence element performance.
· Operating Pressure
You have to select a filter element that has a similar pressure rating as the system pressure.
Selecting the wrong filter can result in huge downtime and repair costs due to element disintegration and component damage.
Can you Clean Coalescing Filter Element?
Yes, you can clean only reusable coalescing elements.
In most cases cleaning coalescing filter media, specialty media, and high efficiency coalescing media can be challenging.
However, some manufacturers make cleanable coalescing element from the synthetic medium.
You must confirm whether the coalescing element you are using is the cleanable type before attempting to clean it.
How much does Coalescing Filter Element Cost?
You can spend between 20 to 40 dollars on a single coalescing filter cartridge at a wholesale price.
You should note that there is a minimum number of elements you have to purchase to qualify for the discounted prices per piece.
The price of the coalescing elements significantly depends on the quality and quantity of the coalescing filter element you purchase.
How can you Determine the Surface Area of Coalescing Filter Element?
Determination of the coalescing filter element surface area is crucial in working out the required number of cartridges for efficient fluid filtration.
Increasing the filtration area helps extend the service life of filter elements and lowers the cost of operation.
Particle and coalesce filter element
Consequently, you can follow these steps to determine the filtration surface area.
- First, you have to determine the length of your filter element by dividing the total flow rate of your process fluid with its specific flow rate.
- Determine the required quantities of cartridges by the figure obtained above with the length of the cartridge you selected.
How do you Maintain Coalescing Filter Element?
You should follow these maintenance tips to ensure that your coalescing elements function optimally.
- Ensure that you store new unused coalescing filter elements in their original unpacked container under a clean and dry environment.
Check the elements for any visible damage before installation.
- Always use the coalescing filter elements from the OEM which are compatible with the filter housing.
Where possible, try and avoid using third party elements. Using third party elements will nullify your warranty cover in case of any damages.
- You should install a particulate pre-filter to remove a huge chunk of the solid contaminants before they reach the coalescing filter element.
This will help you reduce maintenance and downtime costs because the coalescing elements will serve you longer.
- You can install the coalescing filter elements only at the point of use in cases where the process fluid cleanliness differs along the circuit.
- Constantly monitor the differential pressure to confirm the condition of the element.
The differential pressure indicator will enable you to detect any malfunctioning of the elements or when the element is due for change-out.
- Replace worn out or raptured/damaged coalescing filter elements immediately you notice a sharp pressure drop.
- You should also change the filters as soon as they reach their full-service life which varies from 7 to 15 psi depending on the manufacturer’s recommendation.
Alternatively, you can clean and reuse cleanable elements.
- You have to replace the coalescing elements at least once in a year in case the elements fail to reach full-service life within the year.
- Ensure that you drain off the coalesced water in the sump daily or per cycle load to avoid operation interruption.
- Do not back-flow the filter unless permitted by the manufacturer.
What are the Quality Standards for Coalescing Filter Elements?
The quality standards requirements of a coalescing filter element depend on the type of application and industry it operates under.
For example, coalescing filter elements for filtration of compressed air must comply with standards specified under ISO 12500.
Depending on the efficiency of filtration, the element can be classified into different classes as specified under ISO 8573-1.
Similarly, coalescing filter elements used for filtration of fuel products should meet the requirements of ISO 4405 and ISO 4406 standards.
Other important industry standards include ASME B16.5, ASME B16.47, ASME BPVC, and EN 10204 type 3.1.
What are the Safety Precautions when Replacing Coalescing Filter Elements?
You should implement a good safety and precaution guideline to reduce accidents in the workplace and also ensure proper function of the filter element.
The safety measure depends on the type of application, the toxicity of the fluids, and the level of cleanliness required.
You can follow these tips for maximum safety measures when handling coalescing filter elements.
- Observe all the government regulations on safety measures before servicing the filter.
- Before opening the coalescing filter vessel, make sure that you switch off the pumps and close the outlet and inlet valves.
- You should also depressurize and drain the coalesced liquid and process fluid inside the vessel completely.
It helps minimize the recontamination of downstream fluid by dirt contained in the element as well as reduce risk from pressure explosion.
- Disconnect the filter assembly from any electric connection before handling to avoid being electrocuted.
- Avoid touching the surface of a clean coalescing filter with bear hand and other greasy materials.
You should install the cartridge while still covered with the polybag.
Remove the polybag slowly to avoid creating any electrostatic charges on the surface of the cartridge.
- Ensure that you clean the housing vessel every element change-out interval.
Confirm the most appropriate cleaning solution to use as detergent suitability significantly varies between applications. In most cases, you can use a clean product you are filtering or dilute leach.
- When tightening the elements, follow the instructions on the recommended torque, and use appropriate force to avoid overtightening.
- Use a spider to connect multiple cartridges in a single filter housing.
The devices will help you avoid risks of fire explosions from electrostatic charges in applications like fuel coalescing elements.
- Ensure that you close all the valves before you open the fluid lines after servicing.
- Test the filter for normal operation and leakage after every servicing.
Do not subject the filter to full flow operation should you detect any abnormalities.
- When handling toxic fluids like hydrogen peroxide or natural gas, ensure that you implement all the appropriate protective measures.
Also, flush the filter with an inert fluid or gas before you open it for servicing.
For combustible fluid, ensure that the working environment is free from any explosive materials.
How can you Increase the Filtration Efficiency of Coalescer Filter Element?
The filtration efficiency of a coalescing filter depends on numerous factors.
You can manipulate the design and operations to enhance the filtration efficiency of a coalescing filter element.
The following measure will enable you to enhance the filtration efficiency of the coalescing elements.
· Installing a Pre-filter
The efficiency of a coalescing filter element does not solely rely on the percentage of dirt it can remove but also on the service life of the elements.
Since the main purpose of a coalescing element is to remove liquid contaminants, you can install an upstream pre-filter to remove most of the solids.
It will maximize the performance of a coalescing filter element in removing dirt and liquid contaminants.
· Increasing Fluid Velocity
You will increase the chances of smaller droplets impacting the medium fiber rather than flowing around it by increasing fluid velocity and momentum.
Ensure that you find the correct balance to avoid exceeding the maximum allowable velocity which would otherwise increase re-entrainment of the coalesced liquid.
· Using Appropriate Construction Material
The properties of the coalescing medium will depend on the characteristics of the process fluid and liquid contaminants you want to remove.
When you are separating two liquids, then you must select materials that attract the contaminating fluid.
For instance, if you want to remove water from oil, using a hydrophilic material will facilitate a faster amalgamation of the tiny droplets at the intersection of the mesh.
Similarly, oleophilic material will also produce higher filtration efficiency when you are filtering out oil from water.
· Surface Treatment of the Medium
You can also treat the surface of a coalescing media to reduce its wetting properties.
This practice is more so critical in some gas-liquid applications.
Treating the media surface will lower the overall surface energy and enhance the draining of coalescing liquid drops.
It achieves this by lowering the attraction between the coalesced liquid and the medium fiber.
· Reducing the Pore Size of the Medium
Coalescing filter elements use different techniques in removing both solid and liquid contaminants.
The smaller the pore size, the more the contaminants the elements can remove.
Smaller medium pore reduces the probability of droplets to maneuver round the medium fibers.
· Reducing the Viscosity of Process Fluid
You can reduce fluid viscosity by increasing the fluid temperature to optimal.
Reducing velocity reduces the drag forces on the droplets and allows the drops to settle at a higher fluid velocity.
How do you Determine Pressure Drop Across Coalescing Filter Element?
Pressure drop in coalescing filter results from a combination of both fixed and incremental pressure drop.
The fixed pressure loss comes with new housing and elements while an incremental pressure drop is a result of element plugging with dirt as it operates.
You should monitor the pressure drop across the coalescing filter element throughout the period to ensure that you change it as it reaches the change-out pressure.
You can use a differential pressure gauge with a pop-up indicator to show pressure readings on the inlet verse outlet of the element.
Alternatively, you can also install two differential pressure gauges, each at the inlet and outlet ports then subtract the downstream pressure from the upstream pressure.
Ensure that you take the readings only when the system is in operation to avoid the false-negative result.
The pop-up indicator is always marked with green, yellow, and red colors and mainly lets you know whether the element is due for replacement or not.
Green means good, yellow alerts you that the service life is almost over and red means you should replace the elements.
Why Import Coalescer Filter Element from China?
Chinese manufacturers have a state of art facilities that produce high quality coalescing filter elements.
The products meet diverse industrial and regulatory quality standard requirements over a wide range of applications.
We have a dedicated team of leaders and technical experts who will strive to meet your special needs at a reduced price.
When you buy from us, we ensure that we provide a stable and trustworthy relationship with you.
We offer you an opportunity to cut on the cost of production from our discounted prices.
In short, before buying coalescing filter element, you should consider everything mentioned in this guide.
It will help you optimize you coalescing filtration process.
However, if you have more questions on a coalescing filter element, feel free to contact us