AquaSep® XS Coalescers product photo Primary L

AquaSep® XS Coalescers

Introduction

Pall’s new AquaSep XS liquid/liquid coalescer system is a lower cost solution to separate emulsions versus competitive cartridge coalescers, sand beds and electrostatic precipitators (ESPs). Its cost effectiveness is due to the ability of each coalescer element to process a higher flow while still providing superior effluent quality. Up to 60% more flow per element is now achievable, resulting in significantly lower capex, smaller footprint and volume, as well as reduced weight. Outlet quality is superior to competitive offerings. See Figures 1, 2, and 3 below.

Description

The AquaSep XS system is a multiple-stage system starting with filtration to remove particulate matter, followed by either a one-stage horizontal coalescer or two-stage integrated vertical coalescer/separator stack to separate the two liquid phases. AquaSep XS coalescers will remove free water to a level as low as 15 ppmv1 and be effective over a wide range of conditions such as inlet liquid contaminant concentration as high as 10% and interfacial tension less than 20 dynes/cm.

The AquaSep XS coalescer system is available in two different housing configurations. Both configurations begin with a filtration stage to remove solid contaminants.

Table 1: Coalescer Selection Guide

 
Process Condition Recommended Product
The dispersed phase fluid is aqueous and a horizontal vessel footprint is acceptable AquaSep XS coalescer in a horizontal housing without separator
The dispersed phase fluid is oil and the continuous phase fluid is aqueous
The dispersed phase fluid is aqueous and minimal footprint is required AquaSep XS coalescer/separator stack in a vertical housing
 

AquaSep XS Coalescer— Horizontal Housing Configuration

In a horizontal housing, the liquid/liquid mixture enters the coalescing element and flows inside-to-outside, small liquid dispersed phase droplets suspended in the continuous phase come together, or coalesce, as the mixture moves through the AquaSep XS coalescer. The large coalesced droplets of the dispersed phase separate by gravity in the horizontal housing and are removed. The size of the housing is a function of the flow rate, IFT, viscosity, and specific gravity of the liquids.


AquaSep XS Coalescer/Separator Stack— Vertical Housing Configuration

The liquid/liquid mixture enters the coalescing element and flows inside-to-outside. Small liquid droplets suspended in the continuous phase come together, or coalesce, as the mixture moves through the coalescer medium.

Contaminant-free liquid and large droplets of the dispersed phase flow toward the separator located directly below the coalescer stage. The flow is outsideto- inside. The separator medium is hydrophobic preventing the aqueous phase from entering the separator. Only the non-aqueous continuous phase fluid flows through the separator. The two liquids are removed by separate drain connections.


1Performance can vary depending on application.


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Description

Introduction

Pall’s new AquaSep XS liquid/liquid coalescer system is a lower cost solution to separate emulsions versus competitive cartridge coalescers, sand beds and electrostatic precipitators (ESPs). Its cost effectiveness is due to the ability of each coalescer element to process a higher flow while still providing superior effluent quality. Up to 60% more flow per element is now achievable, resulting in significantly lower capex, smaller footprint and volume, as well as reduced weight. Outlet quality is superior to competitive offerings. See Figures 1, 2, and 3 below.

Description

The AquaSep XS system is a multiple-stage system starting with filtration to remove particulate matter, followed by either a one-stage horizontal coalescer or two-stage integrated vertical coalescer/separator stack to separate the two liquid phases. AquaSep XS coalescers will remove free water to a level as low as 15 ppmv1 and be effective over a wide range of conditions such as inlet liquid contaminant concentration as high as 10% and interfacial tension less than 20 dynes/cm.

The AquaSep XS coalescer system is available in two different housing configurations. Both configurations begin with a filtration stage to remove solid contaminants.

Table 1: Coalescer Selection Guide

 
Process Condition Recommended Product
The dispersed phase fluid is aqueous and a horizontal vessel footprint is acceptable AquaSep XS coalescer in a horizontal housing without separator
The dispersed phase fluid is oil and the continuous phase fluid is aqueous
The dispersed phase fluid is aqueous and minimal footprint is required AquaSep XS coalescer/separator stack in a vertical housing
 

AquaSep XS Coalescer— Horizontal Housing Configuration

In a horizontal housing, the liquid/liquid mixture enters the coalescing element and flows inside-to-outside, small liquid dispersed phase droplets suspended in the continuous phase come together, or coalesce, as the mixture moves through the AquaSep XS coalescer. The large coalesced droplets of the dispersed phase separate by gravity in the horizontal housing and are removed. The size of the housing is a function of the flow rate, IFT, viscosity, and specific gravity of the liquids.


AquaSep XS Coalescer/Separator Stack— Vertical Housing Configuration

The liquid/liquid mixture enters the coalescing element and flows inside-to-outside. Small liquid droplets suspended in the continuous phase come together, or coalesce, as the mixture moves through the coalescer medium.

Contaminant-free liquid and large droplets of the dispersed phase flow toward the separator located directly below the coalescer stage. The flow is outsideto- inside. The separator medium is hydrophobic preventing the aqueous phase from entering the separator. Only the non-aqueous continuous phase fluid flows through the separator. The two liquids are removed by separate drain connections.


1Performance can vary depending on application.
Applications

Applications

Not all coalescers provide a high quantitative removal of dispersed liquid contaminants and can handle emulsions with low interfacial tensions (IFTs). For example, conventional cartridge coalescers made of glass fiber media begin to lose efficiency when the IFT of the emulsion gets below 20 dyne/cm. In contrast, the new AquaSep XS coalescer from Pall is constructed of a high-efficiency, polymeric medium, making it well suited for numerous liquid/liquid separation applications with very low IFTs including:

  • Removal of water from refined products with or without additive package, including gasoline, diesel, jet, and LPG
  • Separation of water from hydrocarbon condensates, refinery intermediates, naphtha, propane, propylene
  • Removal of water from aromatics
  • Separation of oil from water
Specifications

Product Specifications

 
Maximum operating temperature 60°C/140°F
Maximum differential pressure 3.4 bard/50 psid at 21°C/70°F
Recommended change-out 1.0 bard/15 psid at 21°C/70°F
 
Performance

Comparative Performance

NOTE:Comparison tests were performed in a Pall laboratory with a limited number of 20 inch elements that were purchased through standard commercial channels. Lab results may not be identical to test results with actual process fluid under field conditions.

Product Benefits

 
Features Advantages Benefits
High Performance
Polymeric Medium
  • Up to 60% higher flow per coalescing element
  • Smaller,lower cost system
  • Reduced incidents of off-spec product
  • Eliminates reprocessing, product degradation and transportation costs
  • Reduces costly corrosion problems in downstream equipment
  • Prevents catalyst deactivation in downstream processes
  • Longer service life of coalescer and prefilter elements
  • Lower operating costs versus less effcient alternative solutions
    • Salt driers, electrostatic separators and sand filters
  • Fewer cartridge change-outs, reduced maintenance costs and waste disposal costs
  • Tolerant to process upsets,can remove slugs of liquids
  • Consistent fluid quality
 
Non-Disarming Medium
  • The medium does not disarm in the presence of surfactants. Disarming occurs when surfactants (either natural or additives) “coat” the surface of the medium
  • Consistent fluid quality
  • Eliminates ongoing labor costs to change out disarmed glass fiber coalescers
  • Ability to separate emulsions with IFTs lower than 20 dyne/cm
  • Reliable use of liquid/liquid coalescers on challenging applications such as final fuels with additive package,refinery intermediate streams, hydrocarbon condensate, stabilization, naphtha feed in ethylene plants
Availability of a High Performance Integrated Stack Design-Coalescer and Separator
  • Higher flow per cartridge because of even flow distribution.In conventional two-stage systems, the separators are located at different distances from the coalescers. This causes poor flow distribution and the potential to re-atomize droplets that can bypass the separators.
  • Consistent fluid quality
  • Smaller,lower cost system
 
Type
Coalescers
Use
Coalescing, Separation
Application
Naphtha/Propane/Propylene Feed, PetroChem Final Product (Liquid), Chem Final Product (Liquid), Chem Raw Material - Liquid, Poly Cmdty Intermediate (Fluids), Poly Engrd & Spcl Intermediate (Fluids)