Efficient Multi-Stage Combined Filtration Separators: Precision Separation for Gas-Liquid/Solid Systems

Introduction  

Efficient multi-stage combined filtration separators can provide customers with efficient and economical gas-liquid/gas-solid separation filtration solutions. To improve separation efficiency and reduce entrainment, meet customers' demanding operating requirements, and protect downstream equipment. Our company produces two types of filter separators: discrete and horizontal. The vertical separator is used for droplet removal applications and small footprint working conditions. Horizontal separator: used for processing high flow rate droplets. The filter separator mainly consists of a cylinder, a head, a support, a quick opening blind plate, a filter element, an inlet, an outlet, a liquid collection bag, and other components. When the gas content is high, a blade separation component can be installed in the settling section of the filter separator.

Working principle

The gas enters the filter through the inlet and first passes through the anti-collision baffle to remove large solid particles and some entrained liquids. It collides with the support tube that supports the filter element (to avoid direct impact of the airflow on the filter element, causing premature damage to the filter material). The larger solid-liquid particles are initially separated and settle to the bottom of the container under the action of gravity (regularly discharged from the discharge outlet).

Then the gas passes through the filter cartridge from the outside in, and the solid particles are carried by the filter medium. The liquid particles gradually aggregate and grow on the inner surface of the filter cartridge due to the aggregation function of the filter medium. When the droplet reaches a certain size, it will fall off from the inner surface due to the impact of the airflow and enter the internal flow channel of the filter before entering the discharge chamber. In the outflow chamber, larger liquid droplets are separated by gravity setling peaks. In addition, there are separation elements in the outflow chamber that can effectively capture liquid droplets to prevent the outlet droplets from being carried, further improving the separation efect. The clean gas flows out of the filter separator afterwards. As the amount of gas passing through increases, particles deposited on the filter can cause an increase in the pressure difference of the gas filter.        When the pressure difference rises to the specified value, it indicates that the filter element has been clogged and should be replaced in a timely manner.

Filtering/Agglomeration System

After passing through the baffle, the gas flows through the filter from the inside out. Due to the increase in diameter, the flow velocity decreases as the gas passes through the coalescence layer. This enhances the coalescence of droplets and provides the possibility of droplet settling under gravity.

The aggregation element is equipped with a pleated filtering section for removing solid grains. The filter layer also prevents the aggregation layer from scaling, which can reduce the separation efficiency. The pleated filter element provides a larger filtering area to achieve good solid retention ability.

The aggregation layer of the aggregation element provides two functions:

1) The structural strength of the component can withstand the pressure difference that occurs on the filter layer due to solid removal. Due to its strength and comprehensive performance of the aggregation layer, the aggregation medium has a 100% free flow area available for effective aggregation, while compared to aggregation elements with porous metal support tubes, the aggregation medium has less than 50%.

2) Agglomeration of glass fibers through ultrafine treatment. Tiny droplets temporarily adhere to fibers, causing them to meet and coalesce into larger droplets.

On the outside of the aggregation element, droplets are discharged along the drainage pipe assembled on the outside of the element to the liquid collection area.

After aggregation, the gas is clean and dry. Gas enters the top of the equipment and flows out of the equipment.

Technical Parameters

Filter separator material: CS, SS

Filtering accuracy: 0.1 p m to 5 p m

Filtration and separation efficiency:>1pm solid impurities,filtration efficiency 99.0%

Solid impurities > 3 μ m, filtration efficiency 99.5%

Solid impurities > 5 μ m, filtration efficiency 99.8%

Solid impurities > 1 μ m droplets,filtration efficiency of 98%

Agglomeration separation efficiency: > 0.3 p m

droplets, filtration efficiency 99.8%

Design temperature: -40-80° C

Design pressure:0.6,1.0,1.6,2.0,2.5,4.0,6.3 MPa

Structural features

Liquid and larger solid particles are achieved by providing barriers in the form of baffles in the airflow entering the coalescer. The density of droplets and solid particles is more than 25 times higher than that of compressed gas. The baffle suddenly turns in the direction of the airflow, and due to their momentum, droplets and solid particles are pushed out of the airflow and collide with the baffle. Droplets coalesce on the baffle to form a liquid film, which captures solid particles. The film flows downwards, and the liquid falls into the non flowing collection area, carrying separated solid particles.

Efficient dust filter element

The high-efficiency dust filter is made of polyester fiber filter and PEM material, without a supporting core, and has high strength and rigidity; Corrosion resistance and erosion resistance; It can also come with a metal support core and be interchangeable with fiberglass filter cartridges; A circular structure that is not easily damaged; The increasing (or decreasing) density of each layer of the filter element gives it high storage and agglomeration capacity;

Efficient folding coalescing filter cartridge

The high-efficiency coalescing filter element is applied in gas filtration,which can effectively remove 99.9% of 0.3um solid particles in the gas. It separates oil, water and other liquid droplets from the gas through coalescing and collects them at the bottom of the filter to prevent the coalescing droplets from entering downstream gas treatment. In gas turbine power plants, natural gas, petrochemical and other fields, it can be used to remove lubricating oil, water or other corrosive substances in steam turbines and compressors, reducing equipment maintenance and upkeep costs.

Application Field

1.The purification and separation of raw gas in the production of petroleum, chemical (such as synthetic ammonia, nitric acid, methanol), natural gas extraction, diesel hydrogenation tail gas recovery and other processes are used to separate and remove harmful substances or recover useful substances with high quality and efficiency.

2.The natural gas distribution system pipeline removes lubricating oil, water, compressor wear products,corrosion products, and other pollutants from the gas.

3.Natural gas metering and monitoring station, protecting gas flow meters to ensure correct flow indication.

4.Natural gas compressor station,protecting compressors and turbines.

5.Natural gas power plants, power plants, refineries, petrochemical plants,reduce solution loss in gas purification units; Clean fuel gas and protect combustion devices; Prevent blockage of the liquid injection well bore during gas overflow; Protect catalysts, desiccants, and adsorbents.

6.Suitable for occasions requiring high liquid storage capacity,both vertical and horizontal collection tanks can be provided.

 Q&A

Q1: How to choose between vertical and horizontal models?

A: Choose vertical for:

Limited space (e.g., offshore platforms).

Low to medium flow rates (<500 m³/h).

Priority on droplet removal.

Choose horizontal for:

High flow rates (>500 m³/h).

Large liquid loads (e.g., gas with >10% liquid content).

Easier maintenance access.

Q2: What determines the combination of separation components?
       A: Base it on the feed medium:

Gas with large droplets + fine mist: Blade + coalescing filter.

Gas with solid particles + droplets: Cyclone + filter element.

Emulsified liquids: Coalescing filter + blade.

Q3: How often should filter elements be replaced?
       A: Replace when the pressure drop across the filter exceeds 0.1 MPa (typically every 6–12 months, depending on contaminatio levels). Blade assemblies can be cleaned periodically (annual inspection recommended).

Q4: Can the separator handle corrosive media?
        A: Yes—opt for 316L stainless steel or Hastelloy® materials for corrosive environments (e.g., sour gas, acidic liquids).