Liquid / Liquid Separation General Description
Liquid / Liquid Separation General Description
Liquid / Liquid Separation General Description
General Description
Development of new media and treatment of existing media permit use of
these coalescers for essentially all process streams where entrainment of
solids and liquid contaminants are present.
tain solids contamination of one form or
another, consideration must be given to
the type of contaminant involved and the
amount of contaminant in the fluid. The
next factor that affects the ultimate design
is the particle size distribution. From the
particle size distribution curve, a determi-
nation of how much of the solids contami-
nant to be retained in the cartridges can
be made. The fact that the solids to be
filtered are either hydrophobic or hydro-
phyllic is of importance. If a solid is hydro-
phobic it will be borne through the sys-
tem by the hydrocarbon phase and will
be more difficult to filter. The hydrophyllic
solid is carried by the discontinuous wa-
ter phase and during the mechanical ac-
tion of coalescence, this solid will largely
be deposited on the media of coalescer
cartridge.
Coalescer Cartridge
The coalescer cartridge is made up of
one or more layers of media. This media
is primarily a porous membrane which
retains its dimensional stability by the
use of thermal setting resins or binders.
Careful selection of the media is impera-
tive to insure that the fluid stream being
processed does not remove the binder in
Figure 1. A typical two-stage vertical coalescer. the media, which would result in media
Three basic designs of cartridge-type natural forces of gravity, the difference collapse and contamination of the fluid. In
coalescers are available for application in the specific gravity of the two liquids order to assure that coalescing of the dis-
in chemical processing. They are com- is important. As will be discussed later, continuous phase is complete, the media
prised of single-stage, two-stage, and the discontinuous phase may be lighter must possess an infinite number of irreg-
three-stage units wherein one, two or or heavier than the continuous phase ular continuous passages of very small
three types of cartridges are provided. without affecting the efficiency of the unit, diameter. These passages are such that
The configuration of each design will vary provided sufficient differential in gravity by impingement and preferential wetting
with the process application and efficien- exists. Since the natural forces of gravity of the media surface, the discontinuous
cy requirements. enter into the operation of the equipment, phase is commingled to a sufficient size
the viscosity of the fluids being processed where it can be removed from the con-
In determining the design of coalescer must also be taken into consideration. tinuous phase by gravitational force or
to be used, the maximum operating con- by contacting a second stage, commonly
ditions and minimum performance ef- One of the most important single factors referred to as a separator cartridge.
ficiencies must be established. With the to consider in the design of cartridge
performance requirements established, type coalescers is the interfacial tension Because of the extremely small pore size
the determination of the basic design and between the continuous and discontinu- of the irregular continuous passages
media to be utilized is made. Among the ous phase. Since the interfacial tension of the coalescing media an accessory
various factors which must be considered controls the maximum droplet size of the function of the media becomes one of
in arriving at the correct design are the discontinuous phase and relative wetting removing solids particles. Therefore, if
physical characteristics of the fluid to be of separating surface, the selection of a a given coalescing media possesses
processed. This applies not only to the coalescing media is of prime importance a sufficiently fine pore size to affect co-
continuous phase but equally well to the when low interfacial tension values are to alescing of a finely dispersed discon-
discontinuous phase. Since all coalesc- be encountered. tinuous phase, it will, at the same time,
ers, whether one-, two-, or three-stage provide excellent filtration characteris-
rely to a greater or lesser degree on the Since most fluid process streams con- tics. The degree of filtration will be in
Due to our continuing program of improvement, specifications are subject to change without notice.
copyright 2006 9910 EAST 56TH STREET NORTH, TULSA, OK 74117-4011 I-201
TEL: 918-272-8700 / 800-223-9910 FAX: 918-272-8787
E-MAIL: [email protected] www.facetusa.com
copyright 2006 9910 EAST 56TH STREET NORTH, TULSA, OK 74117-4011 I-202
TEL: 918-272-8700 / 800-223-9910 FAX: 918-272-8787
E-MAIL: [email protected] www.facetusa.com
Liquid Perchloro-
ethylene Water
pH 5.0
Temperature, °F 122
copyright 2006 9910 EAST 56TH STREET NORTH, TULSA, OK 74117-4011 I-203
TEL: 918-272-8700 / 800-223-9910 FAX: 918-272-8787
E-MAIL: [email protected] www.facetusa.com
For this installation a horizontal two- The contaminated fluid flows into the ous phase may occur depending upon
stage unit using multiple coalescer and large inlet chamber and the immediate the media used in the filter cartridge and
separator cartridges was used. This reduction in velocity will permit a portion the characteristics of the discontinuous
design was selected primarily because of the entrained discontinuous phase phase.
the discontinuous water phase is lighter and solids to settle out. The discontinu-
than the continuous phase. A second ous phase will then pass through the As the filtered product and discontinu-
important factor in selection of this de- lower half of the coalescer pack. Any ous phase flows from the first-stage filter
sign was the high concentration of wa- remaining entrainment is coalesced and cartridge, it is discharged directly into
ter in the process stream. The settling solids are filtered from the fluid as it flows the inside of the second-stage coalescer
area between the two stages permits the through the media. cartridge. The second-stage coalescer
major portion of the water to rise to the cartridge then performs the function of
accumulator sump before reaching the Single-Stage Unit Application completing the coalescing of the dis-
separator cartridges. Typical of a single-stage coalescer in- continuous phase and filtering out any
stallation is the following: remaining solids which may be in the
The physical and chemical characteris- stream. Immediately downstream from
tics of the continuous phase permitted Process problem: Removal of entrained the coalescer cartridge is a void area
use of conventional coalescing and sep- water containing sodium hydroxide from which provides settling space for gravita-
arating media. The hydrochloric acid dis- butadiene. tional fallout of the discontinuous phase.
solved in the water phase had reduced As the product flows to the outlet through
the pH to five which is within normal op- Operating conditions: Specific gravity the third-stage separator cartridge any
erating limits of glass fibers used in the 0.628 at 60°F. Flow 200 gpm Entrained remaining entrainment of the coalesced
coalescer cartridges and silicone treated water 10% volume; pH of water 9.5 to discontinuous phase is repelled and the
cellulose in the separator cartridges. The 10.0. Solids contaminant negligible. clean, dry product leaves the vessel.
operating temperature was considerably
less than the 275°F permitted for this Required performance: Water not to Use of a three-stage device permits a very
type of media. exceed 50 ppm in effluent. For the above wide selection of filter and coalescing
installation a single-stage horizontal unit media. This unit offers great advantages
All metal in contact with the process fluid using a bulk-type coalescer cartridge was for those installations where the solids
was of stainless steel and all non-metal- used. The design was selected because contaminant in the process stream is
lic parts are resistant to the corrosive ac- the pH value of the water phase exceeds relatively high, i.e., 5 mg/l. The first stage
tion of the hydrochloric acid solution. the recommended values for second- filter cartridges can be removed from the
ary separator cartridges of conventional unit without disconnecting any of the pip-
Single-Stage Unit media. The media selected was a fine- ing or without removing the cartridges in
A typical single-stage coalescer is shown grade stainless steel wool compressed the second- or third-stages.
in Figure 2. Single-stage units may be to an optimum density to provide maxi-
comprised of multiple installation of mum contact surface for coalescing and Application
coalescer cartridges as illustrated, or the minimum differential pressure. The use of cartridge-type coalescers, as
entire cross section of the vessel may applied to the chemical process indus-
be packed with a bulk-type media. This Three-Stage Unit try, has resulted from the development
design is used when the differential in A typical three-stage horizontal coalescer of new media and treatment of existing
specific gravity of the two liquid phases is shown in Figure 3. This unit consists media to permit their use. The art of co-
is sufficient to provide separation by of coalescer and separator cartridges alescing has advanced to a point where
gravitational force or where a separator as used in the horizontal two-stage de- there are only a few isolated process
cartridge would not possess sufficient vice, and is provided with a first-stage systems where cartridge-type coalesc-
repellent characteristics to the discon- cartridge whose primary function is the ers cannot be utilized.
tinuous phase. removal of solids contaminant from the
stream. The product enters the low-ve- Cartridge-type coalescers can be pro-
In the design of single-stage units, the locity inlet chamber where the larger vided for essentially all process streams
size of the vessel is of prime consider- particles of solids contaminant will settle where entrainment of solids and liquid
ation since separation is entirely depen- out by gravitational force. In this area, contaminant is present, the only limiting
dent upon the difference in the density any sludge or other heavy entrainment factors being equal density of the two
of the two liquids. Linear velocity in the will also settle out and accumulate in an liquid phases or essentially zero interfa-
settling area of the vessel will vary from auxiliary sump. Controls may be provid- cial tension.
0.25 ft/sec on light fluids to 0.10 ft/sec ed on the auxiliary sump for automatic
on heavier products. If the discontinu- blowdown of the accumulated material.
ous phase is lighter than the continu- As the fluid flows through the first-stage
ous phase the accumulator chamber is filter cartridge, the solids contaminant is
placed on top of the vessel. filtered from the stream. Simultaneously,
some initial coalescing of the discontinu-
Due to our continuing program of improvement, specifications are subject to change without notice.
copyright 2006 9910 EAST 56TH STREET NORTH, TULSA, OK 74117-4011 I-204
TEL: 918-272-8700 / 800-223-9910 FAX: 918-272-8787
E-MAIL: [email protected] www.facetusa.com