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Coalescer

A coalescer, in combination with a demister, achieves a separation efficiency of up to 99.5% in the droplet range 2-5µm.

A coalescer is a pad fabricated from a co-knitted composite fabric consisting partly of monofilaments, and partly of a staple fibre yarn. It is the smaller fibres that allow droplets in the size range of 2-5 µm to be captured in the gas stream. The fibres are much smaller in diameter compared to the threads used in the traditional wire mesh demister pads.

Compared to a traditional wire mesh demister, the pressure drop increases slightly, but not a lot as there is still a lot of space between the fibres in the coalescer.

AB Hansa Engineering AB
Alexander Bergman Droplet separation, Column internals, Spray nozzles & systems, Tank cleaning
I look forward to providing product advice and solutions! Let's meet via a video call or a site visit. You can also phone or email us, of course.
LC Hansa Engineering AB
Linda Caporicci Column internals, Droplet separation, Spray nozzles & systems, Other products
I look forward to providing product advice and solutions! Let's meet via a video call or a site visit. You can also phone or email us, of course.
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Separation efficiency up to 99.5% in the droplet range 2-5µm

Coalescer design

A coalescer is a pad fabricated from a co-knitted composite fabric consisting partly of monofilaments, and partly of a staple fibre yarn. It is the smaller fibres that allow droplets in the size range of 2-5 µm to be captured in the gas stream. The fibres are much smaller in diameter compared to the threads used in the traditional wire mesh demister pads.

The coalescer is usually manufactured as one unit with a support grid. Alternatively, the coalescer is manufactured in several sections to allow entry through manholes and smaller spaces.

Separation efficiency

Droplets in the size range of 2-5µm are trapped in the space between the small fibres in the coalescer and merge into larger droplets, which are then carried away by the gas stream. These larger droplets can then be captured in a completely separate demister. It is also possible to separate droplets in one step by manufacturing a unit consisting of a coalescer part with layers of demister mesh on top.

In installations where a coalescer is combined with a demister, a separation efficiency of 98% to 99.5% is achieved for droplets in the 2-5µm range. The pressure drop increases slightly, but not a lot because there is still a lot of space between the fibres in the coalescer.

Choice of material

Choice of material depends on temperature and composition of the gas stream, among other things. Coalescers are made in a variety of materials in different types of plastic or metal, such as

  • Stainless steel/alloys + Teflon or fibreglass
  • ETFE + Teflon fibres
  • Other materials on request

Checklist important parameters

In order to offer an effective and sustainable solution, below are a number of process parameters that are important to consider when selecting and designing a droplet separator.

Sometimes it is difficult or even impossible to obtain information and data regarding the specific process. Together with our suppliers, we have extensive experience and we can make sound assumptions as a basis for designing the best solution for the process.

Operating data
GasUnit
Maximum gas volume flowm³/h
Gas density (operating conditions)kg/m³
Kinematic gas viscositymm²/s (cSt)
Operating pressurebar (a)
Operating temperature°C
Operating data
LiquidUnit
Liquid contentkg/h
Liquid densitykg/m³
Surface tensionnM/m
Dynamic viscosity of the liquidmPass
Geometrical data
DataInfo/unit
Flow directionhorizontal or vertical
Installed in columncolumn or pipe
Column diameter or dimensionmm
Opening for installationmanhole or vessel flange
Requirements
DataInfo/unit
Type of mist eliminatorwire mesh or vane type
Type of materialPlease specify
Separation efficiency%
Separation efficiency/Limit drop sizeµm
Maximum pressure dropmbar
Other requirementsPlease specify

Choose the right product for effective and optimised droplet separation

Every process is unique. The Knowledge base provides information on how droplet separation works and what questions need to be answered to achieve an effective and sustainable solution.

Begg Cousland Envirotec has vast know-how and experience in the field of droplet separation with a complete range of demisters, coalescers and candle filters.

Many applications may be similar at a first glance, but there are often small differences that are crucial to consider for an optimal solution. With an extensive experience in many industries, Begg Cousland's technical team are able to deliver the most effective solution for a specific problem and process.