Pall

Coalescers
Bring Down Costs Through
Advanced Phase Separation Technology

Pall Phase Separation Technology

For Control And Protection Of Your Plant

very year, refineries, gas processing plants and

CONTENTS
Three Essential Phase
Separation Steps. . . . . . . . . . . . . . . . . . 3

petrochemical plants around the world spend millions

of dollars needlessly without realizing it. Maintenance
cycles are shorter than they should be; operating costs

Pall Liquid/Gas Coalescers . . . . . . . . 4

are higher than necessary; and unscheduled shutdowns

Comparison of Liquid/Gas
Separation Equipment . . . . . . . . . . . 6

causing lost production are all too common.

Pall Liquid/Liquid Coalescers . . . . . . 7

Comparison of Liquid/Liquid
Separation Equipment . . . . . . . . . . . . 8
Pall Coalescer Configuration . . . . . . 9

Fortunately, solutions are readily available from one

source: Pall Corporation, the worlds leading filtration
and separations company.

Liquid/Gas & Liquid/Liquid

Application Tables . . . . . . . . . . . 10-13
Pall Corporation
Customer Support . . . . . . . . . . . . . . . 14
Pall Offices Worldwide . . . . . . . . Back
Cover

Pall SepraSol liquid/gas coalescers, as well as AquaSep Plus

and PhaseSep liquid/liquid coalescers, give you far greater
coalescing efficiency, capacity and contaminant removal
than traditional coalescers or other conventional
separation techniques.

Pall Corporation is a unique resource in phase separation

technology. Only Pall can help you achieve a higher
degree of product control and equipment protection
through teamwork.

Three Essential Phase Separation Steps to

Reduce Operating and Maintenance Costs

Our customers benefit from what

we've learned in developing
filtration and separations
technology that has reduced costs
in hundreds of installations around
the world. There are three
essential steps to achieving cost
reductions in your plant.

3. Separation of the
Dispersed Phase from
the Continuous Phase
Once large droplets are formed,
they have to be separated. In gas
systems, Pall spaces the cartridges to
control the exit velocity of the gas
so that coalesced droplets are not
entrained in this stream.

1. Preconditioning of the Fluid

Pall recommends a prefilter to
minimize solids in the coalescer
influent that can plug the
coalescer, reducing the overall life
and efficiency. The prefilter
provides peak performance of the
coalescing system and a lower
total cost of ownership.
Filtration

2. Coalescence of
the Dispersed Phase
Pall high-efficiency coalescers
merge small droplets of liquid into
larger ones as the fluid stream
passes through several layers of
filter media, each with progressively
larger pores. As droplets compete
for the open pores, they coalesce
forming larger droplets. These larger
droplets are easier to separate
from the continuous phase fluid.
The coalescer size and type are
determined by numerous factors:
physical properties of the fluid,
flow rate, process conditions
and chemical compatibility with
process fluids and additives.
Pall has the expertise and
capability to determine the correct
coalescer size and type for your
specific process parameters.

Filtration: solid particles are

removed from the fluid stream
by the filter medium.

Coalescence
Coalescence: small droplets
are merged into larger
ones as they pass through
several layers of filter
media in the coalescer.

In liquid/liquid systems, depending

on the liquid to be separated,
Pall will provide a separator
cartridge which has repelling
properties toward the coalesced
liquids. Alternatively, the assembly
can be designed to allow time for
the coalesced liquid to settle.

Separation
Separation: gravity
takes effect, the large
droplets are separated
from the product fluid
stream.

When Pall works with you in all

three phase separation steps, you
see the difference in process
efficiency and reduced operating
and maintenance costs.

Pall SepraSol Coalescers For Separating

Liquids and Solids From Gases

Pall can eliminate a common

problem poor liquid separation.
It is a problem that eats away at
profit margins. Liquid aerosols,
which are dispersed in gases,
attack several critical areas of
your process: compressors and
turbo-equipment, amine-glycol
contactors, burner and combustion
equipment, and desiccant
and absorbent beds. Some
telltale symptoms are:

A SepraSol coalescer protects a natural gas turbine

from damage caused by liquid aerosols.

Compressor valves that

need changing out more
than once every two years
Turbo-equipment servicing
more than once a year
Plugging of reboiler heat exchangers or trays in contactor towers
Frequent replacement
of amines and glycols
Frequent foaming
incidents
Loss of efficiency in
burner and combustion
equipment
Frequent desiccant
regeneration or
replacement.

The Efficient Way

to Remove Liquids
Liquid aerosols are formed by three
mechanisms: condensation,
atomization and reentrainment from
upstream separation equipment.
Condensation and atomization
almost always form very stable, fine
aerosols usually smaller than one
micron in diameter.
Such aerosols cannot be
removed by knock-out drums, mist
eliminators, vane packs or
conventional coalescers. If not
removed, these aerosols can damage
downstream equipment.
The solution is Palls patented
SepraSol coalescers. They are rated
up to 99.99% removal efficiency for
solid particles 0.3 micron and larger,
and reduce liquid content in gas
streams down to 0.003 ppmw.
No other alternative offers you this
level of proven effectiveness.

Pall SepraSol Liquid/Gas Coalescers

Outperform All Others

Pall's unique filter media and

cartridge design can handle higher
liquid loads than conventional
coalescers, resulting in the need for
fewer cartridges. The patented
oleophobic/hydrophobic treatment
of the media pack promotes rapid
drainage of coalesced liquids.
And effluent gas exit velocities
are controlled to prevent liquid
reentrainment. It all means higher
flux in the smallest cost-effective
package which ensures continuous
and reliable performance.

1. Higher Flux
Pall's patented oleophobic/
hydrophobic treatment of the media
allows it to handle higher gas
velocity and higher liquid loads
without allowing coalesced liquid
droplets to break up and become
reentrained.
2. Better Drainage
This treatment also promotes rapid
drainage of coalesced liquids and
increases the liquid handling
capacity of the media. Smaller
assemblies are able to handle higher
liquid volumes at lower capital cost,
recover faster from liquid slugs and
operate at lower cost due to the
lower saturated pressure drop.

Left: clean desiccant.

Right: fouled desiccant. Change-out
and regeneration cycles will be
significantly extended using
Palls SepraSol coalescers.

Turbine Blades
Left: Deposits form on turbine blade.
Right: Turbine blade protected by
SepraSol coalescer.

Comparison of Liquid/Gas
Separation Equipment
This chart compares the various equipment available for removing
aerosols. You can see that only Pall SepraSol coalescers effectively
remove aerosols smaller than one micron.

Pall Seprasol
Liquid/Gas
Coalescer

Mist
Eliminator

Vane
Separator

Cyclonic
Separator

Knock-out
Drum

Smallest Liquid
Droplet Efficiently
Removed (Micron)

< 0.1

10

10

300

Relative Operating
Pressure Drop

Medium

Medium

Medium

Medium

Low

Sensitivity to Increased
Liquid Loading

Insensitive

Very Sensitive

Medium

Medium

Medium

Sensitivity to Increased
Flow Rate

Some to None

Very Sensitive

Medium

Medium

Medium

Sensitivity to
Turn-Down

Insensitive

Sensitive

Sensitive

Medium

Medium

3. Higher Liquid Capacity

By handling several times more
liquid volume without liquid
reentrainment in effluent gas,
Pall coalescers reduce equipment
problems downstream. Fewer and
smaller cartridges mean a simpler,
more compact system.

4. No Reentrainment of Liquids
The spacing of the cartridges
enables Pall SepraSol liquid/gas
coalescers to control the exit
velocity of the gas, allowing the
coalesced drops to drain effectively
and not be reentrained in the
effluent gas. Result: liquid-free gas.

Fuel gas burners that are fouled do not maintain a steady, consistent flame.
(Left) A failed combustor housing. You should not have to replace fouled
burner nozzles (center) with new ones (right) more often than once a year.

Pall AquaSep Plus and PhaseSep Coalescers

for Separating Liquids From Liquids

Through better liquid/liquid

separation, Pall can cure a variety of
very costly problems that may not
be obvious to you. If you see any of
these symptoms in your process,
chances are, Pall can help you
reduce costs.
Hazy product (not bright
and clear)
Sodium levels in gasoline
above 1 ppm
High solvent losses downstream
of liquid/liquid extraction units
High caustic carryover from
gasoline, LPG or kerosene
treating units
Carryover of amine in LPG
Oil and hydrocarbon in water and
other aqueous streams

Defining the Problems

Liquid/liquid dispersions or
emulsions are often formed by
process operations such as liquid/
liquid extraction and water washing.
As liquid mixtures cool, the
solubility decreases.
In the case of steam stripped
hydrocarbons, for example,
as the temperature decreases,
water comes out of solution
to form a second distinct liquid
phase, resulting in hazy product.

Also, oil becomes dispersed

in water causing problems in
wastewater treatment plants, steam
systems and in produced water from
oil drilling.
Separating these liquids can
be difficult, depending on the
physical properties of each.
One of the most important
properties to address in sizing
and selecting coalescers is
interfacial tension. Pall coalescers
can handle a broad range
of interfacial tensions.
Interfacial Tension
The lower the interfacial tension,
the more stable the emulsion
and the more difficult the liquids
are to separate. Frequently, the
problem is the presence of a
surfactant which lowers interfacial
tension. Conventional coalescers
begin to lose efficiency when
the interfacial tension is below
20 dyne/cm. In addition, a small
amount of surfactant can
disarm conventional
coalescers, rendering them
ineffective. Surfactants are
everywhere: in corrosion
inhibitors, organic acids,
well treating chemicals,
sulfur compounds and
numerous chemical
additives. Pall AquaSep
Plus and PhaseSep
coalescers separate
liquids with interfacial
tensions as low as
0.5 dyne/cm.

Impact of surfactants on coalescing.

No surfactant coalescing is less difficult.

An AquaSep Plus coalescer eliminates

haze problems from refinery fuels
like gasoline, diesel and jet fuels.

Comparison of Liquid/Liquid
Separation Equipment

Pall
Salt and
AquaSep Plus/ Desiccant
PhaseSep
Tower
System

Conventional
Coalescers

Mesh Pack

Electrostatic
Precipitator

Tank Settling Vacuum

Dehydration
Tower

Lowest
Interfacial Tension
Efficiently
Separated

AquaSep:
3 dyne/cm
PhaseSep:
0.5 dyne/cm

<2 dyne/cm

>20 dyne/cm

>20 dyne/cm

>10 dyne/cm

>20 dyne/cm

<2 dyne/cm

Relative Operating
and Maintenance
Costs

Low

High

Medium

Low

High

Low

High

Effect of Additional
Dispersed Liquid
on Operating Cost

Low

High

Low

Low

High

Low

Medium

Effect of Surface
Active Chemicals
on Efficiency

None

None

Reduces
Efficiency

Reduces
Efficiency

Reduces
Efficiency

Reduces
Efficiency

None

Effect of Additional
Dispersed Liquid
on Efficiency

Low

Medium

Low

High

Medium

Medium

Medium

Sensitivity to
Temperature
Changes

Low

Medium

Low

Low

High

Low

Low

Relative
Maintenance

Low

High

Medium

Low

High

Low

Medium

Palls AquaSep Plus and PhaseSep

liquid/liquid coalescers separate water
from hazy diesel (left)
and oil from wastewater and
produced water, providing
contaminant-free products.

Open here for a Complete Selection Guide for Coalescer Part Numbers/Ordering Information

You can see from this table that Pall coalescers

separate liquids with interfacial tensions far lower
than any other means of separation.

Open here for a Complete Selection Guide for Coalescer Part Numbers/Ordering Information

Two Configurations
for Optimum
Separation Efficiency
Pall AquaSep Plus and
PhaseSep systems are
available in a horizontal and a
vertical configuration. The
right one for you depends on
the liquids in your process.
Both configurations begin with
a prefiltration stage to remove
solid contaminants. This
significantly extends service
life, improves the fluid quality
and decreases the stability of
liquid/liquid emulsions,
making coalescing easier.
Pall's Patented Vertical
Coalescer/Separator Stack
This is the most efficient
technique for separating two
liquids when the dispersed
fluid is water and the interfacial tension is greater than
3 dyne/cm. The coalescer
elements are stacked on
top of a separator element
to ensure uniform flow
distribution from the
coalescer to the separator.

The assembly is smaller and

has a longer service life than
conventional coalescers. After
water droplets are coalesced
in Pall's proprietary media,
water-free liquid and large
droplets of water flow toward
the separator. The hydrophobic
separator medium repels the
aqueous phase, so only the
water-free bulk fluid passes
through the separator. The
two liquids are removed by
separate drain connections.
The Pall Horizontal
Coalescer
If the dispersed liquid phase
is not water, an AquaSep Plus
or PhaseSep coalescer without
a separator is placed in a
horizontal housing. It should
be used to separate oil from
water, two non-aqueous
liquids or when the interfacial
tension of two liquids is less
than 3 dyne/cm.
In this configuration, the
liquid/liquid mixture enters
the coalescing element and
flows inside to out. Small
liquid contaminant droplets
coalesce into larger droplets
which are separated by
gravity and are removed.

Pall vertical liquid/liquid coalescer

Configuration with prefilter on the left
and AquaSep Plus/PhaseSep coalescer shown
far right. Water exits bottom left, water-free
product bottom right.

Pall horizontal liquid/liquid coalescer

Configuration with prefilter far left
and AquaSep Plus/PhaseSep coalescer right.
Contaminant-free continuous phase
exits top right, liquid contaminant,
bottom right.

Pall AquaSep Plus and PhaseSep Stack Assembly

Separator

Coalescer

Fortunately, For Each Problem, There Is A Solution:

Pall Seprasol Liquid/Gas Coalescers.

10

Description

Part Number

Dimensions

Special Features

Applications

SepraSol
Single
Open-ended

CC3LGA7H13

30 / 762 mm length
2.75 / 70 mm diam.

Polyester
drainage layer

Low pressure; low liquid load.

SepraSol
Amine
Coalescer

CC3LGB7H13

30 / 762 mm length
2.75 / 70 mm diam.

Polypropylene
drainage layer

Recovery of carried over amine.

Recovery of oil from ammonia gas.

SepraSol
Double
Open-ended

CC3LGO2H13

30 / 762 mm length
2.75 / 70 mm diam.

Tie-rod seal;
acetal endcaps

Pressure greater than 200 psi;

low liquid load; greater than
5% aromatics in liquid.

SepraSol
Plus
Coalescer

CS604LGH13

40 / 1016 mm length
6 / 153 mm diam.

High liquid pack

design;
stainless steel
endcaps

Liquid loading over 100 ppmw.

Equipment service life between maintenance shutdowns and plant

turnarounds is often shorter than it could be. And the causes of increased
maintenance and operating costs are not always obvious. These tables will
give you some symptoms of costly problems to look for in various plant
applications, followed by brief summaries of the Pall liquid/gas and
liquid/liquid coalescers that offer long-term cost saving solutions.
Inadequate Liquid Removal Can Create Costly Maintenance
and Production Problems.

Application

Symptom

Problem

Gas transmission compressors

Repairs needed in less than 2 years

Gas throughput below design; fouling

and salting of compressor internals.

Reciprocating hydrogen
compressors

Repairs needed in less than 2 years

Gas throughput below design; fouling

and salting of compressor internals.

Amine or glycol contactors

More than two foaming incidents

a year

Gas throughput lower than design;

foaming in contactor, poor energy
efficiency; fouling of exchanger and
reboiler.
Condensable hydrocarbons in the inlet
gas lower the surface tension of the
amine and initiate foaming episodes.

Fuel gas burners

Less than 1 year between

maintenance

Burner nozzles plugged and frequently

maintained; poor flame patterns.

Desiccant or absorbent bed

Less than 3-year change out;

regenerable absorbent less than
20 years

Frequent regeneration problems;

high pressure drop.

Compressor lube oil in refinery,

gas and chemical plants

Lube oil makeup greater than design

High lube oil makeup; fouling of

downstream equipment with lube oil.
Off-spec product (e.g. ammonia).

Amine from contactors

Amine makeup at 2 lb/MMSCF

greater than design

Higher than design amine losses;

fouling of downstream equipment.

High amine loss rate

Gas separation membranes

Fouling in less than 3 years

Poor membrane separation efficiency;

short service life.

11

The Solution is Advanced Technology:

Pall AquaSep Plus and PhaseSep Liquid/Liquid

Poor Separation Can Damage Equipment and Reduce Product Quality.

Application

Symptom - Measured
Interfacial Tension

Problem

Separation of water from:

gasoline, jet fuel and diesel

3 - 25 dyne/cm

Haze problems cause off-spec product. Presence

of surfactants, either existing in the feedstock or added
to the system, reduce interfacial tension, increasing
difficulty of water removal.

Separation of caustic from:

gasoline, jet fuel and diesel

0.5 - 13 dyne/cm

Presence of sulfur compounds result in very stable,

difficult to separate emulsions.

Separation of water from light

hydrocarbons (C6 and below)
and petrochemicals

5 - 20 dyne/cm

Presence of surfactants, either existing in the feedstock

or added to the system, reduce interfacial tension,
increases difficulty of water removal.

Separation of amine from LPG

N/A - difficult to analyze

Liquid/liquid contactor typically the largest source of

amine losses. Sulfur compounds contribute to stabilizing
the emulsion, making separation more difficult.

Separation of hydrogen peroxide

from working solution

20 - 35 dyne/cm

Inefficient phase separation.

Separation of acids from

Wide Range
petrochemicals and hydrocarbons

Carryover of acids common in refinery and specialty

chemical plants; small stable emulsions difficult
to separate.

Separation of oil from:

water

Oil will foul steam system and increase

load to wastewater treatment plant.

Wide Range

anhydrous ammonia

Off-spec anhydrous ammonia.

Pall Liquid/Liquid Coalscer

Selection Guide
Interfacial Tension Between Liquids Is Another Factor in Determining
the Correct Product and Configuration for Your Process.

12

Process Condition

Recommended Product

Contaminating fluid is aqueous,

IFT >3 dyne/cm

AquaSep Plus or PhaseSep

coalescer/separator stack (Vertical Housing)

Contaminating fluid is aqueous,

IFT <3 dyne/cm

AquaSep Plus or PhaseSep coalescer

without separator (Horizontal Housing)

Both fluids are non-aqueous

AquaSep Plus or PhaseSep coalescer

without separator (Horizontal Housing)

Contaminating fluid is oil,

bulk fluid is water

AquaSep Plus or PhaseSep coalescer

without separator (Horizontal Housing)

Coalescers.

Description

Part Number

Dimensions

Special Features

Applications

AquaSep Plus
Coalescer

LCS2B1AH
LCS4B1AH

20 / 508 mm length
40 / 1016 mm length
3.75 / 95 mm diam.

Polymeric medium does

not disarm in presence
of surfactants.
Integral Prefilter

Separation of water from

hydrocarbons.

PhaseSep
Coalescer

LCS2H1AH
LCS4H1AH

20 / 508 mm length
40 / 1016 mm length
3.75 / 95 mm diam.

Fluoropolymer medium
has a wide range
of chemical compatibility.

Separation of caustic or
amine from hydrocarbon.
Separation of hydrogen
peroxide from working
solution.

PhaseSep
Coalescer

LCS2H2HH
LCS4H2HH

20 / 508 mm length
40 / 1016 mm length
3.75 / 95 mm diam.

Broadest range of
chemical
compatibility.

Many acid and solvent

applications.

Separator

LSS2F2H

20 / 508 mm length
3.75 / 95 mm diam.

Hydrophobic
medium does not
allow water to
pass through.

Separation of water
from hydrocarbons.

13

Pall Corporation
A Powerful Resource for Control,
Protection and Teamwork
Pall Corporation brings over
50 years of filtration and
separations experience to your
plant's processes. With the
industry's widest range of
advanced products, Pall can
design a system specifically for
your plant, based on a thorough
evaluation of your needs.

Vertical AquaSep Plus system

removing water from kerosene.

You'll receive technical

consultation and support from
our Scientific and Laboratory
Services Department (SLS).
This is a network of some
400 scientists and engineers
working from more than 20 Pall
laboratories worldwide.

Vertical AquaSep Plus

system removing
water from jet fuel.

14

Pall continues to develop new

products and methods to advance
the state of the art of phase
separation. No other company
offers such a strong core
competency in coalescing
technology to help you reduce
operating and maintenance costs
through improved product control,
plant protection and teamwork.
For more details about our
coalescing technology, call Pall
Corporation at 516.484.5400.
Outside New York state, call
1.888.873.7255. Or fill in and return
the attached Business Reply Card.
For faster service, visit our Web site:
http://www.pall.com.

Vertical AquaSep Plus

system removing
water from diesel.

Horizontal PhaseSep system

removing caustic from gasoline.

SepraSol coalescer
system protecting
a compressor.

15

2200 Northern Boulevard

East Hills, New York 11548-1289
888.873.7255 toll free
516.484.5400 phone
516.484.0364 fax

Visit us on the Web at www.pall.com

Pall Corporation has offices and plants throughout the world in locations including:
Argentina, Australia, Austria, Belgium, Brazil, Canada, China, France, Germany, Hong Kong,
India, Indonesia, Ireland, Italy, Japan, Korea, Malaysia, Mexico, the Netherlands, New
Zealand, Norway, Poland, Puerto Rico, Russia, Singapore, South Africa, Spain, Sweden,
Switzerland, Taiwan, Thailand, United Kingdom, United States, and Venezuela. Distributors
are located in all major industrial areas of the world.

Copyright 2000, 2002, Pall Corporation. Pall,

registered in the USA.

COA-100b

are trademarks of Pall Corporation. indicates a Pall trademark

is a service mark of Pall Corporation.