In industrial environments where separating liquids, gases, or mixed-phase streams is crucial, the efficiency of internal components can make all the difference. The Coalescer Pack is an advanced solution designed to enhance droplet coalescence and deliver superior separation performance across a range of demanding applications.
Why the Coalescer Pack Matters
Effective separation often depends on encouraging tiny droplets to merge into larger ones so they can be more easily removed. The Coalescer Pack achieves this by combining hydrophilic metallic wires and hydrophobic polymer or fiber media in a structured design. The hydrophilic parts attract water droplets, while the hydrophobic fibers repel them. At their interfaces, surface energy differences promote droplet merging, which is the key to its exceptional efficiency.
The large surface area within the pack provides more contact points for droplet capture and growth, significantly improving separation results. This makes the Coalescer Pack ideal for applications involving fine emulsions, mixed-phase streams, or gas moisture removal.
Key Features & Customisation Options
- Material flexibility – Available in multiple metal grades such as stainless steel, Monel, Hastelloy, and Duplex alloys to ensure compatibility with various process conditions.
- Media options – Choose from polymeric materials like polypropylene, fluoropolymers, PVDF, or combinations with metal and glass fibers for enhanced chemical and thermal resistance.
- Adjustable design – Offered in multiple thicknesses (typically between 300 mm and 600 mm) and in different geometries such as round, rectangular, or ring-shaped pads to suit specific vessel layouts.
- Wide industry use – Commonly implemented in petrochemical units, power generation systems, desalination plants, acid processing units, and gas treatment facilities.
Benefits
- High separation efficiency – Promotes droplet growth and coalescence to minimise entrainment and carryover.
- Resilience under harsh conditions – Durable construction ensures reliable operation even in corrosive or high-temperature environments.
- Reduced maintenance – The structured media minimises fouling and helps maintain cleaner internals, extending equipment life.
- Custom-engineered fit – Each unit can be tailored to match the vessel’s geometry and process requirements.
- Optimised pressure drop – Designed to balance performance with acceptable flow resistance.
Real-World Applications
In refinery or chemical process vessels where moisture or fine mist is present, the Coalescer Pack provides a field for tiny droplets to merge into larger ones, allowing gravity to separate them from the gas stream. This results in cleaner gas output, reduced corrosion, and improved downstream performance.
Similarly, in desalination or absorber systems handling multiphase mixtures, the pack enhances phase separation, ensuring cleaner product streams and less load on subsequent equipment.
Why Choose This Solution
The Coalescer Pack stands out for its engineered precision and adaptability. Each unit is built to meet process-specific challenges, offering a blend of efficiency, durability, and operational reliability. For industries where separation quality directly impacts productivity and equipment health, this is a dependable and high-performance choice.
Final Thoughts
When your process demands efficient phase separation — whether liquid-liquid or gas-liquid — the Coalescer Pack delivers a smart and customisable solution. By using a combination of hydrophilic and hydrophobic media, it enhances droplet formation and separation, ensuring cleaner output and more stable operations.
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