Droplet Separator with Heater

Name: Droplet Separator With Heating For Marine & Offshore Environments
Availability: InStock

Droplet separators are vital for operational precision in gas flow systems. Their intricate internal vane configurations maintain optimal gas velocities and flow rates to remove liquid droplets (1).

Seamless filter integration improves separation efficiency and gas purity.

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Choosing the right separator type is crucial to balance pressure drop against velocity for effectiveness across varying conditions and demister needs, whether vertical flows or otherwise.

As official distributors, we recognize these components enable overall system performance in gas flow by going beyond simple filtration.

Simply put, the droplet eliminator acts as a guard, making sure only the cleanest air gets through to equipment like air handling units (AHU) in HVAC systems or engine intakes.

What is a droplet separator?

A droplet separator removes liquid droplets from gas streams. Droplets collide and coalesce on surfaces inside the separator, forming larger drops. These larger drops drain out of the separator via gravity, diverting the separated liquid from the gas.

It separates gas and liquid in applications like HVAC, marine and offshore installations, and other industrial processes. They are designed to remove liquid contaminants and droplets from gas streams through inertial impaction and gravity drainage.

When optimally designed, they remove harmful particulate matter while balancing pressure drop across an AHU, turbine, and other ventilation equipment.

How droplet separation work

High-efficiency droplet separators work by helping droplets come together in gas streams (2). When liquid droplets in the gas flow touch the inside surfaces of the separator, they gather and increase in size.

Appropriate separator selection factors in liquid loading rates, droplet sizes, and permissible downstream liquid concentrations. Different internal designs and materials suit liquid-gas properties like viscosity and surface tension.

By considering these factors, precise engineering can lead to substantial reductions in carryover across different conditions.

Incorporating coalescing and particulate filters enhances separation efficiency, ensuring Class A results as per EN 13030:2001 standards.

With custom sizes, modular construction, and options like mask louvers for architectural discretion, we can provide reliable solutions.

Primary and Secondary Separation

In high-efficiency equipment, the process unfolds in two distinct stages: primary and secondary separation.

During primary separation, the gas flow laden with droplets passes through curved and specially formed baffle vanes. These vanes induce inertia forces on the droplets, diverting them from the original gas flow.

The geometry of the vanes and the characteristics of the gas and fluid determine whether the droplets continue with the gas flow or come in contact with the separator surfaces, initiating the primary separation.

In the subsequent secondary separation stage, the baffle vanes’ curvature and shape come into play. Specifically designed phase-separation chambers ensure the complete removal of the liquid film formed during primary separation from the gas flow.

This intricate two-stage process, governed by the dynamics of inertial forces, defines the efficiency of the system.

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Key Features

Contaminant Removal

High Efficiency

Low-Pressure Losses

Maintenance-Free

Customizable Drainage Systems

Diverse Material Construction

Efficiently clears sea spray, rain, salt, and aerosol debris.

Removes over 99% of 5-micron water particles.

Operates smoothly without significant pressure drops.

Requires minimal upkeep post-installation.

Adaptable drainage systems for varied needs

Vanes are available in:

Marine-grade aluminum
Stainless steel
PVC

Vane type separators

Vane-type separators utilize a set of baffle vanes designed for different gas flow orientations – vertical, horizontal, or oblique. The vanes divert droplets through inertial impaction, collecting them and allowing the coalesced liquid film to drain off via gravity.

Depending on the orientation, they offer high separation efficiency for droplets above 15 μm and can handle gas velocities up to 10 m/s.

Two-stage vane-type units provide primary inertial separation through the vanes and secondary separation as the liquid film flows out.

Design of a droplet separator

Different types of droplet separators like profiles, demisters, coalescers, and candle filters are used depending on the liquid load, removal efficiency targets, and droplet size distribution.

The droplets in the gas collide with the mist eliminator surface and coalesce into a film of liquid, which then flows to the bottom of the droplet separator under gravity.

The profiles are vertically oriented for horizontal flows to utilize gravity for liquid drainage while also allowing high gas velocities.

Optimally designed droplet separators balance pressure drop across the unit with separation efficiency to remove contaminants, prevent corrosion, enable product recovery, and reduce emissions.

Special designs like two-stage separators provide the coalesced liquid film’s inertial separation and secondary drainage.

How Droplet Size Influences Equipment Selection in Gas Flow Systems

The droplet size distribution in a gas flow system determines the type of separation equipment required to remove liquid contaminants effectively.

Vane-type separators provide efficient separation for larger droplets above 15 μm while minimizing pressure drop across the system. Wire mesh demisters remove droplets to 5 μm through impaction on the mesh surface. Coalescing filters with composite knitted fabrics are utilized to capture smaller droplets from 2-5 μm, while sub-2 μm droplets require candle filters with tightly packed microfiber beds to achieve diffusion-based separation.

Therefore, understanding the target droplet size range is critical when selecting appropriate gas-liquid separators to protect downstream equipment and meet purity requirements.

Droplet separator manufacturer

As an authorized distributor for industry-leading droplet separator brands. With expertise in high separation efficiency, we provide equipment that are designed to hit efficiency targets.

Contact us to discuss your needs – we’ll help select optimal components to remove solid particles, divert mist from the gas flow, prevent corrosion, and reduce emissions from manufactures like Halton.

What is a droplet separator?

A droplet separator separates gas and liquid in applications like HVAC, marine and offshore installations, and other industrial processes. They are designed to remove liquid contaminants and droplets from gas streams through inertial impaction and gravity drainage. Optimally designed droplet separation removes harmful particulate matter while balancing pressure drop across an AHU, turbine, and other ventilation equipment.

Why is pressure drop essential when selecting and designing a droplet separator?

Pressure drop is an essential consideration when selecting and designing a droplet separator because it impacts process efficiency and operating costs. The amount of acceptable pressure loss depends on factors like the liquid entrained in the gas, flow rate, and removal efficiency targets. Increased velocity improves droplet removal as droplets collide and merge on the separator surface before flowing to the bottom, but it also quadruples the pressure drop across the unit. Candle filters provide high efficiency but create substantial back pressure. Separators for horizontal and vertical flows are designed to balance pressure loss with separation performance. Removal efficiency targets may be set by emission regulations or by protecting downstream equipment. Minimizing pressure drop leads to increased process efficiency for large gas flow applications like industrial ventilation systems and marine engine air intakes. Optimally designed separators for demanding applications balance these factors, removing droplets and diverting liquid while maintaining energy efficiency. Understanding pressure drop implications enables proper separator sizing and selection.

Which other parameters affect the selection and design of a droplet separator?

Several other important parameters affect droplet separator selection and design, especially for demanding applications like HVAC systems. Liquid load tolerance is crucial as the liquid film grows and is increasingly affected by gravity before draining from the gas flow. Units available for both horizontal and vertical installation suit different liquid loads. Separation efficiency targets may be set by statutory emission requirements or to reduce a certain amount of contaminants, avoiding corrosion downstream. Temperature ratings should be mentioned when ordering, as material heat tolerance impacts performance. Key design features like multi-stage configurations enable incremental separation enhancement.

Understanding all operating conditions and installation factors is necessary to optimize separator performance, costs, and process protection through customization.

Standard Material Choices and Finishing Options

PART	MATERIAL	FINISHING
Droplet Eliminator	Aluminum EN AW 6060	Painted RAL9010, C3 acc. standard* ISO 12944-2 as standard
Droplet Eliminator	Stainless steel EN 1.4404 (AISI 316L)	Painted as an option
Mask louver	Aluminum EN AW 5754 / AW 6060	Painted RAL9010, C3 acc. standard* ISO 12944-2 as standard
Mask louver	Stainless steel EN 1.4404 (AISI 316L)	Painted as an option
Frame	Aluminum EN AW 5754	Painted RAL9010, C3 acc. standard* ISO 12944-2 as standard
Frame	Stainless steel EN 1.4404 (AISI 316L)	Painted as an option
Net	Stainless steel EN 1.4404 (AISI 316L)	–
Filter	ISO Coarse 70% panel filter or ePM2,5 65% bag filter, other types available on request	–

Applications

Droplet separators find applications in various industries and environments where the control and removal of liquid droplets from gas streams are crucial. Some common applications include:

Marine Industry: Used in ship engine rooms to prevent saltwater and moisture ingress into ventilation systems.
Oil & Gas Sector: Employed in gas processing & drilling facilities to separate liquid droplets from natural gas streams.
Chemical Processing Plants: Utilized to maintain air quality by removing liquid aerosols and contaminants from industrial processes.
Energy Generation: Utilized in power plants to safeguard gas turbines, wind turbines, and engines by effectively removing liquid particles that have the potential to cause damage.
HVAC Systems: Integrated into heating, ventilation, and air conditioning systems to ensure clean and dry air circulation in commercial and residential buildings.
Industrial Manufacturing: Applied in various manufacturing processes to control emissions and enhance air quality.
Environmental Control: Used in facilities dealing with hazardous substances to prevent the release of harmful airborne particles.
Waste Treatment Plants: Employed to remove liquid droplets from exhaust gases in waste incineration processes.
Agricultural Facilities: Installed in agricultural equipment to protect engines from moisture and particles in the air.
Data Centers: Integrated into air handling units to maintain a controlled and clean environment for sensitive electronic equipment.