US20070062886A1 - Reduced pressure drop coalescer - Google Patents
Reduced pressure drop coalescer Download PDFInfo
- Publication number
- US20070062886A1 US20070062886A1 US11/230,694 US23069405A US2007062886A1 US 20070062886 A1 US20070062886 A1 US 20070062886A1 US 23069405 A US23069405 A US 23069405A US 2007062886 A1 US2007062886 A1 US 2007062886A1
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- Prior art keywords
- coalescer
- dispersed phase
- fibrous media
- fibers
- horizontal
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D17/00—Separation of liquids, not provided for elsewhere, e.g. by thermal diffusion
- B01D17/02—Separation of non-miscible liquids
- B01D17/04—Breaking emulsions
- B01D17/045—Breaking emulsions with coalescers
Definitions
- the invention related to fibrous media coalescers.
- Fibrous media coalescers are known in the prior art for coalescing and separating a medium having two immiscible phases, namely a continuous phase and a dispersed phase.
- the continuous phase is air
- the dispersed phase is oil
- fuel-water separation systems such as fuel filters
- fuel is the continuous phase
- water is the dispersed phase
- water-oil separation systems water is the continuous phase
- oil is the dispersed phase.
- the invention is particularly well suited for engine crankcase ventilation applications, but may be used in other separation systems having immiscible fluids, e.g. air-oil, fuel-water, water-oil, etc.
- the trade-off may be higher pressure drop and/or shorter life and/or larger package size.
- the present invention provides desirable options for more favorable trade-offs, including lower pressure drop.
- FIG. 1 schematically illustrates coalescence
- FIG. 2 is a graph showing loading and saturation.
- FIG. 3 is a perspective view of a coalescer in accordance with the invention.
- FIG. 4 is a front elevation view of the coalescer of FIG. 3 , and shows a further embodiment.
- FIG. 5 is like FIG. 4 and shows another embodiment.
- FIG. 6 is like FIG. 4 and shows another embodiment.
- FIG. 7 is like FIG. 4 and shows another embodiment.
- FIG. 8 is like FIG. 4 and shows another embodiment.
- FIG. 9 is like FIG. 4 and shows another embodiment.
- FIG. 10 is like FIG. 4 and shows a further embodiment.
- FIG. 11 is a schematic illustration showing fiber orientation angle.
- FIG. 12 is like FIG. 11 and shows another embodiment.
- FIG. 13 is like FIG. 11 and shows another embodiment.
- FIG. 14 is like FIG. 11 and shows another embodiment.
- FIG. 15 is like FIG. 11 and shows another embodiment.
- FIG. 16 is like FIG. 11 and shows another embodiment.
- FIG. 17 is like FIG. 11 and shows another embodiment.
- FIG. 18 is like FIG. 11 and shows another embodiment.
- FIG. 19 is like FIG. 11 and shows another embodiment.
- FIG. 20 is like FIG. 11 and shows another embodiment.
- FIG. 21 is like FIG. 11 and shows another embodiment.
- FIG. 22 is like FIG. 11 and shows another embodiment.
- FIG. 23 is a microphotograph of fibrous media taken with a scanning electron microscope at 43 ⁇ magnification.
- FIG. 24 is a microphotograph of fibrous media taken with a scanning electron microscope at 35 ⁇ magnification, at a 90° orientation relative to FIG. 23 .
- FIG. 25 is a schematic illustration of a further embodiment showing fiber orientation across a localized pocket.
- FIG. 1 shows a coalescer 20 for coalescing a medium 22 having two immiscible phases, namely a continuous phase 24 and a dispersed phase 26 .
- the continuous phase 24 is air
- the dispersed phase is oil, e.g. in the form of a fine mist having droplets 26 of about one micron and smaller in diameter.
- the continuous phase 24 flows from upstream to downstream, i.e. left to right in FIG. 1 .
- the coalescer includes fibrous media 28 capturing droplets of the dispersed phase, coalescingly growing the droplets into larger drops, for example as shown at 30 , 32 , which further coalesce and grow to form pools such as 34 which drain as shown at 36 .
- droplets 26 can collide and grow in size by drop to drop coalescence.
- the droplets Upon entry into coalescer 20 , the droplets are captured by impaction, interception, diffusion, or electrostatic or other filtration mechanisms. Droplets grow in size as captured and uncaptured droplets coalesce to form larger drops.
- Dispersed phase saturation varies within the coalescer, typically with increasing saturation as one approaches the downstream face (right hand face FIG. 1 ), due to viscous forces, and with increasing saturation at the bottom of the coalescer due to gravity.
- Saturation like porosity, is a dimensionless number representing the fraction or percent of a filter media's void space that is occupied by the captured dispersed phase. Saturation does not mean that the entire void volume is filled with the captured dispersed phase such as oil, but rather that the element is holding as much oil as it can. At saturation, more oil is held at the bottom and right than at the top and left in FIG. 1 .
- FIG. 2 is a graphical plot of pressure drop, ⁇ P, in millimeters of water, verses time in minutes.
- ⁇ P pressure drop
- the rate of capture is greater than the rate of drainage.
- the rate of capture equals the rate of drainage.
- plugging or excessively high pressure occurs due to solid contaminants being captured and held by the coalescer and/or the rate of capture exceeding the rate of drainage from the coalescer.
- the solids holding capacity of the coalescer is increased and the rate of drainage of the coalescer is increased.
- the noted saturation profile is important in coalescer design because increased saturation corresponds to decreasing effective porosity within the fibrous media bed and increasing restriction.
- the present disclosure provides a coalescer with fibrous media adapted to reduce pressure drop thereacross by increasing drainage therefrom. This is accomplished in various ways, to be described.
- FIG. 3 shows a fibrous media coalescer 40 having a hollow interior 42 and providing inside-out flow, namely incoming flow as shown at 44 into hollow interior 42 , and then flow from hollow interior 42 outwardly through fibrous media 46 as shown at arrows 48 .
- Coalescer 40 has a first cross-sectional area A 1 along a first horizontal plane 50 , and a second cross-sectional area A 2 along a second horizontal plane 52 .
- Horizontal plane 52 FIGS. 3, 4 , is vertically below horizontal plane 50 .
- Cross-sectional area A 2 is less than cross-sectional area A 1 .
- Coalescer 40 has a perimeter 54 having a plurality of chords thereacross, including vertical chords such as 56 and horizontal chords such as 58 .
- the longest of the chords, e.g. 56 extends vertically.
- the horizontal chords include a first horizontal chord, e.g. 58 , along horizontal plane 50 , and a second horizontal chord 60 along horizontal plane 52 .
- Horizontal chord 60 is shorter than horizontal chord 58 .
- the volume of the element that is dispersed phase saturated is minimized, where restriction is greatest and contaminated fluid flow rate and removal are least. Conversely, the volume of the element is maximized where restriction is least and contaminated fluid flow rate and removal greatest. Secondly, a greater proportion of element volume is available to capture and hold any solids that may plug the coalescer or otherwise cause excessive pressure drop.
- the lower section is more restrictive and has a lower flow rate than the upper section, due to increased local saturation relative to the upper section.
- FIGS. 3, 4 show the noted given shape in the vertical plane as a hollow racetrack shape.
- Other given shapes in the vertical plane are possible, for example a hollow oval shape 62 , FIG. 5 , a hollow triangle shape 64 , FIG. 6 , a hollow square shape 66 , FIG. 7 , a hollow trapezoid shape 68 , FIG. 8 , and a hollow circle shape 70 , FIG. 9 .
- Inside-out flow is preferred because flow velocity decreases with distance into the media, which minimizes possible re-entrainment and carryover of coalesced drops into the clean side and reduces the velocity in the portion of the coalescer where saturation is high. This is a particular advantage for racetrack and oval shapes because of their better space utilization due to the smaller upstream open hollow space in the interior of elements of these shapes. Outside-in flow is also possible.
- the fibrous media is provided by a plurality of fibers having a nonrandom dominantly vertical orientation, FIG. 4 .
- the fibers are preferably polymeric and preferentially oriented around the periphery of the given shape and where possible parallel to the direction of gravity.
- the fibers preferably extend dominantly circumferentially tangentially along perimeter 54 .
- the fibers preferentially extending dominantly circumferentially tangentially along perimeter 54 are dominantly vertical and provide increasing drainage pressure at lower regions of the coalescer.
- the elements are preferably made by electro-spinning or melt-blowing the fibers or wrapping or winding sheets of fibrous media around the element periphery giving the fibers the noted preferred orientation.
- the preferred orientation and alignment of the fibers reduces the resistance of captured drops to flow and enhances drainage by forming flow paths and channels parallel to gravity.
- polymeric fibers formed by melt-blowing or electro-spinning are preferred, but other materials may also be used.
- vibration or oscillation of the coalescer in a vertical direction is a further way to enhance drainage, minimize restriction, and increase coalescer life.
- a shaker 72 as shown in dashed line which in one embodiment may be an internal combustion engine or other mechanical component, vibrates or oscillates the coalescer in a vertical direction. This movement or vibration in the vertical direction accelerates the captured drops, and the sudden reversal in direction causes them to shear from the fibers and drain with minimum resistance.
- the normal vibration of an engine or other equipment facilitates such vibration, however it may be desirable to provide judicious positioning and mounting of the coalescer or by the addition of a mechanical vibrator for vibrating the coalescer.
- the coalescer has a lower region, e.g. at plane 52 , FIG. 4 , of greater dispersed phase saturation and smaller volume than an upper region, e.g. at plane 50 , to minimize the volume of fibrous media that is saturated with the dispersed phase where restriction is greatest and continuous phase flow rate least and contaminant removal least, and to maximize the volume of the fibrous media where restriction is least and continuous phase flow rate greatest and contaminant removal greatest.
- a lower media element 74 is provided of greater dispersed phase wettability than fibrous media 46 and in contact with the lower region of coalescer 40 and wicking coalesced drops from fibrous media 46 at the lower region.
- fibrous media 46 is non-wetting with respect to the dispersed phase, and lower media element 74 is wetting with respect to the dispersed phase.
- the cosine of the dispersed phase contact angle of lower media element 74 is greater than the cosine of the dispersed phase contact angle of fibrous media 46 .
- the purpose of wicking layer 74 is to draw oil from the coalescer and direct it to a collection vessel, such as the engine or a sump.
- wicking layer 74 is a non-woven filter media, though alternatively it could be the walls of the sump itself or other material with suitable wettability characteristics.
- the above disclosure provides various means for reducing pressure drop across the coalescer, including enhancing drainage of the coalesced dispersed phase from the coalescer.
- the pressure drop across the coalescer increases with time until the rate of drainage of the coalesced dispersed phase (e.g. oil in the case of crankcase ventilation filters) equals the rate of dispersed phase capture.
- the equilibrium pressure drop can be reduced by increasing the drainage rate, which in turn reduces the dispersed phase saturation of the coalescer and increases the coalescer's effective porosity. By increasing the porosity, the solids loading capacity of the coalescer is increased, as is coalescer life.
- Fibers may be beneficially oriented with respect to gravity and with respect to one another, as above noted.
- a first dominant fiber orientation angle ⁇ is defined as the angle of fiber extension 76 , FIGS. 11-22 , relative to horizontal, i.e. relative to a direction which is perpendicular to gravity.
- ⁇ is 0°.
- ⁇ is minus 45°.
- ⁇ is minus 90°.
- FIGS. 14, 17 , 19 ⁇ is 45°.
- Fibers may also be beneficially oriented with respect to the direction of flow.
- a second dominant fiber orientation angle ⁇ is defined as the angle of fiber extension 76 relative to flow direction 24 .
- ⁇ is 0°.
- ⁇ is minus 45°.
- FIGS. 13, 17 , 21 ⁇ is minus 90°.
- FIGS. 14, 18 , 22 ⁇ is 45°.
- FIGS. 11-22 show various exemplary flow directions among the plurality of flow directions from hollow interior 42 outwardly through fibrous media 46 .
- FIGS. 11-14 show a flow direction 24 parallel to horizontal.
- FIGS. 15-18 show a flow direction 24 at minus 45° relative to horizontal.
- FIGS. 19-22 show a flow direction 24 at 45° relative to horizontal.
- cosine ⁇ be greater than 0.5, i.e. that ⁇ be less than 60° and greater than minus 60°.
- FIG. 23 is a microphotograph showing dominant fiber orientation generally parallel to gravity and perpendicular to flow direction, as shown by the indicated arrows.
- FIG. 24 is a microphotograph showing fiber orientation relative to gravity, wherein the direction of flow is into the page.
- sufficient numbers of fibers may be provided having the desired orientation to enhance drainage locally. Because the coalesced dispersed phase drains more freely from such areas, the low local dispersed phase saturation and pressure drop are maintained, and the net effective saturation of the coalescer is reduced.
- 6,387,144 incorporated herein by reference, for example by needle punching to create such localized pockets, depressions, or indentations with fiber orientation angles ⁇ and ⁇ different than 0° and other than 90° or minus 90°.
- Other means may also be used for forming the localized pockets, for example the media may be spiked with larger fibers, wires, nails, brads, or similar structures having a high length to width aspect ratio oriented such that ⁇ and/or ⁇ is other than 90° or minus 90° as desired.
- a thread-like material may be sewed into the coalescer media using a sewing machine or the like, with the threads being oriented along an angle of 0° (parallel to flow direction), and the puncturing needle and thread would cause the surrounding media fibers to orient at angles other than 90° or minus 90°.
- the localized pockets could be created using a heated needle or an ultrasonic welding type process. This will create a saturation gradient causing the coalesced dispersed phase to drain from the coalescer. Hence, even though all fibers do not have a desired orientation angle ⁇ other than 0°, drainage will nonetheless be enhanced compared to having all fibers oriented with ⁇ equal to 0°.
- the present system provides a method of increasing the life of a coalescer.
- the coalescer has a pressure drop thereacross increasing with time until the rate of drainage of the coalesced dispersed phase equals the rate of capture, providing an equilibrium pressure drop.
- the method increases coalescer life by reducing dispersed phase saturation and increasing porosity and solids loading capacity by decreasing equilibrium pressure drop by increasing the rate of drainage.
- the method involves providing fibrous media as a plurality of fibers and dominantly orienting the fibers preferably along a first dominant fiber orientation angle ⁇ less than 0° and greater than or equal to minus 90° and preferably along a second dominant fiber orientation angle ⁇ less than 60° and greater than minus 60°.
- the coalescer is vertically vibrated.
- the method involves minimizing the volume of fibrous media that is saturated with the dispersed phase where restriction is greatest and flow rate and removal least, and maximizing the volume of the fibrous media where restriction is least and flow rate and removal greatest, by providing the coalescer with a lower region of greater dispersed phase saturation and smaller volume than an upper region.
- the coalesced drops are wicked away from the fibrous media at the lower region of increased dispersed phase saturation.
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- Physics & Mathematics (AREA)
- Thermal Sciences (AREA)
- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Nonwoven Fabrics (AREA)
- Filtering Materials (AREA)
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Priority Applications (8)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US11/230,694 US20070062886A1 (en) | 2005-09-20 | 2005-09-20 | Reduced pressure drop coalescer |
US11/346,679 US8114183B2 (en) | 2005-09-20 | 2006-02-03 | Space optimized coalescer |
BRPI0616182-0A BRPI0616182B1 (pt) | 2005-09-20 | 2006-04-25 | Coalescedor and the life increased method |
DE112006002480T DE112006002480T5 (de) | 2005-09-20 | 2006-04-25 | Coalescer mit reduziertem Druckabfall |
CN2006800347665A CN101282773B (zh) | 2005-09-20 | 2006-04-25 | 压降减小的聚结器 |
PCT/US2006/015934 WO2007035192A2 (en) | 2005-09-20 | 2006-04-25 | Reduced pressure drop coalescer |
US11/940,729 US7828869B1 (en) | 2005-09-20 | 2007-11-15 | Space-effective filter element |
US12/982,259 US8545707B2 (en) | 2005-09-20 | 2010-12-30 | Reduced pressure drop coalescer |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US11/230,694 US20070062886A1 (en) | 2005-09-20 | 2005-09-20 | Reduced pressure drop coalescer |
Related Child Applications (3)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US11/273,101 Continuation-In-Part US7674425B2 (en) | 2005-09-20 | 2005-11-14 | Variable coalescer |
US11/346,679 Continuation-In-Part US8114183B2 (en) | 2005-09-20 | 2006-02-03 | Space optimized coalescer |
US12/982,259 Continuation US8545707B2 (en) | 2005-09-20 | 2010-12-30 | Reduced pressure drop coalescer |
Publications (1)
Publication Number | Publication Date |
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US20070062886A1 true US20070062886A1 (en) | 2007-03-22 |
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ID=37882999
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
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US11/230,694 Abandoned US20070062886A1 (en) | 2005-09-20 | 2005-09-20 | Reduced pressure drop coalescer |
US12/982,259 Active 2026-10-10 US8545707B2 (en) | 2005-09-20 | 2010-12-30 | Reduced pressure drop coalescer |
Family Applications After (1)
Application Number | Title | Priority Date | Filing Date |
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US12/982,259 Active 2026-10-10 US8545707B2 (en) | 2005-09-20 | 2010-12-30 | Reduced pressure drop coalescer |
Country Status (5)
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US (2) | US20070062886A1 (zh) |
CN (1) | CN101282773B (zh) |
BR (1) | BRPI0616182B1 (zh) |
DE (1) | DE112006002480T5 (zh) |
WO (1) | WO2007035192A2 (zh) |
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DE112006002921T5 (de) | 2005-11-14 | 2008-12-18 | Fleetguard, Inc., Nashville | Variabler Koaleszer |
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US20100050871A1 (en) * | 2008-09-03 | 2010-03-04 | Cummins Filtration Ip Inc. | Air-Jacketed Coalescer Media with Improved Performance |
US20110124941A1 (en) * | 2009-05-15 | 2011-05-26 | Cummins Filtration Ip, Inc. | Surface Coalescers |
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US20110168647A1 (en) * | 2008-10-08 | 2011-07-14 | Cummins Filtration Ip Inc. | Modular Filter Elements for Use in a Filter-in-Filter Cartridge |
US8114182B2 (en) | 2007-11-15 | 2012-02-14 | Cummins Filtration Ip, Inc. | Authorized filter servicing and replacement |
US8360251B2 (en) | 2008-10-08 | 2013-01-29 | Cummins Filtration Ip, Inc. | Multi-layer coalescing media having a high porosity interior layer and uses thereof |
US20140284263A1 (en) * | 2011-12-09 | 2014-09-25 | Mann+Hummel Gmbh | Fuel Filter of an Internal Combustion Engine and Filter Element of a Fuel Filter |
US9138671B2 (en) | 2012-08-30 | 2015-09-22 | Cummins Filtration Ip, Inc. | Inertial gas-liquid separator and porous collection substrate for use in inertial gas-liquid separator |
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Also Published As
Publication number | Publication date |
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WO2007035192A3 (en) | 2007-11-01 |
BRPI0616182A2 (pt) | 2013-02-19 |
US8545707B2 (en) | 2013-10-01 |
WO2007035192A2 (en) | 2007-03-29 |
CN101282773A (zh) | 2008-10-08 |
DE112006002480T5 (de) | 2008-08-07 |
US20110094382A1 (en) | 2011-04-28 |
CN101282773B (zh) | 2012-01-25 |
BRPI0616182B1 (pt) | 2017-11-21 |
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