Product category:
Separation and Membrane Systems
News Release from: MahleFilter Systems | Subject: Coalescer-filter
Edited by the Processingtalk Editorial
Team on 06 July 2006
Coalescer-filter separates water and
hydraulic oil
Water ingress in hydraulic and lubricating oil systems does not only reduce the operating-life of pressure fluids, but also of machining components
Water ingress in hydraulic and lubricating oil systems does not only reduce the operating-life of pressure fluids, but also of machining components Investigations have shown, that free water in hydraulic fluids restricts considerably the operating-life of a complete system
This article was originally published on Processingtalk on 11 Nov 2004 at 8.00am (UK)
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Consequential damage can be corroded metallic system parts, wear of bearings, prematurely blocked filters, hydrolysis of pressure fluid as well as additive degradation.
The results of water ingress, recognised too late, are varied, such as repair costs, delay in delivery or lost production.
If water ingress is found, the immediate elemination of defects is necessary.
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Mahle has developed the coalescer-filter to meet this requirement.
According to VDMA-unit sheet 24568, it is necessary to keep water content below 1 ppm (0.1%) for pressure fluids of the HE-group.
There should be no free water at all available in group HLP.
Free water results always in turbidity, which is visually recognisable.
Physically seen, turbidity results from a two-phase mixture (emulsion), with the finest water droplets in the pressure fluid.
Because of that, one route is to perform a mechanical separation of the water droplets.
This principle, called a coalescer, was picked up and developed to a market matured product.
The coalescer consist of several different levels.
In the first working step, the finest water droplets are collected and brought together to a larger unit.
The developed, millimetre size water droplets leave the coalescer layer and meet with a special hydrophobic equipped fabric.
A separation of the pressurised fluid occurs there.
By sedimentation, the water comes out of the circuit.
It is important for the process that a certain differential pressure in the coalescer will not be exceeded.
For perfect operation, it is important to consider the viscosity.
The coalescer can be operated fully automatically.
For this, there are different possibilities of control.
As an example, differential-pressure controlled volume flow with a pump or also regulation of the volume flow with a pressure limiting valve.
The lower the emulsifying additives available in the pressure fluid, the better the coalescer operates.
Consequence: Expensive special oils in systems, which are often exposed by ingress of water, can be replaced by simple inexpensive pressure fluids.
Because of the newly developed turbidity sensor from Mahle, there is the possibility to monitor the hydraulic fluids constantly.
Because of that, ingressed free water can immediately be recognised and indicated.
If a machine is equipped with a turbidity sensor, the failure is recognised immediately and a coalescer installed in the bypass-flow, will be connected.
After a short period of time, the pressure fluid is dry again.
The defect can be eliminated without any damage to the machine, or lost operational period of time.
Design parameters are available for hydraulic fluid groups HLP, HETG and HEES.
Conclusion: With the newly developed coalescer-filter, an inexpensive appliance has been created.
In connection with the new turbidity sensor, the ingressed water can be removed very fast.
A high system safety and availability is guaranteed, as the turbidity sensor is responsible for the rapid identification and for immediate removal of water.
All fluid-technical applications provide a large number of possible uses, exposed by water ingress, e.g hydraulic systems with water cooler, mobile applications like construction machines, power plants, wind energy converters, marine technology etc.
The system is the subject of a patent application.
Details must be checked for each application.
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