PHASE SEPARATORSLiquid/Liquid Phase Separation

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FRANKEN FILTERTECHNIK KG

Company Page 3

Know-how Page 4

Engineering Page 6 Layout, calculation, CAD, CFD

Development Page 8

Manufacture Page 9 VesselsPhase separation stages

PT Phase Separators Page 10 Plants Phase separation stages

MPT Phase Separators Page 16 Plants Phase separation stages

Special Plants Page 22

50 μm

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FRANKEN is an experienced international manufacturer of high-quality plants and components for liquid/liquid phase separation.

Why Phase Separators?FRANKEN Phase Separators remove droplets with diameters greater than 0.1 µm from liquid/liquid dispersions.The resulting improvement in the purity of liquid recovered from both the dispersed and the continuous phases increases product quality and reduces the need for downstream treatment. FRANKEN Phase Separators can increase profits significantly, yet have low investment and operating costs.

Separation of droplets in a microfiber bed

Flow through MPT phase separation profiles

Special Process EngineeringDroplet-droplet coalescence on microfibers, wire mesh and profile surfaces allows large droplets (d > 1,000 µm) to form quickly and efficiently. As these droplets flow through the Phase Separator vessel, density differences cause them to migrate to the liquid interface under the influence of gravity.

With careful design backed by practical experience, this straightforward and robust technology ensures separation right down to the solubility limit even under difficult conditions. Since coalescence is a mechanical separation pro-cess, it cannot remove dissolved liquids.

High-Level EngineeringTo make sure that we understand every detail of what is taking place inside our separators, we simulate them using computational fluid dynamics (CFD). In-house laboratory tests confirm the CFD results and help us to become ever more precise. FRANKEN Phase Separators can be used even under extreme process conditions thanks to a wide choice of materials of construction.

Quality through Know-howFRANKEN Phase Separators set the standards in innovation, know-how, engineering and quality. To ensure that we always meet these standards, we design and manufacture every vessel and its internals ourselves. As a supplier of customized plants, we work closely with our customers at all times.

Focus on the EnvironmentOur technologies contribute to ecological sustainability and lower energy use.Modular and extensible design helps to make FRANKEN Phase Separators future-proof.At the end of their operating lives, the internals can be refurbished or recycled.

Perfect SeparationFRANKEN Phase Separators are designed for optimal coalescence in separating organic or aqueous droplets.To design each separator we take into account the droplet size distribution at the inlet, the wetting behavior of the two liquids, and the interfacial tension.

50 μm 50 μm 50 μm

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Phase Separator know-how

The separation task defines the phase separation procedure.

Formation: thermal turbidity by cooling

mechanicalpumps agitators flow

droplet size [µm]

PT

MPT

PTG

2 – 240 hours 5 – 120 minutes < 300 seconds

Coalescence process

(100 ml beaker)

Density difference guides thedroplets to the profile surfaces

Droplet-droplet coalescence at the profile surfaces

Displacement of coarse droplets (d>1,000 µm) at certain profile

areas

Coarse droplets shift to theinterface under gravity

Droplet-droplet coalescence atthe interface

Flow guides the fine droplets tothe microfibers

Droplet-droplet coalescence at the fiber crosspoints

Displacement of coarse droplets (d>1,000 µm) at the fiber bed

outlet

at profile surfaces at the interfacein microfiber beds

Dro

plet

form

ation

and

sep

arati

on

PT MPT PTGDensity difference kg/m³ > 10 > 50 > 150Viscosity of continuous phase mPas < 500 < 20 < 5Viscosity of dispersed phase mPas < 500 < 1,000 < 2,000Interfacial tension* mN/m > 2 > 2 > 2Maximum concentration of dispersed phase vol % < 10 any anyDifferential pressure (clean / maximum) bar g < 0.05 / 1.5 < 0.02 < 0.02Solid particles µm < 5** < 25

Dro

plet

siz

e an

d fo

rmati

on

*pure mixture with no surfactants **install prefilter if necessary

Proc

ess

cond

ition

s

PT Phase Separatorfor fine droplets > 0.1 µm

MPT Phase Separatorfor medium droplets > 10 µm

PTG Phase Separatorfor coarse droplets > 50 µm

10-2 10-1 100 101 102 103 104

Settling time:

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PTProduct treatment- Water from silicone oil- Water from polycarbonateProcess enhancement- Rh solution from aldehyde- Extractant from Cs solution- Benzene from hydrochloric acid

MPTBiodiesel- Glycerin from methyl ester- Fatty acids from glycerin waterHydrocarbons from wastewater Process enhancement- Caustic soda from vinyl chloride- Silcone oil from hydrochloric acid

PTGProcess enhancement- Water from cumene- Raffinate from methyl pyridineCapacity enhancement- Reservoir water from crude oil- MCB/DCM from wastewater- Hydrocarbons from water

Applications:

TPX stage with phase separation elements

MPT module with phase separation profiles

Flow distribution

Effective separation of coalesced droplets in a Phase Separator.

PT Phase Separator

MPT Phase Separator (unpressurized model)

PTG Phase Separator

Outlet

Outlet

Outlet

Inlet

Inlet

Inlet

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Phase Separator engineering

Process conditions- Flow rate- Operating pressure and temperature- Required separation efficiency- Solid content

Calculation procedure• Phase Separator type (PT / MPT / PTG)• Specific efficiency of phase separation internals• Vessel dimensions

MPT Phase Separator

Properties of dispersion (liquid/liquid)- Density and viscosity of the fluids- Droplet size (settling time)- Interfacial tension under process conditions

FRANKEN Phase Separators are designed to customers‘ specific requirements.

Vessel designPED 97/23/EG (AD2000&DIN), ASME, and other design codes

Selection of materialsCarbon steel, stainless steel, special metals, plastics, coatings, linings

MPT profile rows(pressure vessel)

MPT module (unpressurized vessel)

high low

Pressure vessel

Unpressurized vessel

Calculation and selection of• Module type and number• Material of the phase separation profiles• Gap height and profile type

CFD simulation (velocity plot)

N5a

N5a

N5b

N5b

N5cN3

N2

N2

N3

N4

N4

N1

N1

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Analytical procedure• Laboratory trials for phase separation• Field test• Scale-up/ CFD simulation

PT Phase Separator

Special equipment- Measuring instruments- Sight glasses- Heating- Insulation

Design- Design code and inspections- Design pressure and temperature- Materials- ATEX

Modular design of FRANKEN Phase Separators to allow tailoring to each separation task.

ConnectionsN1 DispersionN2 Main phaseN3 Secondary phaseN4 Ventilation

N5 DrainAdditionalmeasuring instruments,sight glasses, pressure relief valves

• Flow distribution in the inlet area• Optimization of retention time• Improved interface adjustment• Improved discharge of the two phases• Ability to upgrade phase separation stages

PTG Phase Separator

Static pressure

Velocity

CFD simulation

Calculation and selection of• Element type and number• Materials for the phase separation elements• Fiber material and diameter• Porosity of the fiber bed• Separator / demister stage (optional)

Phase separation element

N5a

N5a

N5b

N2

N2

N3

N3

N4

N1

N1

N5b

high low

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Phase Separator development

Our continuing research and development yields increasingly precise calculations of droplet coalescence, separation efficiency and pressure drop.

Pilot-scale TUPS 400 Phase SeparatorCapacity: 0.5 – 5.0 m³/h

Phase separation element (2‘‘) for laboratory testsCapacity: 6.0 – 60 l/h

Scale-up from lab and pilot plants

Experiment: Fine droplet separation in a microfiber bedSeparation of water from octanolInterfacial tension: 6.6 mN/mDroplet size at inlet: 1.0 – 25 μm

Specific capacity: 7.5 m³/m2/hInlet concentration: 10 vol %Separation efficiency: > 99.95 %Pressure drop: 48.8 mbar

Experiment: Separation of droplets at phase separation profilesSeparation of cyclohexanone from waterInterfacial tension: 3.8 mN/m

Laboratory tests provide quick verification of calculated results, leading directly to improved engineering and superior products.

Our extensive knowledge allows us to take on new and demanding applications, such as liquid/liquid dispersions with: - high viscosity (up to 500 mPas)- low surface tension (down to 2 mN/m) or surfactant contamination - extreme pH (1– 14) requiring corrosion resistance

Detail of experiment:Coalesced big droplets behind the phase separation element

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Phase Separator manufacture

We manufacture not only the internals of our Phase Separators but also the vessels, as well as complete plants.

Carbon steel vessel fabrication Stainless steel vessel fabrication

The vessels must meet the highest standards if our phase separation stages are to operate to best advantage.

Making all our own vessels ensures consistently high quality, on-time delivery, and continuing advances in fabrication techniques and workflow management.

Careful vessel manufacture guarantees precise sealing of an MPT phase separation stage

Support plate for a PT Phase Separator showing phase separation elements

PT Phase Separator as an integral part of a plant module PT Phase Separator with ball bearing swivel device for the vessel head

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PT Phase SeparatorsFine droplet coalescers

PT Phase Separators can separate the finest droplets down to 0.1 μm diameter from liquid/liquid dispersions. The only limiting factor is solubility.PT Phase Separators improve the efficiency of chemical processes and the quality of liquid products.PT Phase Separators are developed for the specific requirements of the process industries. They can be used anywhere that requires liquid/liquid separation.

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Application: SeparationofgasolinefromprocesswaterType: PTX 1200Flow rate: 36 m³/hSpecialfeatures: Coalescermediummadeofmicro-stainlesssteelfiberstoresistalkalinecontinuousphase Switchableprefilter

BENEFITS:

Separationdowntothesolubilitylimit

Lowpressuredrop(<50mbar)

Wideselectionofmaterials

Lowoperatingcosts

Lowmaintenance

Customizedengineeringandmanufacture

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PT Phase Separators

Application: SeparationofcausticsodasolutionfromvinylchlorideType: PTX 800 (left)Flow rate: 44 m³/hSpecialfeature: MPT1800pre-separator(right,95m³/h)forbothproductstreams

Application: SeparationofextractantsfromwastewaterType: PTX 600-FFlow rate: 6 m³/hSpecialfeature: Integratedprefilterstage

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Application: SeparationofhydrochloricacidandsiliconeoilType: PT 800, PT 500Flow rate: 8 m³/h, 3 m³/hSpecialfeature: Vesselswith3mmPVDFlining,andphaseseparationstagemadeofPVDF

Application: Separationofwaterfromliquefiedgas/aldehydeType: PTX 700Flow rate: 15 m³/hSpecialfeature: Designpressure100bar

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PT phase separation stages

Pre-assembled phase separation stage made of stainless steelReady for expansion by adding four additional phase separation elements

Phase separation elements are easy to exchangeNo lifting devices or special tools needed, and no disassembly of pipework

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Phase separation stage made of PVDFCoalescer medium is microfiber made of acid-resistant glass or PTFE

Phase separation stage for retrofitting into a vesselMultipart design allows mounting through manhole

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MPT Phase SeparatorsSeparation of droplets and solids using profile surfaces

MPT Phase Separators can completely separate droplets of d > 10 μm from liquid/liquid dispersions.MPT Phase Separators are ideal for the process industries and in wastewater treatment.MPT Phase Separators operate with negligible pressure drop, and are available for both pressure vessels and rectangular vessels.

BENEFITS:

Veryhighseparationefficiency

Widechoiceofmaterials

Noenergyrequiredforoperation

Nooperatingcosts

Maintenance-free

Customizedengineeringandmanufacture

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Application: SeparationofhydrocarbonsfromrefinerywastewaterType: MPT 2000Flow rate: 60 m³/hSpecialfeatures: Integratedseparationofsolids MPTphaseseparationstagecanberemovedonrollers

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MPT Phase Separators

Application: SeparationoffattyacidfromglycerinwaterType: MPT 1400Flow rate: 5 m³/hSpecialfeatures: Operatingtemperature80°C,vesselliningmadeofspecialhardrubber MPTmodulesmadeoftitanium,overflowtankwithinterfacecontrol

Application: Separationofsiliconeoilfromhydrochloricacid(>37%)Type: MPT 1800Flow rate: 95 m³/hSpecialfeatures: Vesselwith3mmPVDFlining,andMPTmodulesmadeofPVDF

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Application: Separationofsiliconeoilfromhydrochloricacid(8%)Type: MPT 158Flow rate: 25 m³/hSpecialfeatures: Vesselliningmadeofhardrubber MPTmodulesandallinternalsmadeofPVDF

Application: Separationofglycerinfrommethylester(biodiesel)Type: MPT 208Flow rate: 17 m³/hSpecialfeature: Ambient-pressureseparationofhighlyviscousglycerinphase(300mPas)

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MPT phase separation stages

Final mounting of MPT modules made of polypropylene in a rectangular vesselThese will be used to separate glycerin from biodiesel

MPT module made of PVDF ready for installation, showing rim sealing

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Inlet distributor and two-part MPT profile row for vessels of 2,400 mm diameter

Rows of MPT profiles for mounting in a pressure vessel

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Application: SeparationofrubbersolutionfromwaterType: MS 1200/500-CFlow rate: 6 m³/hSpecialfeatures: Twomixingchambers,twovariabledoubleweirs Settlingareawithzerodeadspace

Application: Separationof10%sulfuricacidfromhydrocarbonsType: MPT 1000-CFlow rate: 9 m³/hSpecialfeatures: Mixer-settlerwithdoubleweirandaspecialphaseseparationstage VesselliningmadeofECTFE Phaseseparationstagemadeofpolypropylene Mechanicalhandlingsystemforphaseseparationinternals

Phase Separators – special plants

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Application: SeparationoffattyacidsfromwastewaterType: MPT 256-CFlow rate: 25 m³/hSpecialfeatures: MadeofAISI904Lstainlesssteel Integratedheatingsystem MPTmodulescanbecleanedwithoutinterruptingtheprocess

FRANKEN FILTERTECHNIK KGMax-Planck-Strasse 750354 HuerthGermany

Phone: +49 (0) 2233 97440-0Fax: +49 (0) 2233 97440-40Web: www.frankenfilter.comE-mail: info@frankenfilter.com

© 2009 FRANKEN FILTERTECHNIK KG