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The Plate Pack Coalescer uses parallel plates at a specific angle, typically 45 or 60 degrees, to accelerate liquid-liquid separation based on the Stokes Settling principle. Dividing flow into smaller channels reduces the Reynolds number into the laminar regime and shortens the distance a dispersed droplet must travel before coalescing. The result is improved separation efficiency and reduced residence time compared to open gravity separation.
Plate geometry and spacing are selected based on service conditions, efficiency requirements, and solids content to mitigate fouling and extend runtime between cleaning cycles. Available in metallic alloys and polymers to suit corrosion and temperature requirements. TrayTec supplies and installs Plate Pack Coalescers to your vessel specification.
Custom plate spacing, angle & length
Resistant to fouling
Enhances liquid-liquid separation
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Plate angle, typically 45 or 60 degrees, and plate spacing determine the channel dimensions through which the process stream flows. Closer plate spacing reduces the distance a dispersed droplet must travel to reach a plate surface and coalesce, improving separation efficiency and reducing required residence time. Wider spacing increases tolerance for solids in the process stream, extending runtime between cleaning cycles at a tradeoff in separation efficiency. The correct combination of angle and spacing is determined by the fluid physical properties, required effluent quality, and expected solids loading. Contact TrayTec with your process data to confirm the right plate geometry for your application.
The Plate Pack Coalescer is the preferred choice when solids are present in the process stream. Its wider, open plate channels are less susceptible to blinding than the finer corrugated foil geometry of the Stokes Coalescer, and the plate design can incorporate specific features to manage solids accumulation and extend runtime between shutdowns. The Stokes Coalescer provides higher surface area and is suited for moderate fouling services, but is more sensitive to solids loading than the plate pack configuration. Contact TrayTec to confirm which coalescer geometry is appropriate for your specific process stream and solids content.
Yes. Installing a plate pack coalescer inside an existing gravity separator is one of the most common debottlenecking approaches for liquid-liquid separation performance. The plate pack increases the effective settling area within the existing vessel volume, improving separation efficiency and throughput without vessel replacement or modification. The design must account for inlet device configuration, plate orientation relative to flow direction, and solids management within the existing vessel geometry. Contact TrayTec with your existing separator drawings and process conditions to assess retrofit feasibility.
