MerlinPre-conditioning SystemThe solution to top productivity, cost savings & reliability
MerlinPre-conditioning Systemis the ultimate protection for all on-line process gas analyzers and equipment against particulates, liquids and mists found in process gases. It employs a patented and innovative technology to protect on-line gas analyzers over a wide range of operating conditions. It is the solution to top productivity and to ensure signi�cant cost savings in the plants.
The heart of the Merlin Pre-Conditioning System is the Merlin Low Flow Cyclone separator. The cyclone separator is designed to handle high loading of liquids and particulates at a very low gas flow rate.
Using centrifugal forces, it separates liquids and particulates by directing them axially and downward, collecting in the manual knock-out pot. At the same time, sub-micron particulates and mists impinge and adhere to the liquid layer. Cleaned gases flow upward and exit the separator.
Five years of intense research and development resulted in a technological breakthrough in the Merlin cyclone that prevents splashing inside the separator. Splashing produces fine mists that can easily entrain back into the exiting gas flow, eventually forming larger water droplets and damaging critical downstream on-line gas analyzers and equipment.
The innovative cyclone core ensures the Merlin Pre-Conditioning System operates effectively and with the highest reliability.
Tested and provenStress testing witnessed by TUV
Maintenance-free The cyclone generator has no moving parts, no wear and tear and maintenance
A compact core powering productivity in plants.
Innovative Features & the Magical Di�erence
Innovative Low Flow Rate DesignSpecially designed to work optimally at low flow rate (60-350 Nl/h) commonly found in the analyzer systems. Tested to 2 Nm3/h with no carry-over.
Green Technology No filter element, no clogging,replacement cost and down time.
Energy SavingWhen cooling is required, instrument air or cooling water consumption is reduced by up to 50% through ultra-high efficiency condenser.
Easy InstallationCompletely mechanical design allows for easy installation in hazardous areas.
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In Comparison
How the Merlin Pre-Conditioning System works
The wet and oily gases enter the Merlin Pre-Separator from the left. Particulates, liquids and mists are first separated by centrifugal forces without using any filter element.
The gas, saturated with fine particulates and mists, then go into the Galatica Condenser. Larger liquid droplets with fine particulates are formed through slight cooling using vortex cooled air or cooling water. This can be precisely controlled by an optional temperature control valve.
MERLIN PRE-CONDITIONING SYSTEM
COMPARISON AS FAST LOOP FILTRATION:
TRADITIONAL FAST LOOP FILTER/ MEMBRANE SYSTEM
Employs cyclonic centrifugal forces
No moving and consumable parts,Significant savings in maintenance costs
Removes particulates up to 10 micron or finer
No filter,No clogging issues
Innovative break through concept for maintenance-free critical fast loop primary filtration
Employs fine pore media filter element
Frequent replacement of clogged filter element, High maintenance costs
Removes particulates and condensate at up to 0.01 micron if not clogged
Clogged filter results in no flow to analyzers, carry-over damages analyzers
Design more suited as final protection filter
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4.
3.
1.
1. 2.
3. 4.The gas and liquid dropletsare separated by the Merlin Separator by centrifugal forces.Fine separation occurs at low flow rate (60-350 Nl/h) and low pressure without any filter.
The liquid condensate with particulates are collected in the bottom manual knock-out pots for manual draining. Automatic draining is possible with the optional Optimus Automatic Drainer for large amount of liquid condensate with high particulate loading. The cleaned sample exits the system on the right.
Manpower
ReplacingFilter
Elements
Environmental Pollution
Filter Disposal Hazards
ProcessDowntime
Damaged Analyzers/Equipment
Traditional Filter and Knock Out system protect on-line gas analyzers by using fine pore filter media (1-7 micron size) or Teflon membrane (0.1 micron size) to trap particulates, liquids and mists. They are selected based on a perceived handling load.
However, in reality, this perceived handling load is a dynamic factor in plant processes, especially during plant optimizations, startup and upset. When these fine pores in the filter media is clogged with particulates and liquids, continuous flow across the filter media under pressure will result in break through and carry-over. This damages critical on-line gas analyzers for process control and safety monitoring. Filter failure has been known to cause a series of problems in the plant.
Each year, thousands of dollars are spent replacing clogged or spent filters and knock out systems for on-line gas analyzers. These are only the tip of the iceberg leading to other hidden issues and costs.
With the loss of quality control, process down time and replacement of expensive damaged on-line analyzers and equipment, plants often suffer significant losses.
Last but not least, maintenance staff get exposed to unknown chemical hazards. Environment pollution can also occur due to incineration of spent filter elements.
The running costs of traditional �ltration system are high and its impact runs deep.
Hidden costs of Traditional Fast Loop Fltration
HIDDEN COSTS
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For Low Gas Flow andLow Liquid Condensate
Type
CFor Reflux and Medium Liquid Condensate Handling
Type
X
The Merlin System Family
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For Reflux and Extreme Liquid Condensate Handling
Type
R
SPECIFICATIONS OF MERLIN SYSTEM TYPE C, X AND R
Sample Inlet Connections (Merlin Pre-Seperator)
• ½” NPTF • SS 316 Stainless Steel, NACE Compliance SS316 SSt, Monel, Hastelloy C• Operating Temp & Press: -10 to +200 deg C, 20 to 50 barg. Optional: 100 barg or higher• Internal Volume: 160 CC (for response time calculation considerations)• Separation capacity: Normal conditions 60 Nl/h to 1000 Nl/h with 30 l/h liquid condensate
Galatica Condenser
• SS 316 Stainless Steel, NACE Compliance SS316 SSt, Monel, Hastelloy C• Operating Temp & Press: -20 to +200 deg C, 20 to 100 barg or higher• Internal Volume: 300 CC (for response time calculation considerations)• Temperature Control Valve Control Set Points: 5 to +50 deg C• Cooling Medium: Instrument Air, 1-6 barg, Flow: 30 NL/M to 425 NL/M• Cooling Medium: Cooling water, 150-500 l/H typically
Merlin Separator
• SS 316 Stainless Steel, NACE Compliance SS316 SSt, Monel, Hastelloy C• Operating Temp & Press: -10 to +200 deg C, 20 to 50 barg. Optional: 100 barg or higher• Internal Volume: 160 CC (for response time calculation considerations)• Separation capacity: Normal conditions 60 Nl/h to 1000 Nl/h with 30 l/h liquid condensate, 99.9% of liquid condensate and particulate of 10 micron size and larger
Optimus Automatic Drainer/ Manual Drain Pot
• SS 316 Stainless Steel, NACE Compliance SS316 SSt, Monel, Hastelloy C• Operating Temp & Press: -10 to +200 deg C, 20 to 50 barg. Optional: 100 barg or higher• Internal Volume: 500 - 1000 CC (not for response time calculation consideration as gas sample is “isolated” from drainer)• Liquid handling Capacity: Normal conditions 30 l/h to 100 l/h liquid condensate
Ambient Operating Temperature• Typically 5 to 50 deg C
Other Materials and Operating Temperature & Press available on request.
PRACTICAL ANALYZER SOLUTIONS PTE LTD
32 Ang Mo Kio Industrial Park 2
Sing Industrial Complex #06-13 (O�ce), #03-17 (Factory/ Training)
Singapore 569510
Tel: 6836 8383 Fax: 6836 8328
