One of the most frequent questions we receive about our KLS line of separators has to do with their effectiveness at low gas flows. This probably stems from confusing our Helical Coil technology with old fashioned centrifugal units which were highly dependent on flow force. The two are significantly different, not only in science, but in results.
Third party research, as well as years of field use, have proven that turndown is not an issue for the Mueller KLS Separator. The patented helical coil geometry generates a surprisingly high G swirl that efficiently removes contaminates from the gas stream regardless of flow. For contaminates to remain in the gas stream, the buoyancy and drag forces must overcome the inertial force created by the high G swirling action. Through CFD analysis, Stress Engineering Services Inc. has found that even at minimum gas mass flows (1.5 lb /min) the helical coil produces nearly 200 G's. This high G centrifugal force acting on the contaminate particles is far greater than the combined buoyancy and drag forces even at these low gas flows, ensuring very effective separation.
In addition to generating a high G swirl, the KLS geometry forces the gas to turn inward toward the center axis as it exits the gas channel outlet. This transition from the outlet of the helical gas channels to the inlet of the clean gas outlet tube does two things: it makes following the gas path difficult because the gas is moving inward while the high G swirl is forcing the contaminate outward; plus the radius of the swirling flow decreases due to the clean gas outlet tube geometry, causing the inertial forces to increase. Combined, these effects allow the KLS to operate across a wide range of operating variables without negatively affecting the separation performance.
An additional fascinating finding from the Stress Engineering study was that at relatively high gas flows (41.5 lb /min) our helical element generates over one million G's of force. Clearly, the patented Mueller Helical Coil is a remarkable piece of technology that operates without moving or replaceable parts, harnessing the natural laws of physics to achieve superior contaminate removal.