Aviation & Diesel Fuel Filtration and Separation Solutions
Fuel cleanliness is a critical safety and performance requirement in aviation, transportation, mining, rail, marine, and heavy equipment operations. Even trace amounts of water, particulate matter, surfactants, or additives can lead to engine malfunction, corrosion, reduced combustion efficiency, and severe operational risk.
Mechasol Aviation and Diesel Fuel Filtration & Separation Systems are engineered to provide continuous, high-efficiency removal of water and solid contaminants, ensuring fuel quality that meets or exceeds international aviation and industrial standards. Our solutions combine robust pressure vessels, certified filtration elements, and modular system configurations, designed for both fixed installations and mobile fueling applications.
Coalescer Separator Systems
System Function and Principle
Two-stage coalescer separator systems represent the primary line of defense against water and particulate contamination in aviation and diesel fuels. These systems operate without internal moving parts, ensuring high reliability and low maintenance requirements.
Fuel enters the coalescer separator housing under pressure and passes through a first-stage coalescer cartridge, where:
Ultra-fine solid contaminants (sub-micron level) are captured,
Dispersed water droplets are forced to merge (coalesce) into larger droplets.
The enlarged water droplets then separate by gravity and settle in the housing sump, while the partially cleaned fuel continues to the second-stage separator cartridges, which remove any remaining free water before the fuel exits the system.
Key Advantages
Continuous removal of solids and water
High separation efficiency under varying flow conditions
No internal mechanical components
Proven reliability in aviation fueling infrastructure
Housing Configurations
Vertical or horizontal vessels
Designed and manufactured in accordance with EI 1596
Engineered for easy cartridge replacement and minimal downtime
Wide range of inlet/outlet nozzle orientations and accessory options
Mechasol coalescer separators are suitable for commercial airports, military fueling systems, refinery terminals, pipeline transfer points, and mobile fueling units, delivering effluent purity levels required by airlines, oil majors, and government authorities worldwide
Aviation Filters
Coalescer Filter Cartridges
Design and Construction
Mechasol coalescer cartridges are manufactured to meet the 6th Edition of EI 1581, ensuring compliance with the most stringent aviation fuel filtration standards.
Cartridges are available in two mounting styles:
Self-centering rod mount with treated metal end caps
Screw-base configuration with injection-molded, glass-filled nylon ends
The screw-base design provides:
A permanently bonded Buna-N gasket seals against the V-type knife-edge adapter, ensuring a positive, leak-free seal throughout the cartridge service life.
Standard Performance Characteristics
Multi-layer media for high dirt holding capacity
Removal of ultra-fine solids (< 1 micron)
Maximum water coalescing efficiency
Balanced flow distribution
Operating temperature up to 240°F (115°C)
Differential pressure resistance exceeding 75 psi (5.17 bar)
pH operating range: 5 to 9
Available in screw-base and open-end designs
Aviation Filters
Separator Cartridges
Functional Role
Separator cartridges act as the final water barrier in a two-stage coalescer separator system. Their primary function is to prevent any entrained or coalesced water droplets from passing downstream.
Design Features
Cleanable and reusable construction
Treated hydrophobic media offering superior water repellency
Synthetic screen ultrasonically seamed around an epoxy-coated metal core
Adhesive-bonded metal end caps with Buna-N gaskets
Performance Characteristics
Flow direction: outside to inside
Excellent resistance to water breakthrough
Operating temperature up to 240°F (115°C)
pH range: 5 to 9
Balanced flow design to prevent channeling and premature failure
Alternative gasket, adhesive, and metal materials are available upon request for special fuel compositions or environmental conditions
Aviation Filters
Clay Treater Housings
Purpose and Application
Clay treater housings are typically installed upstream of coalescer separators to remove surface-active agents, additives, and color bodies present in jet fuel. These contaminants may originate during refining or be introduced during multi-product transportation via pipelines, ships, or trucks.
Such compounds can disarm coalescer cartridges, significantly reducing water separation efficiency. Clay treatment protects downstream filtration systems and extends cartridge service life.
Operating Principle
Fuel flows through an inlet chamber and an internal equalizer tube, which evenly distributes the fuel through multiple clay cartridges. Contaminants are removed by adsorption, producing treated fuel suitable for final water separation.
Key Benefits
Aviation Filters
Particulate Filter Housings
Function
Particulate filter housings remove rust, sand, pipe scale, metal particles, and dirt from fuel streams. They are commonly installed upstream of clay treaters and coalescer separators to protect sensitive downstream elements.
Housing Design
Single-pass, continuous filtration
Compatible with single, double, or triple-length high-efficiency cartridges
Designed for easy servicing and low maintenance
Mechanical Standards
Designed to EI 1596 or applicable codes
ASME Section VIII or EN 13445 construction
Typical rating: 150 psi @ 250°F (10.3 bar @ 121°C)
Higher pressure and temperature ratings available
Closure Options
Standard housings are fabricated from welded carbon steel, with alternative materials available upon request
Aviation Filters
Particulate Filter Cartridges
Performance Characteristics
Mechasol particulate filter cartridges are designed for high dirt holding capacity and long service life, with no unloading characteristics during operation.
Standard Features
Micron ratings: 2, 5, and 10 μm (others on request)
Operating temperature up to 240°F (115°C)
Maximum differential pressure: 75 psi (5.17 bar)
pH operating range: 5 to 9
Flow direction: outside to inside
Materials
Carbon steel structural components
Corrosion-protected metal parts
Standard Buna-N gaskets (alternatives available)
Aviation Filters
Mechasol Engineering Advantage
Certified aviation and industrial fuel filtration solutions
Compliance with EI, ASME, EN, and international aviation standards
Robust vessel design and high-performance filtration media
Modular system configurations for fixed and mobile installations
Long service life, low maintenance, and operational reliability