FILTRATION NEWS

September/October 2011 Volume 30 No. 5 www.filtnews.com

INTERNATIONAL

Your Global Source

Oil and Gas Industry Filtration

Filtration Market in Oil/Gas Sector Filtering Heavy Feed Stock Solutions for Hydrocarbon Condensate

Chase Machine & Engineering:

Investing in Core Business

Oil & Gas | Filtration

centrifuges, organoclay absorbents, microfiltration, and different oil resistant membrane materials and membrane types. GeoPure produced a 200-gpm unit incorporating some of the pretreatment options and, used it successfully for about nine months to treat Barnett Shale frac water of at least 13,400 mg/liter total dissolved solids. ProChemTech invented a sequential precipitation process for treatment of flowback water. The first precipitation removes suspended solids, iron, and barium from the flowback water as solid, typically non-hazardous, sludge cake. The remaining scale formers (calcium, iron, magnesium, manganese, and strontium) are precipitated to make one solid sludge cake, which could be used as an alkaline soil amendment or for abandoned mine spoil reclamation. The process does not materially change the concentration of dissolved solids in the FRW. ProChem concludes that the only known alternative to their process is the GE Thermal Evaporation process, which uses a vertical-tube evaporator to convert industrial wastewaters into distilled water for reuse. OTHER MEMBRANE TECHNOLOGIES MTRs FuelSep systems purify raw gas sidestreams to premium quality fuel gas. MTR membranes easily remove H2S, C3+, CO2, N2 and water from fuel gas at moderate pressure. Because these impurities are taken out of the fuel gas and returned to the compressor suction, there are no effluent streams to be disposed of. Any C3 + removed from the fuel gas goes back into the main gas stream, so all NGL in the raw gas stream is available for downstream recovery, if desired. These units have no moving parts, are simple to install and operate unattended. Many units are operating worldwide. H2S is found in natural gas in many locations, and this high H2S gas cannot be transported from the wellhead to pipelines without treatment. MTRs membranes can provide a simple, lowcost, compact solution for reducing H2S in natural gas. Argonne National Laboratory and Nalco Company have reached an agreement for an electrodeionization technology to reduce the cost of technology that can process biomass-based feedstocks into biofuels and chemicals. Specifically, Argonnes patented technology allows for the deionizing or the continuous removal of charged products like organic acids from aqueous streams and eliminates the requirement to continuously add neutralizing agents. Conventional bioprocessing technologies require significant capital expenditures on energy-intensive steps to recover these products and generate large waste streams. Snowpure also has experience with electrodeionization for bioprocessing. This technology is primarily used in ultrapure water. However, biofuels and seawater desalination promise to open even bigger markets. These technologies and applications are covered extensively in the Free Global Knowledge Orchard2.

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CARTRIDGES Cartridges are used in water treatment but also product purification. They are also used in conjunction with the lubrication for fans, turbines, compressors and other rotating equipment. A big application for cartridges is filtration of the biofuel product. Parker Hannifin supplies the Turbine Series filter assemblies, which are installed on the vacuum side of the fuel transfer pump for best efficiency and to protect precision engine components from dirt, rust, algae, asphaltines, varnishes, and especially water, which is prevalent in engine fuels. SCRUBBERS AND ABSORBERS Scrubbers and adsorbers are used for cleanup of various exhaust gases as well as purification of CO2 for resale in the corn-based ethanol process. Coalescers are used to remove impurities from the fuel gas stream. The multi-step Claus process recovers sulfur from the gaseous hydrogen sulfide found in raw natural gas and from the byproduct gases containing hydrogen sulfide derived from refining crude oil and other industrial processes. The byproduct

gases mainly originate from physical and chemical gas treatment units (Selexol, Rectisol, Purisol and amine scrubbers) in refineries, natural gas processing plants and gasification or synthesis gas plants. These by-product gases may also contain hydrogen cyanide, hydrocarbons, sulfur dioxide or ammonia. MACROFILTRATION These are two main routes for liquefying coal: indirect and direct. The indirect process requires both particulate and acid gas removal from the flue gas stream. Ceramic filters or venturi scrubbers are used for particulate removal. Acid gases are removed in processes similar to those described above for natural gas purification. Absorbers and coalescers have a place. The second liquefaction approach such as used by headwaters is direct liquefaction. With the commercial success of a direct liquefaction system in China, this alternative may become the preferred route. It has lower capital costs and less of a carbon footprint than indirect liquefaction. There is also more reliance on filtration of liquid. The solid/liquid separation is one of

the most important unit processes in the direct approach. One device for primary separation is a pre-coat pressurized rotary drum filter. There are a few uses of filters in others parts of the process. One example is a filter to stabilize caustic use in tank cleanings. Ethanol plants typically have many fermentation tanks. The system is optimized so that one tank is offline for cleaning. This clean up is important and must be done in a short period of time. Caustic is added through a caustic control valve to maintain peak cleaning efficiency. In one location, an Eaton (Ronningen-Petter) filter was installed on a recirculation loop off of the caustic make-down tank. Cost savings were realized with the use of this filter.
FN

For more information contact: Bob McIlvaine Tel: 1-847-784-0012 Ext. 112 Email: rmcilvaine@mcilvainecompany.com Website: www.mcilvainecompany.com
1

http://www.mcilvainecompany.com/Decision_Tree/subscriber/Tree /UnivDB/appl2.asp?ref1=480 2 http://www.mcilvainecompany.com/Decision_Tree/subscriber/Tree /UnivDB/prod2.asp?prodname=Electrodeionization

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Oil & Gas | Filtration

The Challenge of Filtering Heavy Feed Stocks

By Rick Jacobs, Eaton Corporation
he drive to increase profits at petroleum refineries requires operators to focus on operating efficiencies including a constant search for lower cost feed stocks. This search has led to the processing of heavier, more sour feed stocks. The most recent push is to process more of the Canadian Tar Sands. The challenge in processing these feeds is twofold. First is simply cracking the heavy feed to make more light ends and second is to remove the sulfur to meet regulatory limits when producing fuels and other products. Choosing and maintaining the right equipment and systems to meet these demands is crucial. Eatons filtration equipment is well-suited to help refineries process these difficult feeds as

well as make their hydraulic systems work reliably, effectively, and operate at their maximum capacity. PROCESS FILTRATION Feed stock filtration systems protect fixed bed catalyst units from plugging because of contaminate in the crude. The effect of plugging is high differential pressures that cause the bed to be shut down prior to the catalysts full utilization. The heavier the feed, the more contaminants are generally present and the higher the risk for plugging. The heavier feed stocks also are more difficult to filter because of higher viscosity and the presence of asphaltenes. Eaton has more than 500 ReactoG-

ard systems globally installed and operating. The systems are protecting Hydro-treaters, Hydro-crackers and Hydro-desulfurization units. ReactoGard systems are clean-in-place units utilizing automatic backwashing technology for regeneration. This cleanin-place technology is an environmentally friendly solution compared to disposable media options that require disposal through incineration or other methods. The automatic operation is controlled with PLC or DCS controls providing minimal operator intervention. Eatons ReactoGard V is the fifth generation of this technology and has: A 50% reduction in footprint Up to a 70% reduction in valves

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ReactoGuard system Improved backwash efficiency over other designs Highly efficient media to ensure catalyst bed operation will utilize its full reactivity potential

Amine filter unit AMINE FILTRATION Designed to operate in the amine loop, Eatons ClearAmine unit is known for its efficiency. Higher sulfur feeds push the amine loop harder to treat the increased volumes of sour gas. The primary issue with this is as the amine loop processes the higher levels of sour gas it produces more corrosion in the loop. These corrosive particles

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Oil & Gas | Filtration

Off-line filters process. This allows the system to be backwashed with water without dilution of the amine stream or amine contamination in the backwash water. The unit also can be set up on the lean side with an adjustable slip stream system allowing more of the stream to be filtered removing more of the solids. The automatic procedure permits cleaning to occur without operator intervention, this means placing the filter on the rich side is an option. This permits the stream to be filtered full flow, protecting downstream equipment like the heat exchanger and minimizing the need for replacement of disposable media on the slip stream sentry filters. Traditional disposable media on the rich side is not recommended because it increases operators possible exposure to H2S lethal gas during filter changes. These capabilities provide an EHS advantage over traditional disposable media solutions that risk operator exposure and require disposal of the used media. HYDRAULIC COMPONENT FILTRATION Off-line Filter Units Effective oil service for hydraulic and lubrication systems in petroleum refineries requires using an operating filter, the application of a filter unit for off-line filtration, oil change, and filling. To prevent contamination, the fluid should be filled through a fine filter of an off-line filtration unit. Mobile (UM) and stationary (US) offline filtration units with electric motors improve the cleanness and quality of the operating fluid and prolong its durability, thereby preventing early failure of system components. Eatons expertise has led to the development of explosion-proof mobile off-line filter units (UMP) in two different sizes and performance possibilities with a pneumatic double diaphragm pump. A chemically resistant membrane, which can easily be changed, ensures a prolonged life

increase the solids load in the stream when using traditional slip stream disposable media systems. The increased solids load results in issues in the amine loops processing equipment.

Heat exchangers are particularly susceptible to solids as they are an area of decreased velocity where solids fallout and foul the heat exchanger. This causes increased maintenance and unplanned shutdowns on the amine loop. The free solids in the stream also can become coated with hydrocarbons increasing the hydrocarbon content. The inc r e a s e d hydrocarbons cause foaming in the contactor that decreases the efficiency of the amine loop. Specifically designed for this application, the C l e a r A m i n e s clean-in-place unit uses backwashing technology to regenerate the filter. The cleaning sequence can also use a purging

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cycle. Changing the filter element without any tools eliminates the need for system downtime. Due to its compact design and a transporting trolley moving the unit close to locations that are difficult to access is easy. Stainless Steel Filters In the oil and gas industry, stainless steel filters protect compressors, pumps, and turbines. They are mounted in suction, pressure, or return lines and are available in single or duplex as well as filter modules for high filtration efficiency at high volume flows. The goal is to prevent contaminants from entering the hydraulic and lubrication oil systems and avoid early failure of system components, thereby significantly improving the system reliability. This high performance filter series is suitable for pressure ranges from 16 bar up to 420 bar, and is easy to operate and service. High-quality filter elements with high dirt holding capacities are available in different

Contamination and Condition Monitoring Systems

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Oil & Gas | Filtration

filter materials. The change-over stainless steel pressure filters (EDA, EDU, EHD, EDSF series) have an additional user benefit, a change-over ball valve that makes it possible to switch from the dirty to the clean filter side without interrupting the operation. This makes it possible to change or service the contaminated filter element while in the off position. Keeping Hydraulic Components and Systems Running Efficiently Through Monitoring Many factors can reduce the service life of hydraulic components and systems in petroleum refineries. It is critical to define and maintain a fluid cleanliness level on a continuous basis to prevent particle, water, or gas contamination. Knowing these levels is the most valuable information an operator can have. It permits further analysis concerning: Filter configuration efficiency Changes of the wear situation in systems Secondary contamination Accurate, on-time information enables the operator to respond quickly to adverse system changes with adequate counteractive measures. While monitoring fluid cleanliness may not be new, the innovations from off-line measurement to on-line measurement in contamination monitoring is. At the present time manufacturers have their focus on developing devices for in-line measurements. Eaton is a pioneer in this field, developing a whole in-line monitoring system of sensors and indicators particle counters, water contamination monitoring systems, and oil condition monitoring systems. Applying those measuring techniques in different configurations ensures a continuous monitoring and state conditioning diagnosis of hydraulic systems, and even more wear surveillance and early recognition of damage, which is essential for hydraulic and lubrication systems. CONTAMINATION MONITORING Contamination has many effects on hydraulic systems in petroleum refineries such as: Accelerated oil aging Shortened fluid lifetime Failure of additives Corrosion Cavitation Abrasion Erosion Increased wear

Therefore, defining the precise level of contamination at any time is

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crucial for the functionality and efficiency of a system. This involves two methods of taking fluid samples from the system at regular intervals and testing them. The first would be sending such a fluid sample to a laboratory for analysis. The second is to use a mobile electronic instrument designed for this purpose. Eatons condition monitoring systems provide accurate, immediate, mobile and stationary fluid monitoring and particle counting in accordance with ISO, NAS, and SAE standards. Eatons wide range of products for particulate contamination measurements are an essential part of any broad maintenance concept. Eaton systems are intended for in-line, off-line and many on-line applications as well. Eatons mobile Contamination Control System CCS 4 determines the exact particle size distribution of the contamination, water saturation, and fluid temperature. Measurement results are meant to be a base for evaluating the wear condition of hydraulic components, adherence to norms, and early detection of damages. The CCS 4 can be handled in on-line pressurized operating modes as well as for depressurized samplings (e.g. tank sampling). Measurements are displayed as particle numbers according to contamination classes: ISO 4406:99 ISO: 4406:87 NAS 1638 SAE AS 4059 Water saturation and temperature Theoretical water content in ppm Internally stored measured values easily transfer using an USB-interface or a RS232-interface. By monitoring and controlling the oil cleanliness level, early detection of solid particles and other contaminants help avoid unplanned maintenance; significantly decrease operating costs as well as unforeseen shutdowns. Eaton also offers many other filtration and separation solutions including a full line of cast and

fabricated strainers, process and utility water filtration with automatic backwash units, gas liquid separators, and a full line of disposable media solutions.
FN

For more information contact: Eaton Corporation - Hydraulics Group Filtration Division Tel: 1-732-767-4203 - Fax: 1-732-494-0793 Email: MargaretDeAngelis@eaton.com Website: www.eaton.com

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