Knowing where to start when selecting the right filtration system can be tricky. That’s why working closely with filtration experts early on in your system design can pay dividends.
Here are a couple of examples of how customers have benefitted from our advice and designed a filtration system that’s appropriately sized for the application.
Why filtration is important
Filtration plays a critical role in many industrial processes, to remove solid contaminants and particulates from product streams. Properly specified filtration systems guarantee the quality of the end product as well as protect equipment from the risk of damage, and avoid the associated cost to replace such equipment.
However, if a filtration system is not set up correctly for the application, or is not looked after with regular servicing, then additional costs can quickly add up.
- Filter elements may need changing more frequently, or maintenance work will be higher than expected, which could result in extended periods of downtime.
- Blocked filters could result in higher energy consumption as the processing system attempts to maintain flow rates, and in turn this leads to higher operational costs.
- Expensive additives may be required to achieve the desired product quality.
- Poor filtration performance can even result in loss of reputation, loss of business and lost profit.
Example 1 – Don’t rely on generic data sheet specification
One of the key reasons that filtration systems are poorly designed and maintained is an over-reliance on generic datasheet specification. This commonly results in either oversized filtration systems, which leads to unnecessary higher capital cost, or sub-optimal filtration choices, which means the system is designed to fail prematurely.
To make sure your filtration system is fit for purpose and the filtration sizing and media selection is optimised, standard filtration specifications should only be used as the starting point. They should then be developed using application-specific data based on your priorities. Ideally, further testing should take place soon after commissioning to confirm the system is operating as predicted.
Use application-specific data to cut costs in half
One of our customers in the Middle East used generic flow calculations when specifying a new filtration system as part of a plant upgrade to improve productivity. Based on their calculations, tenders for the filtration package were only able to propose systems that were over-sized and that were not physically able to fit in to the available space in the plant.
We took a different approach. Rather than going off the generic specifications, we worked closely with the customer to fully understand their specific purity requirements. Then we assessed the entire production process to determine the type and size of contaminant that the new filtration system would need to remove.
Armed with the customer-specific data, we were able to design a new bespoke compact filtration skid that fitted in the physical space, as well as exceed the efficiency requirements of the application.
The compact filtration system used few components than alternative tenders’ solutions, and there were multiple benefits to following this approach:
- CAPEX was reduced by 40%
- OPEX was halved
- The lower cost enabled faster budget sign-off and meant the customer was quicker to market with its higher purity product
Example 2 – Review the operating conditions to reduce filter changeouts
There are many misconceptions about why existing filtration systems do not perform properly. Filters are often blamed for a filtration systems failure, but ninety percent of the time, the reason is not actually the filter’s fault! They are simply the point of failure because they are overloaded.
You need to get to the bottom of the problem and find out what is having a negative effect on the filter. In our experience, there are two main root causes of filter failure:
- Poor initial specification
- A change in process
Carry out Process Flow Analysis to minimise maintenance
Another of our customers had been overspending on maintenance for years due to inadequate filtration. They were having to replace filters more frequently than expected because the concentration of solid and liquid contaminants in the recycled gas stream from a direct reduction plant (DRP) reactor was higher than planned for. The result was having a negative impact on production levels and they were experiencing higher downtime levels then they liked.
We installed our Gas Filtration Test Skid at the customer’s site to conduct a detailed analysis of the actual process gas conditions over several days, without interrupting production.
The filters that the customer was using were intended to retain solid contaminants down to 50µm and results showed that the filters provided an initial removal efficiency of 93-95% for particulates 50µm in size. However, there were large volumes of particulates sized between 2µm – 40µm present in the flow, which caused issues. When combined with the high residual liquid concentrations present, the finer particles were found to be forming a slurry on surfaces downstream. This affected the filter element structure, process pipework, valves and the internal compressor surface/blades.
Additionally, tests highlighted that the flow permeability of the 50µm filter was reduced by more than 20-25% due to liquid saturation of the media. The wetting of the filter media occurs very quickly, so the differential pressure starting point is higher than that for a dry gas application.
With detailed information at hand, we made a series of recommendations to the customer so they could reduce their maintenance levels, save on filtration change out costs, and improve their process uptime. We suggested:
- A reconfiguration of the existing filter to 98% @ 100µm, reducing element differential pressure and improving operational life.
- A finer filtration system downstream to achieve the customer’s optimum requirement of 5-10µm while still improving the operational lifetime overall.
Don’t let poor filtration decisions cost you
By involving our experts at an early stage in filtration system design and specification, we can help you to select the right filtration system, and avoid issues associated with poor design. We can deliver tangible benefits at every stage of the filtration lifecycle, helping you to improve operational efficiencies and drive down costs.