Customer Application Brief
Oil and Gas
Chemical Loadout Filtration
Introduction
Chemical manufacturing plants can use several filtration stages to help protect equipment, optimize process efficiency, and
maintain product quality. Feedstock, additives, and solvents are routinely filtered at the point of process entry to help protect
downstream equipment. Mid-process filtration is typically used to optimize efficiency of the reactor, heat exchanger, or other
process equipment. Final product or loadout filtration is critical to maintaining the product quality specifications that the plant
must meet for its customers. This Application Brief focuses on the loadout filtration stage in chemical manufacturing.
The Process
While chemical processes are unique and varied, depending on the type of product being manufactured, most processes can be
broken down into a common pattern:
•
A feed is introduced to the process, and is often combined with additives, solvents, or catalysts to enable a desired reaction
downstream.
•
The mixture is transferred to a reactor, or a series of reactors, where the desired chemical reactions take place under pressure
and temperature.
•
The desired final product is drawn out of the process and sent to storage, while the byproducts of the reaction are either
recycled or sent to a waste stream.
•
The final product is transferred from storage to the distribution point – tanker, rail car, or pipeline. Transfer flow rates are
typically very high in order to move inventory from storage quickly.
Feed
Additive
Solvent
Final Filter
Loadout
Waste/Recycling
Figure 1 — Typical Chemical Manufacturing Process
The Problem
Contamination in the final product can create several problems:
•
Equipment Fouling – Rust and scale picked up in the storage tank or downstream piping can foul distribution
equipment, such as pumps, valves, nozzles, and meters, reducing or completely stopping loadout flow rates. A chemical
plant generates revenue through sale of its final product – the faster it can turn around final product from storage to
loadout, the more efficient its overall process. Reduced or no flow not only results in maintenance costs to clean or
replace process equipment, but also results in delayed revenues.
•
Off-Spec Product – Contamination can cause off-spec product, which can lead to product rejection and reprocessing. This
can lead to increased maintenance costs to clean or replace equipment. Importantly, it can also lead to lost revenues for
the off-spec product, lost revenues during any maintenance shutdown, and potentially lower future revenues if business is
lost. To reduce contamination problems, it is often necessary to recirculate the product several times through the final filters
(multi-pass filtration) until the required specifications are reached, which reduces overall plant productivity.
The Solution
To reduce the risk of off-spec product associated with contamination, 3M
Purification Inc. recommends the use of cartridge filtration in the loadout
section. Depending on the application, 1 – 10 µm is appropriate for most
chemical loadout processes.
The 3M™ High Flow series filter system is ideally suited to provide
effective filtration at the high flow rates typical in chemical loadout. The
3M High Flow series filter system utilizes large diameter (6.5” O.D.)
compound radial pleated cartridges in a compact housing design. High
efficiency polypropylene microfiber media is used in the 3M High Flow
series filter cartridges resulting in good chemical compatibility with a
wide variety of chemicals and consistent, predictable particle retention
efficiencies.
Compared to nominally rated 2.5” filter cartridges or bag filters, the 3M
High Flow series filter system offers the following advantages:
• Higher Particle Retention Efficiencies (99.9%) – providing for
consistent and reliable filtration of particulates that can cause offspec product.
2000 GPM System (7571 LPM)
3M High
Flow Series
Filter System
TM
Competitive
2 ” Depth
Cartridges
7 Cartridges
in a
24” Diamter Housing
120 Cartridges
in a
36” Diamter Housing
Figure 2 — 3M™ High Flow Series Filter
System vs. conventional 2.5” cartridge system
• High Flow Capability – the unique construction of the 3M High Flow series filters permits flow rates up to 500 gpm in a
single cartridge.
• Compact Housing Design – the high flow capability results in a smaller housing required for a given flow rate translating into
reduced up-front capital expenditure requirements and footprint.
• Ease of Use – with fewer required cartridges, filter change-outs are much easier. In addition, the 3M High Flow series filter
system incorporates a “twist-to-lock” cartridge seating mechanism, providing for a positive indication of proper sealing and
reducing the possibility of bypass.
Figure 2 shows the benefits of the 3M High Flow series filter system vs. a conventional 2.5” cartridge system for a 2000 gpm flow
requirement. For more information on the 3M High Flow series filter system, please request 3M Purifiation literature LITCHF1.
Conclusion
Effective filtration is important in the loadout stage of chemical manufacturing. Failure to reduce contaminants can lead to offspec product, and contribute to increased maintenance costs, lost revenues, and reduced productivity. Use of the High Flow system
is recommended to reduce these problems. The high efficiency media incorporated into the 3M High Flow series filter cartridges
results in consistent filtration levels and optimum protection of distribution equipment. The high flow capability, up to 500 gpm
per cartridge, translates into smaller filter housings, lower
capital expenditures, reduced time and labor costs for filter
Important Notice: The information described in this literature is accurate to the best of our knowledge. A variety
of factors, however, can affect the performance of the Product(s) in a particular application, some of which are
change-outs, and improved output productivity.
uniquely within your knowledge and control. INFORMATION IS SUPPLIED UPON THE CONDITION THAT THE
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NATURE WHATSOEVER RESULTING FROM THE USE OF OR RELIANCE UPON INFORMATION.
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particular purpose and suitable in your specific application.
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Tel (800) 243-6894
(203) 237-5541
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