Filtration and Separations

Technologies for Petroleum Refining

Understanding Root Causes...
Finding Solutions
 Pall helps refiners identify
problems and apply solutions
Refiners are constantly looking to increase
production capabilities, reduce costs, and
generate increased revenues and profits. To
accomplish this goal, refiners regularly search
for new ways to improve efficiency, while
continuing to deliver highquality products at
profitable prices. Pall can play a key role in
this continuous improvement process. Our
products and services help optimize productivity,
reliability, quality, safety, and environmental
protection, while reducing overall operating
costs.

Pall understands the importance of improving

these key business components. Success here
can directly impact a refiners bottom line.

The first step to continuous improvement is

to identify problem areas and understand the
root cause. After proper detection and
documentation, Pall works to develop a
solution to the problem that best utilizes our
advanced separations and filtration technology.

We put decades of experience and know-how

to work to design and implement long lasting
solutions that enable refiners to:
Meet tighter clean fuels product specifications
Meet tougher environmental regulations
Maintain or increase refinery throughput
Lengthen run time
Reduce maintenance

Pall Corporation maintains its position as the

world leader in filtration and separations
technology with a steady stream of innovative,
high-quality products backed by excellent
service and support. We invest heavily in
R&D and technical service to provide the
refining industry with exceptional returns on
their investment.

Our filtration and separations solutions have

been successfully deployed within refineries
throughout the world.

2
Total Fluid ManagementSM solve the problem. We are eager to Contents
take on new challenges and are
Pall follows a comprehensive, committed to keeping up with
Total Fluid Management approach to evolving market demands. Separation of
identifying and solving contamination Pall offers worldwide technology Solids from Liquids
problems. consultation and support through Pages 9-15
our Scientific and Laboratory
Our advanced technologies and Services (SLS) department. SLS is a Separation of
services help refiners: worldwide network of scientists and
engineers experienced in investigating Solids from Gases
Increase production
and solving various and often Pages 16-20
Reduce unscheduled downtime
Meet environmental emission complex problems encountered in
standards fluid clarification and separation Separation of Liquids
Reduce corrosion rates, lengthen processes. In addition, a specialized and Solids from Gases
plant life, and improve safety group of scientists and engineers is Pages 21-22
Raise product yield and conversion solely dedicated to customers in the
Minimize product reprocessing petroleum refining industry. Pall has
Enable capacity expansion with state-of-the-art laboratories located Separation of
minimum capital expense throughout the United States, Liquids from Liquids
Help to debottleneck existing Europe, and Asia. Pages 23-24
plants during revamps or clean
fuels upgrades All Pall manufacturing facilities
Help to utilize opportunity crudes adhere to uniform manufacturing
Enable refiners to meet tighter procedures and have been granted
product specifications International Standards Organization
Lower energy costs (ISO) certification to ISO 9001. This
Lower maintenance costs ensures that Pall filtration and
Protect catalyst beds separation products and systems
will perform exactly as specified,
Pall offers a full range of high-quality no matter where they are installed.
filtration and separations systems
that meet the unique requirements Root cause analysis and Total Fluid
of the diversified refineries that we Management are the principles on
serve. We design and manufacture which we base our success in the
nearly all of our media, elements, petroleum refining industry. We look
vessels, and fully integrated separations forward to applying our knowledge,
systems. By supplying the broadest technology, and experience to help
array of polymeric, inorganic, metallic, you achieve a higher level of
and ceramic media available, Pall is process control and efficiency in
able to select the optimal filter medium your operations.
to meet specific process requirements.

In rare cases, where Pall does not

have an appropriate product, we
work with the customer to develop a
new, customized product that can

SLS test facility.

3
 Filtration and Separation Liquid/Gas Coalescers1
Recommendations Application Problem Benefits
6 Hydrocarbon carryover into Minimized or eliminated
The process diagram and corresponding charts illustrate Amine and amine plant causes foaming, production losses due to sulfur
typical applications within a refinery. Processes are detailed Sulfur excessive amine losses, and plant trips; reduced environmental
within the drawing and include major applications. The Recovery Unit can lead to either reduced license level exceedance; stable
amine plant capacity or impact amine plant operations; and
numbered items coincide with the recommended the ability to meet final product increased amine plant capacity.
filter/separation application tables below. Note: should a sulfur specifications in fuels.
Amine plant upsets; sulfur
particular concern or filtration/separation application arise plant trips; and environmental
that is not addressed in this brochure, please contact emissions above license limits.
your local Pall representative for assistance. 7 Fuel gas composition changes Reduced or eliminated routine
Refinery rapidly and contains burner cleaning program;
Fuel Gas condensable hydrocarbons; improved furnace fine tuning;
liquids and solids will foul, plug reduced fuel gas usage;
burners and combusters; low reduced greenhouse gas
Particulate Filters/Backwash Filters1 NOx and ultra low NOx burners emissions; safer furnace
are especially sensitive to operation and on-spec NOx
Application Problem Benefits plugging. emissions.
1 Liquid hydrocarbon and Reduced solvent losses and foaming; 8 Liquid hydrocarbons and solid Reliable hydrogen compressor
Aromatics particulates cause foaming improved energy consumption; Hydrogen contaminants such as corrosion operation; significantly reduced
and fouling problems. reduced maintenance, labor, Compressor products or ammonium chloride maintenance and repair costs.
and disposal costs. Protection in hydrogen gas streams can
lead to premature failure of
Solid particulates plug and Improved conversion efficiency reciprocating compressor
2 deactivate catalyst bed and and profitability; fewer catalyst suction and discharge valves,
Catalyst foul feed exchanger; water can change-outs; improved and piston ring failure resulting
Protection deactivate some catalysts. conversion/yield; lower in H2 compressor downtime
maintenance, labor, and catalyst and excessive unscheduled
costs; longer cycle times; less maintenance and in some
backwash fluid reprocessing; cases can cause lost production.
extended campaign life.
Refinery final products contain Improved product quality; fewer
3 particulates and water. reprocessing and contamination
Final Product costs; lower maintenance and Liquid/Liquid Separators1
Filtration disposal costs. Application Problem Benefits
Catalyst fines reduce value of Improved product quality and 10
4 slurry oil. revenue; reduced critical nozzle Off-spec products; high salt or Improved product quality/on-spec
Fluid Catalytic erosion; increased yield; reduced Final clay tower usage; corrosion in products; fewer reprocessing and
Cracking Unit coke formation in FCC reactor; Product storage tanks. contamination costs; lower
Slurry Oil less backwash fluid to reprocess; Filtration maintenance and disposal costs;
higher profitability of FCCU. free up tank storage; improved
cash flow and fewer delayed
Amine foaming. Amine losses prevented; sulfur shipments.
5 plant operation improved.
11 Water may contain caustic and Improved conversion efficiency
Rich / Amine
Loop Catalyst other solid particulates; plug or and profitability; fewer catalyst
Protection deactivate catalyst bed. change-outs; lower maintenance,
labor, and catalyst costs.
12 Caustic or amine carries over Improved profitability; lower
Blowback Filters1 Treating into product stream causing reprocessing costs; reduced
Application Problem Benefits off-spec product; carried-over maintenance and labor costs.
caustic can disarm sensitive
9A Existing equipment is unable to Tougher environmental license catalyst.
Reduced meet tightening emission levels limits met continuously and FCC 13 Desalter upsets can cause oil Less emissions from water
Particulate required by environmental plant shutdown and/or capacity Desalter carryover to waste treatment treatment plant; allows debottle-
Environmental authorities for particulate and reduction averted; turbo expander plant and upset water treatment necking of desalter and reduced
Emissions micro-particle matter. Poor reliability improved dramatically. plant operation and emissions corrosion rates in CDU overhead;
reliability of turbo expander and to the environment; desalter improved FCC catalyst yield and
inability to meet desired FCC upsets or crude charge rate longer FCC catalyst life.
campaign length of 3-5 years increase can cause brine
between major repairs or carryover to CDU and result in
overhaul of turbo expander. high corrosion rates in crude
9B Poor reliability of CCR recycle Reliable CCR operation and overhead; salt in FCC feed can
CCR gas compressor; high production of H2 and reformate. reduce FCC catalyst yield and
Recycle Gas maintenance costs; loss of shorten catalyst life.
expensive reformer catalyst. 14 Liquid hydrocarbon ingress; More stable Amine system
1 Amine Unit foaming incidents; upsets at operation, reduced foaming,
In applications where different options are listed, Pall Corporation will
Protection sulfur plant. longer A/C life; less sulfur plant
assist project engineers in determining the best filtration solution for trips.
their situation.

4
 Refinery Filtration and Separation Applications
H2
8
HYDROGEN SULFUR
PRODUCTION RECOVERY

Gas
6
7
Acid Gas
LPG

8
Naphtha
MRU HYDROTREATING
2 11
Sour Gas
AMINE
Atmosphere Distillation

Fuel Gas 7 6 5 14
Crude Desalter 13
Oil Kerosene & Middle Distillates
Sour Gas
13 2 2 11
HYDROTREATING
11 H2 Sour Gas
Brine Fuel 11
8 Gas
ISOMERIZATION 7 2
7
2
Fuel Fuel Gas H2
Gas 8 9A 9B
11 Off
7 Gas
DEHYDROGENATION
Sour Gas Flue
Gas
9A
7 Fuel FLUID
Gas Oil Gas CATALYTIC
HYDROTREATING
CRACKING
2 11 13
Distillation
Vacuum

Fuel H2
Gas 7 Fuel Gas 8
7
To FCC 2 11
Coker Gas Oil
COKER

Fuel Gas
7 8

LUBE OIL PLANT

5
 Sulfur

Refinery Fuel 7
Gas
TAIL GAS Stack
TREATING 5

AMINE LPG
12
ISOMERIZATION
11 Gasoline 3 10
H2 AROMATICS
7 Fuel Gas 8 1 EXTRACTION Benzene, Toluene,
Xylene 3 10
CATALYTIC
REFORMING Gasoline
3 Solvents 3 10
Fuel Gas
7 9B

HYDROTREATING Jet Fuel

Benzene Kerosene 3 10
H2 Fuel Gas
8 Petrochemical 3 10
7 Feedstock
CAUSTIC Gasoline
TREATING Higher Olefins 3 10
12
MTBE Gasoline
2 3 10
2 11
12

MeOH 2
ALKYLATION Gasoline 3 10

Gasoline 3 10

Slurry Oil 4
H2
8
HYDROCRACKING Jet Fuel, Diesel 3 10

7 Fuel Gas
Coke

Lube Oil Basestock 3

6
 Understanding
Root Causes . . .
Then Applying
Filtration and
Separations
Technology

7
t

Open here to review filtration applications found in refineries.

 Products that Meet Refiners Needs
With an extensive portfolio of Palls advanced technologies include:
filtration and separation products,
Pall can help refineries improve fluid Separation of
quality and increase profitability by Solids from Liquids
optimizing the performance of their
processing equipment. Many of Palls
products were developed specifically
for the refinery industry, in Separation of
collaboration with our customers. Solids from Gases

Our close relationship with refiners

and process licensors has helped
Separation of Liquids
Pall understand current and future
needs. Our awareness and dedication and Solids from Gases
to this market has fueled our product
development programs and sharpened
our technical and scientific skills. As a Separation of
result, Pall is continually introducing Liquids from Liquids
new products to help improve the
production and efficiency of our
customers operations. Details of each technology can be
found in the sections that follow.

At the heart of every filtration and

separation system is the medium
which performs the separation. Pall
manufactures 21 distinct families of
media, providing over 150 grades of
polymeric, inorganic, metal, and
ceramic filter products and phase
separation systems. This allows Pall
to supply high-quality products with
the appropriate medium and grade
for specific refinery applications.

Palls filter media.

8
Separation of Solids from Liquids

Separation of Solids from Liquids

A variety of filtration methods can
be used for solid/liquid separations Backwash Filters Disposable Filters
due to the differing concentration of
solids in liquid streams. For high PSS sintered powder stainless Profile II depth filters
solids loading, a backwash system steel filters Ultipleat filters with Profile
may be the optimum filtration PMF metal fiber filters depth filter media
solution, while disposable filters Rigimesh sintered woven wire Marksman pleated filters
would be used for lower solids mesh filters Nexis melt blown filters
loading applications. In some cases, AccuSep sintered stainless Claris melt blown filters
removal of solids may require a steel filters Duo-Fine pleated filters with
combination of backwash technology microfiberglass media
followed by a disposable filter for Hi-V resin bonded filters
polishing. Regardless of the amount Pleated filters with Epocel
of solids present in the liquid, Pall medium, Ultipor GF Plus
can provide a product or combination medium, HDC II medium
of products to achieve optimum Profile Coreless melt blown
performance and economy. filters
Ultipor HT filters
Pall originally developed backwash High Flow filters
technology in the 1960s in response to
the needs of hydrogenated chemical
producers. This technology was
introduced to refiners and started to
gain acceptance in the late 1980s
when refiners needed to upgrade the
value of slurry oil in Fluid Catalytic
Cracking (FCC) units by removing
catalyst fines.

Today Palls advanced backwash

technology is used in other refining
processes for the purpose of extending
the life of fixed bed catalyst reactors
and improving conversion in
hydrotreaters and hydrocrackers.
Palls backwash systems offer
significant benefits over conventional
wedgewire systems that can be used
to protect fixed bed catalyst reactors.

Palls backwash systems have extremely low operating and maintenance costs compared
to other technologies such as electrostatic separators and hydrocyclones.

9
 Backwash Systems Rigimesh Medium vs. Wedgewire
Benefits of Palls
A backwash system is designed to Backwash Systems
remove and/or collect suspended
solids from a liquid process stream Longer run times between fixed
while periodically regenerating itself. bed catalyst change-out
A porous filter medium with suitable Higher throughputs
pore size will efficiently collect solids Lower differential pressure
on its surface, where they form a Longer cycle time between
permeable cake. During backwash, backwash regeneration
a reverse flow will be initiated at a Lower utility costs
predetermined filter pressure drop Significantly reduced backwash
Rigimesh medium approximate void
and/or time interval, discharging the fluid reprocessing cost (up to volume = 30%.
collected solids to recovery. The filter seven times less backwash fluid
will then be returned to full forward to reprocess)
flow. Its pressure drop just after Payback in less than one year
backwash will remain essentially Extremely low cost of operation
constant through backwash cycles. vs. wedgewire systems

The efficient operation of Pall backwash

systems require high standards in vessel
design, tubesheet assembly, piping,
instrumentation, and valve selection. At
the heart of the system is Palls filtration
media. With a variety of porous filter Typical wedgewire element approximate void
volume = 4%.
media available, both metallic and
nonmetallic, and backwash techniques,
Palls backwash systems are designed Backwash Systems vs. Other Technologies
and optimized for specific refinery Pall Backwash Electrostatic Wedgewire Hydrocyclones Sand Beds
applications. System Separator
Efficiency High Medium and Low Medium Low
For example, many hydrotreaters use Variable
backwash filters to remove solids
Solids-Loading High Medium Low High High
from the feed and protect the feed Capability
exchanger and catalyst bed. In the
Operating and Very Low High Very High Low Low
past, wedgewire media was used for Maintenance Cost
this purpose. However, this media only
Backwash Fluid <2% >10% 2-20% 6% 1-2%
provides about three to five percent Requirement vs.
void volume in this application. Throughput
Replacing the wedgewire elements Sensitivity to None Very High None None None
in the filter vessel with Pall Rigimesh Flow Rate Change
elements provides approximately Temperature Range High Low High Medium High
seven times higher void volume and
Reliability and Safety High Medium Low Medium Medium
twice the filter area. An upgrade of Operations
should be based on a need for finer
filtration and higher throughputs prior
to backwash cycles. Retrofits and
new, scaleable systems are available.

10
 Separation of Solids from Liquids
Refineries receive a high return on investment after installing Palls backwash filters to protect catalyst beds and to remove catalyst fines from FCC
slurry oil.

Gas Assist Backwash Method Gas Assist Backwash System

The gas assist backwash method is Benefits of Palls Gas Assist
used when process flow rates are Backwash Systems Backwash
Gas In
high or continuous, and uninterrupted
flow is required. For backwash, one Longer catalyst life Process
Reduced incidence of Out
vessel is isolated and the downstream
side of the vessel is pressurized with off-spec product
a controlled quantity of filtered air Low reprocessing and/or
or other suitable gas. The vessel disposal costs due to low
volume of backwash fluid Process
drain port is rapidly opened, resulting In
in a hydraulic pulse that bumps the Low maintenance cost for
collected solids from the filter surface. valves and control equipment Solids Recovery

Forward flow is restored to the vessel Infrequent out-of-vessel One or more vessels
and the remaining filter vessels are element cleaning
Isolate one vessel for backwash
backwashed sequentially.
A compressed volume of gas
During gas assist backwash, the provides a high-velocity reverse
Combining the gas assist backwash flow of liquid remaining in vessel
expanding gas bubble forces the
with the high dirt-holding capacity of
liquid through the elements in the
Palls backwash media results in long
reverse direction (inside-out) at a
cycle times between backwashing
velocity as high as seven times the
and reduced reprocessing costs which
normal forward flow velocity. This
substantially improve unit economics
effectively dislodges the accumulated
over the life cycle of the equipment.
cake from the elements, while
significantly reducing the volume of
liquid required. Thus, the concentration
of the solids discharge is high.

11
 Metallic Backwash Filters

PSS Porous Metal Filters PMF Metal Fiber Filters Rigimesh Stainless Steel
Manufactured of sintered stainless PMF filters are manufactured of fine Woven Wire Mesh Filters
steel powder, the PSS S medium diameter 316L stainless steel fibers Palls proprietary process permits the
offers exceptionally uniform that are sintered at their points of use of finer-diameter wires in the
permeability and absolute removal contact to produce a uniform, manufacturing of Rigimesh stainless
efficiencies. strong, tapered-pore medium. This steel woven wire mesh filters. The
medium provides remarkably high result is low pressure drops, more
PSS elements are seamless in
dirt-holding capacity, with one or pores per unit area, and better dirt-
construction with a very high void
more inner layers providing holding capacity than other woven
volume (up to 60% in some grades).
absolute-rated filtration. metal filters.
This provides very high dirt-holding
capacity and low pressure loss, The medium is sintered for improved
especially in very fine grades, which tensile, yield, shear, and fatigue
permit design at high flux to help strength. Rigimesh filters maintain
reduce capital costs. a uniform pore size and exhibit no
In addition to the standard product media migration, even under high
made from 316L stainless steel, we temperature and pressure conditions.
supply PSS medium in Inconel 2,
nickel, nickel molybdenum, and
aluminide alloys.

2 Inconel is a registered trademark of Special

Metals Corporation.
AccuSep Sintered Metal
Filters
AccuSep sintered metal filters are
made of sintered stainless steel, in
a seamless tubular format. AccuSep
elements are produced by a
proprietary process which creates a
high void volume in a strong and
very uniform medium. The medium
is relatively thin, resulting in a
structure that is up to three times
more permeable than most
conventional pressed sintered
metal tubes.

12
Liquid Disposable

Separation of Solids from Liquids

Filters Performance Comparison -
Profile II Filters vs. Competitive Depth Filters
When the solids concentration is
relatively low (10 ppm), Palls Filter Brand
disposable filters will efficiently and
Particle Size Profile II Filter W1 W2
economically remove solids from (m) (P200) Wound Filter Spun Depth Filter
liquid streams. Disposable filters can 20 m Absolute 1 m Nominal 1 m Nominal
be used to remove solids from 20 = 5000 1 = 1 1
finished refinery products and from
Percent Removal Efficiency
solvents such as amine and sulfolane.
0.5 NA NA NA
Palls disposable filters are 1 NA NA NA
characterized by high dirt-holding
capacity and lot-to-lot uniformity. 2 <50% <50% <50%
Our filters provide long service life 4 75% 75% 50%
and improved protection for
equipment and personnel. They are 10 95% 95% 87.5%
designed to prevent both unloading 25 >99.98% 96.7% 93.3%
of trapped particles and media
50 >99.98% 98% 96%
migration. The filters are self-aligning
in Palls vessels, with positive sealing
to eliminate fluid bypass.
Filtration Beta Ratio Comparison -
Profile II Filters vs. Competitive Depth Filters
Benefits of Palls 10000 P200 99.99
Disposible Filters 5000 99.98
2000
Gradient of pore sizes for full 1000 99.9
utilization of the filter 500
Strength and durability to
Filtration Ratio Beta

200
withstand changing process

Efficiency %
100
conditions 99
50
Chemical and thermal W1
20
compatibility with process
10 W2
conditions to ensure long life
5
Absolute-rated3 for reliable,
2
reproducible performance
1 50
backed by documented
performance data 5 10 15 20 25 30
Cost-effective, nominally-rated Particle Size (m)
filters are available for less Filtration beta ratio of Profile II filters (P200) and two competitive polypropylene depth filters
critical applications rated at 1 m nominal.

3 An absolute rating is defined as Bx=5000

as measured utilizing the widely accepted
modified OSU F-2 test.

13
 Liquid Disposable Filters

Profile II Filters Ultipor GF Plus Filters Epocel Filters

Profile II filters are available in The Ultipor GF Plus medium consists Epocel filters have a pleated, high-area
polypropylene, nylon or polyphenylene of resin-bonded glass fibers supported construction which provides long service
sulphide (PPS) media. These elements by upstream and downstream polymeric life and consistent production. Constructed
have an upstream continuously graded substrates. This unique construction of epoxy-resin-impregnated cellulose,
pore section and a downstream provides for a strongly bonded, migration- this fixed-pore construction eliminates
absolute-rated section, which increases free, high dirt-holding capacity medium. unloading and media migration. Epocel
service life many times. Ultipor GF Plus filters are used successfully filters provide a broad range of chemical
in a variety of refinery applications. compatibility and are recommended for
These filters are suitable for a wide
the clarification of a wide range of fluids
range of applications, involving both
and gases.
corrosive and non-corrosive fluids.
Profile II filters are ideal for prefiltration
and final filtration.

Claris Filters
Claris filters are polypropylene melt
blown filters. Claris filters feature an
E-core, Extruded Fibrous Core, structure
which provides excellent strength. Their
gradient pore structure enhances their Hi-V Filters
dirt-holding capacity. Claris filters feature Hi-V filters are resin-bonded disposable
an all polypropylene construction for easy filters designed for highly viscous fluids.
Profile Coreless Filters and safe filter incineration and disposal. Hi-V filters use wound resin impregnated
Profile Coreless filters are absolute-rated fibers that are four to six inches in length,
filters used to filter gases or liquids. They much longer than typical molded filters
have high capacity, low cost, and are which use fibers of less than one-eighth
ideal for applications such as amine inch.
loop filtration, compressor protection, Hi-V filters feature high flow rates, high
or final product filtration. The coreless contaminant-holding capacity, no center
construction allows for easy and safe cores, and reliable, consistent filtration.
filter incineration and disposal.

HDC II Filters
HDC II filters are constructed of all
polypropylene pleated media. These filters
feature a high area, high dirt-holding
capacity, and extended service life. HDC
II filters are ideal for use in applications
where economy and reliability are
crucial.

14
 Separation of Solids from Liquids
Nexis Filters
Nexis high-efficiency depth filters are
manufactured using an advanced,
Duo-Fine Filters microprocessor-controlled, Co-located Marksman Filters
Duo-Fine filters are high-capacity pleated Large Diameter (CoLD Melt) production
Marksman filters are available as
filters with microfiberglass media. The process. This proprietary process allows
high-capacity, pleated, depth filters or
microfiberglass media provides exceptional the creation of multiple filtration zones
high-capacity melt blown filters. These
dirt-holding capacity for long service life. within a single filter cartridge. The benefits
filters feature a large 152.4 mm (6 inch)
include: efficient contaminant removal,
Duo-Fine filters are available in a variety diameter, high surface area, and high
long service life, and improved strength.
of core options to satisfy a wide-range flow capacity. Marksman filters are
of temperature compatibilities. available in a variety of grades and sizes
to meet specific application requirements.

Ultipor HT Filters Ultipleat High Flow Filters Profile UP Filters

Ultipor HT filters are pleated, high area Ultipleat High Flow filters are coreless, The unique Ultipleat (U) crescent-shaped
elements designed for long service life. large diameter, single open-ended, pleated construction of the Profile (P) depth filter
The unique medium structure is a filters with an inside-to-outside flow pattern. provides longer life than most pleated
high temperature composite. The filters These filters utilize Palls proprietary, polypropylene filters. Optimized for the
are qualified for use up to 218C/425F crescent-shaped pleats and are available removal of gels and other viscous fluids,
with compatible fluids. in a range of materials. The Ultipleat the Profile UP depth filter provides
Designed specifically for high temperature High Flow filters come in diameters of excellent chemical compatibility with
applications and well suited for many 152.4 mm (6 in) and lengths from 508- low extractables. These filters are the
refinery applications, these high 2023 mm (20-80 in). Ultipleat High Flow appropriate choice for a wide range of
temperature filters are used to process technology enables the use of considerably applications in the refining industry.
tough oil fractions, containing fine fewer filters and smaller housings for
suspended solids typically found in high flow rate applications.
processes related to desulfurization and
fuels upgrading. Filter operability at
high temperatures can often mean
elimination of intermediate tanks for
product cooling and save energy on
product reheating costs upstream of the
hydroprocessing units.

15
 Separation of Solids from Gases
Pall continually develops state-of-the-
art technology for solid/gas separation Blowback Filters
to deal with aggressive environments,
PSS sintered powder
extreme temperatures, and high
stainless steel filters
contaminant concentrations. Pall has
PMF metal fiber filters
worked with both refiners and process
Rigimesh sintered woven wire
licensors to develop blowback
mesh filters
systems that efficiently separate
solid particulates from gas streams.
Gas Particle
Disposable Filters
A filter medium with sufficiently
small pores is selected for this Pall pleated filters with Ultipor
application. Solids form a permeable GF Plus medium, HDC II
cake on the filters surface that is medium, or Epocel medium
dislodged at a predetermined pressure Ultipleat filters with Profile
drop (a function of cake thickness depth filter media
and compressibility) by initiating a Profile II filters
reverse pulse (blowback). The Profile coreless filters
dislodged solids are purged from
the filter system, where they may be Palls blowback filter system in operation.
returned directly to the process for
reuse, or removed from the process Blowback Systems vs. Other Technologies
stream and sent to a storage or
Pall Blowback Cyclone Baghouse Scrubber Electrostatic
collection unit. The filter is then Filters Precipitator
returned to full forward flow and to
Efficiency of Solid Separation >99.99% 98% 99.9% 99% 99%
an initial pressure drop that remains from Gas Stream
essentially constant through repeated
Separation Efficiency Varies No Yes No Yes Yes
blowback cycles.
with Solids Loading
Relative Operating Medium Medium Medium High Low
Palls blowback systems use either
Pressure Drop
porous metal composite or ceramic
filters. The comprehensive capabilities Maximum Operating 899C 1093C 232C 232C 482C
Temperature (1650F) (>2000F) (450F) (450F) (900F)
of Palls blowback systems are high-
lighted in the chart to the right. Sensitivity to Changes Insensitive Very Some Very Very
in Flow Rate Sensitive Sensitivity Sensitive Sensitive
Precooling Required Upstream of No No Yes Yes Yes
Solid Separation Device
Solids-Loading Reduction Prior No No Yes Yes Yes
to Final Separation Required
Reliability and Safety of High High Low Medium Medium
Operation

16
Blowback Filters

PSS Porous Metal Filters PMF Metal Fiber Filters Rigimesh Stainless Steel
Manufactured of sintered stainless PMF filters are manufactured of fine Woven Wire Mesh Filters
steel powder, the PSS S medium diameter 316L stainless steel fibers Palls proprietary process permits the
offers exceptionally uniform that are sintered at their points of use of finer-diameter wires in the
permeability and absolute removal contact to produce a uniform, manufacturing of Rigimesh stainless
efficiencies. strong, tapered-pore medium. This steel woven wire mesh filters. The

Separation of Solids from Gases

medium provides exceptionally high result is low pressure drops, more
PSS elements are seamless in
dirt-holding capacity, with one or pores per unit area, and high
construction with a high void volume
more inner layers providing dirt-holding capacity.
(up to 60% in some grades). This
absolute-rated filtration.
provides high dirt-holding capacity The medium is sintered for improved
and low pressure loss, especially in tensile, yield, shear, and fatigue
fine grades, which permit design at strength. Rigimesh filters maintain a
high flux to help reduce capital costs. uniform pore size and exhibit no
In addition to the standard product media migration, even under high
made from 316L stainless steel, we temperature and pressure conditions.
supply PSS medium in Inconel,
nickel, nickel molybdenum, and
aluminide alloys.

Dynalloy Stainless Steel

Filters
Dynalloy filters are made of
depth-type, stainless steel fiber
media manufactured under strict
ISO 9001 quality control measures.
Fabrication begins with the
Dia-Schumalith Ceramic manufacturing of discrete micron
Filters size fibers. A uniform mat of these
fibers is constructed in a randomly
Dia-Schumalith ceramic filters are
laid orientation. The mat is compacted
better suited for applications
and sintered (metallurgically bonded)
requiring higher temperatures and
to provide strength and integrity.
greater corrosion resistance than
The result is a high void volume,
most sintered metal alloy filters.
closely controlled pore size media
The silicon carbide support body
ideal for corrosion-resistant
and alumina membrane of the
applications.
Dia-Schumalith filter ensures a low
differential pressure at high flux rates.
17
 Gas Particle Disposable Filters

HDC II Filters Epocel Filters Ultipor GF Plus Filters

HDC II filters are constructed of all Epocel filters have a pleated, high- The Ultipor GF Plus medium consists
polypropylene pleated media. These area construction which provides of resin-bonded glass fibers supported
filters feature a high area, high long service life and consistent by upstream and downstream
dirt-holding capacity, and extended production. Constructed of epoxy- polymeric substrates. This unique
service life. HDC II filters are ideal resin-impregnated cellulose, this construction provides for a strongly
for use in applications where fixed-pore construction eliminates bonded, migration-free, high dirt-
economy and reliability are crucial. unloading and media migration. holding capacity medium. Ultipor
Epocel filters provide a broad range GF Plus filters are used successfully
of chemical compatibility and are in a variety of refinery applications.
recommended for the clarification of
a wide range of fluids and gases.

Profile II Filters Profile Coreless Filters Ultipor HT Filters

Profile II filters are available in Profile Coreless filters are absolute- Ultipor HT filters are pleated, high
polypropylene, nylon or rated filters used to filter gases or area elements designed for long
polyphenylene sulphide (PPS) liquids. They have high capacity, low service life. The unique medium
media. These elements have an cost, and are ideal for applications structure is a high temperature
upstream continuously graded pore such as amine loop filtration, composite. The filters are qualified
section and a downstream absolute- compressor protection, or final for use up to 218C/425F with
rated section, which increases service product filtration. The coreless compatible fluids.
life many times. construction allows for easy and
safe filter incineration and disposal.
These filters are suitable for a wide
range of applications, involving
both corrosive and non-corrosive
fluids. Profile II filters are ideal for
prefiltration and final filtration.

18
Jet Pulse Blowback Method Palls Blowback System
The jet pulse blowback method
eliminates the need for large vessel Process Out
isolation valves. Full forward flow is
maintained at all times. Groups
Blowback Gas
of elements are blown back
sequentially by directing a high-
pressure pulse of gas into the throat
of each element. The pulses last
between 0.1 and 1.0 seconds, at two
to three times the process pressure. Process In
During this period, the flow to the
elements being cleaned is reversed
momentarily by a high-pressure jet Solids Recovery
pulse. The shock wave set up by
the reverse pulse, enhanced by the One or more vessels

Separation of Solids from Gases

venturi in the element throat,
Full forward flow maintained
effectively removes the accumulated
cake from the elements. Groups of elements blowback
sequentially
Forward flow overcome by high-
pressure pulse in reverse flow.
Short duration (0.1 to 1.0 seconds)

Palls blowback filters are used to remove catalyst fines from vent gas.

19
 Palls blowback systems are used with an even more
in many applications. A few of the corrosive and hotter
more common ones are listed environment than FCC,
below. Palls PSS porous stainless
steel filters or Dia-
Catalytic Reforming Schumalith ceramic
Palls blowback systems are used filters have proven to
in catalytic reforming units where be efficient and reliable.
catalyst is continuously regenerated Unlike cyclones, the
to protect against erosive wear and removal efficiency of
fouling of the recycle gas compressor. Pall blowback filters
These systems filter the elutriation remains constant during
gas that is recycled back to the variations in gas flow rate.
regenerator. For this application,
Palls PSS porous stainless steel B) If turbo expanders
filters (rated one micron in gaseous are not used PSS
service) with jet pulse (blowback) clean-in-place blowback
in-situ cleaning are used. PSS filters filters are recommended
have been installed successfully at to consistently meet
refineries throughout the world. emission guidelines.

Catalytic Cracking The removal efficiency

Blowback systems used to remove of PSS filters remains
catalyst fines from FCC flue gas constant during flow
allow the refiner to: surges (upset conditions)
Meet emission guidelines and is not affected by
Fully protect downstream process changes in the electrostatic Filter tubesheet assembly installation
equipment. charge of the particulate
matter, as is the case with Dehydrogenation Processes
The current permissible particulate electrostatic precpitators. PSS porous stainless steel filters
emission for a fluidized-bed catalytic process the catalyst regenerator
cracker (FCC) globally is <50 mg/Nm3. C) If third- and fourth-stage off-gas at dehydrogenation plants
This mark is moving to <40 mg/Nm3 cyclones are in place, replacing the operating fluid bed reactors. Palls
for the world, and in some cases as fourth-stage with PSS filters will blowback system reduces
low as 10 mg/Nm3 for given countries. improve solids capture, which may particulate emissions in a single
be sufficient to meet emission step, to levels at or below regulatory
Depending upon the economics at guidelines with minimum capital guidelines. Older plants had used
a specific refinery, there are several investment. two stages of cyclones followed by
blowback options: flue gas scrubbers to reduce such
The use of fourth-stage blowback particulate emissions.
A) Where turbo expanders are filters has proven to be the most
in service a hot gas filter is cost-effective way to meet <50 mg/Nm3
recommended upstream of the emissions in FCC flue gas applications.
expander to maintain maximum
power recovery and extend turbine D) FCC hopper vent filters can be
blade life. used to reduce fugitive emissions
during catalyst loading/unloading
In hot gas applications (up to and transfer.
850C/1560F) as related to coal
gasifiers and fluid bed coal combustors

20
Separation of Liquids and Solids
from Gases
Palls SepraSol liquid/gas (L/G) coa-
lescers have been used in refineries Liquid/Gas Coalescers
and gas processing plants for more
than thirty years. Palls liquid/gas SepraSol liquid/gas coalescers
coalescers provide maximum liquid SepraSol Plus liquid/gas coalescers
and solid removal at low saturated SepraSol Double Open-ended
pressure drops to reduce mainte- liquid/gas coalescers
nance and operating costs associat-
ed with contaminated gas. The
elements highly effective filtration
area and glass fiber resin-bonded
pleated cartridge construction is
surrounded by non-woven polymeric
support and drainage layers. The
coalescer is rated at 0.3 m (99.99%
removal efficiency) for solid particles,
and produces downstream liquid
aerosol concentration as low as
0.003 ppmw. These specifications
ensure long service life, minimized

Separation of Liquids and Solids

operating costs and minimal labor
requirements, as well as greatly
improved equipment reliability.

from Gases
Palls liquid/gas coalescers merge,
or coalesce, small droplets of liquid
into larger drops. A gas is forced to Palls liquid/gas coalescers remove liquids and solids from hydrogen and fuel gas, protecting
flow through several layers of filter turbo machinery and combustion equipment.
media, each layer having a
progressively larger mean pore Liquid/Gas Coalescers vs. Other Technologies
opening. As droplets compete for
the open pores, they coalesce, and SepraSol High Mist Vane Cyclonic Knock-out
Efficiency L/G Eliminator Separator Separator Drum
the process continues until the Coalescer
larger drops continually collect
and drain into a collecting sump. Smallest Liquid <0.1 5 10 10 300
Droplet Efficiently
Removed (Micron)
Palls liquid/gas coalescers remove
Relative Operating Low Medium Medium Medium Low
virtually all liquids in gas streams Pressure Drop
(down to 0.003 ppmw liquid in
Sensitivity to Low High Medium Medium Medium
the effluent gas). In addition, Palls Increased Liquid Loading
liquid/gas coalescers have a proprietary
Sensitivity to Medium High Medium Medium Medium
oleophobic/hydrophobic treatment Increased Flow Rate
that ensures efficient removal and
Sensitivity to Low High High High Low
quick recovery from process upsets
Turn-Down
that send slugs of
liquid downstream.

21
 Palls liquid/gas coalescers are used coalescers are recommended to can reduce the costs associated
in many applications. A few of the protect mol sieves / PSAs on with foaming such as reduced
more common ones are listed below. isomerization units, polypropylene processing capacity and increased
units or in hydrogen plants for amine losses. Liquid/gas coalescers
Hydrogen Recycle Gas hydrogen purification. can also recover any amine that is
Compressor Protection carried over into the acid gas going
Palls liquid/gas coalescers are Gas Treating Processes / Sulfur to the sulfur plant or the sweet gas.
installed in front of hydrogen Recovery By reducing upsets in the amine
compressors to prevent costly In amine treating units, foaming can plant, the sulfur plant can be
unscheduled downtime. Refiners be initiated by liquid hydrocarbon protected from upsets and the
have been able to extend regular contaminants in the feed gas. number of trips or incidences of
maintenance schedules by installing Installation of a liquid/gas coalescer off-spec sulfur can be reduced
liquid/gas coalescers upstream of upstream of the amine contactor along with a reduction in
the compressors. Because refinery environmental emissions.
hydrogen streams are particularly
prone to changes in purity and liquid
concentration, Palls oleophobic/
hydrophobic treatment is extremely
beneficial in this application.

Burner Protection
Liquid and solid contamination in
fuel gas streams is a universal problem
for refineries. By removing such
contaminants, liquid/gas coalescers
significantly reduce the maintenance Liquid / Gas Coalescers for Optimum Performance
associated with plugged burner tips
Palls liquid/gas coalescers perform with maximum removal efficiency and
in process furnaces. Low NOx and
economy that reduces equipment downtime, labor and maintenance costs.
Ultra Low NOx burners are even
Palls unique filter medium provides single-stage coalescing, separating
more susceptible to plugging. Because
liquid aerosols smaller than 0.1 micron in size. Palls proprietary coalescer
the concentration of liquids in fuel
treatment improves the drainage of liquids through the coalescer, enabling
gas can change instantaneously, Palls
the use of smaller assemblies and minimizing up-front capital costs. The
oleophobic/hydrophobic treatment
treatment also lowers operating costs by operating at a lower liquid saturated
again is particularly beneficial.
pressure drop and by recovering quickly from process upsets.
Lube Oil Recovery
Most compressors have an oil Effect of Chemical Treatment
lubricating system. Lube oil is often on Coalescer Performance Coalescing Mechanism
discharged into the process gas in
Treated Element
Downstream Oil Concentration (ppmw)

aerosol form. A liquid/gas coalescer Untreated Element

COALESCING

placed at the discharge of a compressor 5.00

will recover the lube oil and prevent Liquid

Drops
contamination of downstream catalyst, 0.020 Droplets
Liquid

Droplets Fall
desiccant, and activated carbon beds. in Gas
in Air
Due to
0.010 Flow
Flow
Gravity
Drops Fall

Due to

Molecular Sieve / PSA Protection 0.000

Gravity

Most mol sieves or PSAs used for

0% 25% 50% 75% 100%
drying process streams are sensitive Small Liquid Droplets Coalesce to Form Large Drops

Percent Maximum Flow Rate

to free water which increases
regeneration frequency and reduces
Chemically treating the medium can Small droplets coalesce to form large
the life of adsorbents. SepraSol L/G significantly increase the flow per cartridge. droplets.

22
Separation of Liquids from Liquids
When refinery customers alerted Pall Palls liquid/liquid coalescers
to recurring problems with hazy fuel do not disarm in the presence Liquid/Liquid Coalescers
and caustic carryover, Pall worked of surface active agents in the
with them to provide a long-term fuel. AquaSep Plus liquid/liquid coalescers
solution. As a result, Pall developed PhaseSep liquid/liquid coalescers
two new products the AquaSep Small flow liquid/liquid coalescers
liquid/liquid coalescer and the Lucid liquid/liquid separators
PhaseSep liquid/liquid coalescer.
Pall consulted with its customers
during every step of the product
development cycle to ensure that the
new products would meet their needs.

Today, AquaSep Plus coalescers and

PhaseSep coalescers are installed in
refineries throughout the world and
are used in a variety of applications
including:

Removal of water from gasoline,

diesel, kerosene, and jet fuel
Protection of catalysts and adsorbents
from water contamination
Removal of carried-over caustic
from caustic treating processes
Removal of carried-over amine
from LPG
Removal of H/C from amine
Protection of salt driers and clay
towers

Palls AquaSep Plus coalescer and

PhaseSep coalescer are multiple-stage
systems. These systems first remove
particulate matter, then coalesce and
separate the water or liquid
contaminant from a hydrocarbon
stream. An AquaSep Plus coalescer
Separation of Liquids from Liquids

or PhaseSep coalescer can remove

entrained water to a level at or
below 15 ppmv.

Palls PhaseSep liquid/liquid coalescer

has been demonstrated to reduce
the sodium concentration downstream Palls AquaSep Plus and PhaseSep coalescers are the most cost-effective technology for liquid/liquid
of a caustic treating unit to below separation compared to other methods, including tank settling, electrostatic precipitation, salt
0.5 ppmw of sodium. In addition, drying, sand filtration, and coalescing by mesh pads.

23
 Unique Stack Design
Palls AquaSep Plus coalescers and
PhaseSep coalescers are stacked on
top of a separator element. This
proprietary stacking method optimizes
the flow distribution from the
coalescer to the separator, ensuring
that each separator has equal flow.
In conventional two-stage systems,
the separators are located at different
distances from the coalescer, causing
unequal distribution of flow to the AquaSep Plus Liquid/Liquid Coalescers and
separator. Also, conventional two- PhaseSep Liquid/Liquid Coalescers
stage systems require several coalescer
elements for each separator. Palls AquaSep Plus liquid/liquid coalescers and PhaseSep liquid/liquid coalescers
stack design results in an overall were developed to efficiently separate very stable liquid/liquid dispersions
smaller assembly size and a longer and provide high-fluid quality and value. They are compatible with highly
coalescer/separator life. acidic and basic fluids. The high-performance stack design allows an even
flow distribution which permits a high flow rate in a smaller assembly. Also,
the long life of the cartridge results in fewer change-outs, which reduces
Low Interfacial Tension (IFT) maintenance and disposal costs.
The ability to remove water
improves as the IFT between the AquaSep Plus and PhaseSep Liquid/Liquid Coalescer
two phases increases. The IFT
effectively measures the stability of
an emulsion or dispersion. The IFT
AquaSep Plus/
is a critical factor when considering Prefilter PhaseSep
liquid/liquid coalescence because Coalescer
the largest possible stable droplet
size that will form by the coalescence Separator
process will be dictated by IFT. A
system with a high IFT (> 20 dyne/cm) Outlet
can sustain a large stable coalesced
Inlet
droplet size. Systems with low IFT
Drain
(i.e., water in fuels with additives
< 20 dyne/cm) form smaller stable
coalesced droplets and require a AquaSep Plus/PhaseSep liquid/liquid separation system with
coalescer/separator stack in a vertical housing.
high-efficiency coalescer/separator.
Liquid/Liquid Coalescers vs. Other Technologies
Disarming Pall AquaSep Salt and Conventional Pack Bed Electrostatic Tank
Surfactants in fuels have a tendency Plus/PhaseSep Desiccant Coalescers Tower Precipitator Settling
to form fuel/water hazes and can System Tower
degrade the performance or disarm Lowest Interfacial AquaSep Plus: <2 dyne/cm >20 dyne/cm >20 dyne/cm >10 dyne/cm >20 dyne/cm
conventional glass fiber coalescers. Tension Efficiency 3 dyne/cm
Separated PhaseSep:
Palls liquid/liquid coalescers do not <2 dyne/cm
contain glass fiber, instead they are Relative Operating and Low High Medium Low High Low
constructed of polymeric material using Maintenance Costs
a unique proprietary process. This results Effect of Additional Low High Low Low High Low
Dispersed Liquid on
in a long, reliable, low-maintenance Operating Costs
service life when compared to Effect of Surface Active None None Reduced Reduced Reduced Reduced
conventional liquid/liquid coalescers. Chemical on Efficiency Efficiency Efficiency Efficiency Efficiency
Palls liquid/liquid coalescers are Effect of Additional Low Medium Low High Medium Medium
immune to disarming caused by Dispersed Liquid on
Efficiency
surface active components like
Sensitivity to Low Medium Medium Low High Low
naphthenate or sulfonate carryover, Temperature Changes
or the addition of corrosion inhibitors, Relative Maintenance Low High Medium Low High Low
dispersants, and static dissipators.
24
About Pall Corporation
For more than 60 years, Pall Pall continues to develop new
Corporation has been solving products and systems to further
complex contamination problems its cutting-edge phase separation
for diverse customers around the technology. Palls core competency
world. With revenues of more than in coalescing technology has helped
$2.7 billion, Pall is the largest and reduce operating and maintenance
most diverse filtration, separations, costs at refineries.
and purifications company in the
world. Our products and services We invite you to learn more about
allow customers to meet regulatory our technology, products, and
requirements and increase output services. For more information
while reducing total cost of ownership. contact your Pall representative
Our enabling technologies help or visit us on the web at:
make customers products better, www.pall.com.
safer and even possible.

Environmental protection
Pall is dedicated to helping customers minimize their
carbon footprint, maximize recycling and waste reduction,
and ensure the most efficient utilization of natural
resources and raw materials. We are applying the same
know-how and dedication to our own operations.

We team with customers in ways specific to their industries,

providing them with technologically advanced products and
engineered process solutions that improve and strengthen
their businesses while reducing their environmental
impacts. Customers worldwide look to us to help them purify and conserve
water, consume less energy, and minimize emissions and waste. Pall is
committed to ENABLING A GREENER FUTURESM. To find out more about
our green initiatives, visit us on the web at www.pall.com/green.

25
Fuels and Chemicals Visit us on the Web at www.pall.com
Pall Corporation has offices and plants throughout the world. For Pall representatives in your
25 Harbor Park Drive area, please go to www.pall.com/contact
Port Washington, NY 11050
+1 516 484 3600 telephone Because of technological developments related to the products, systems, and/or services
described herein, the data and procedures are subject to change without notice. Please
+1 888 873 7255 toll free US consult your Pall representative or visit www.pall.com to verify that this information remains
valid. Products in this document may be covered by one or more of the following patent
Portsmouth UK numbers: EP 0 930 926; US 5,443,724; US 6,332,987; EP 1 165 205; US 6,342,283;
+44 (0)23 9230 3303 telephone US 6,662,842; US 7,473,360; EP 0 830 191; US 5,591,335; US 5,653,833; US 5,681,469;
US 5,690,782; US 5,730,820; US 5,733,581; US 5,741,395; US 5,783,011; EP 0 930 926;
+44 (0)23 9230 2507 fax US 5,480,547; US 6,332,987; EP 0 433 661; EP 0 667 800; EP 0 982 061; EP 1 380 331;
processuk@pall.com US 5,543,047; US 5,690,765; US 5,725,784; US 6,113,784; US 7,083,564; US 7,318,800;
EP 0 470 485; US 5,252,207; US 5,552,048.

Copyright 1995, 2011, Pall Corporation. Pall, , AccuSep, AquaSep, Claris, CoLD Melt, Dia-Schumalith,
Duo-Fine, Dynalloy, Epocel, HDC, Hi-V, Lucid, Marksman, Nexis, PhaseSep, PMF, Profile, PSS, Rigimesh,
SepraSol, Ultipleat, and Ultipor are trademarks of Pall Corporation. Indicates a Pall trademark registered in
the USA. , Total Fluid Management, and ENABLING A GREENER
FUTURE are service marks of Pall Corporation.

PR-900b Produced in the USA. December 2011