Black powder in gas pipelines is a pervasive solid contaminant in natural gas transmission and distribution systems worldwide, primarily composed of iron oxides, iron sulfides, and some silica. This contamination originates from the internal erosion and corrosion of carbon steel pipelines. Whether adhering to the pipe wall or accumulating at the pipe bottom, black powder significantly impacts system efficiency by increasing roughness, reducing flow area, and elevating pressure drops. The consequences extend to product contamination, erosion wear in compressors, instrument clogging, and erosion and sealing issues in valves, affecting equipment from large industrial burners to residential appliances.
To date, finding an effective solution for black powder removal has been challenging. Traditional commercial cyclonic separation technologies, while available, only effectively capture larger particle sizes, and cartridge filters frequently clog, requiring multiple daily changes. Magnetic separation technologies, although effective, demand substantial investment. Maintenance practices, including pigging, are labor-intensive and result in considerable downtime. The high-pressure oil and gas separator market demands a highly efficient final dedusting system capable of being placed upstream or as an alternative to cartridge filters. This system must effectively capture particles across all sizes, aiming to reduce both maintenance and operational expenses.
ACS group of cyclones and accessories for Iron Oxides separation in natural gas networks at 16bar for EDP Gas in Portugal | ACS Cyclone for Iron Oxides separation in compressed air network at 8bar for Air Liquide in Poland |
Sider Gas, commonly referred to as Steel Mill Gas or GLD, is a complex byproduct of the steel production process. Generated during critical phases such as coke-making, blast furnace operations, and steelmaking in basic oxygen or electric arc furnaces, Sider Gas encompasses a variety of particulates, including tar and soot, trace metals from coke ovens, iron and calcium oxides from blast furnaces, and metallic particles from steel conversion processes. These particulates pose a significant risk of fouling or damaging the internal components of gas engines, thereby diminishing their efficiency and lifespan. Traditional cleaning methods typically employ cartridge filters; however, these require intensive maintenance.
The market demands an efficient dedusting system that can be integrated upstream of cartridge filters to effectively capture a wide range of particle sizes, thereby aiming to streamline maintenance and reduce operational costs. Advanced Cyclone Systems (ACS) responds to this need with a suite of high-efficiency/high-pressure cyclone batteries designed to significantly ease the load on cartridge filters, thus substantially reducing maintenance demands.
In the realm of oil refineries, Fluid Catalytic Cracking (FCC) processes play a pivotal role, where the separation and recovery of powder catalysts emerge as a primary concern. Following the regeneration process, the FCC flue gas exits the regenerator, overflowing from an array of internal cyclones. The catalyst dust, typically exceeding concentrations of 150 mg/Nm³, is then directed through an additional separation unit, the Third Stage Separator (TSS), which bifurcates the flow into a diluted stream and a concentrated stream. For plant managers, a primary goal is to harness the clean overflow for heat recovery or energy production through a Turbo Expander while managing the release of the concentrated fraction into the atmosphere.
Facing stricter emission regulations, there is an imperative need to control catalyst emissions from the TSS's underflow or to contemplate a complete overhaul of the TSS system. This necessitates a durable, high-pressure particle collection system that can withstand extremely high temperatures. Cyclonic separators (oil and gas) present a cost-efficient alternative to the more expensive sintered filters. Strategically placed after the TSS within the concentrated gas stream, this system aims at emission control before integrating the flow with the overflow for heat recovery (Option A), or it could be situated immediately after the regenerator, effectively replacing the TSS (Option B).
Advanced Cyclone Systems introduces its agglomerator hurricane cyclonic separators (EX and MK lines), featuring an alumina-based lining that offers numerous benefits. Its design, characterized by low abrasiveness geometries and remarkable efficiency, eliminates the need for barrier-type filters. This innovative approach ensures an effective solution for catalyst recovery and emission control within FCC processes, aligning with both operational efficiency and environmental compliance objectives.
Option A - Cyclone system for the concentrated dirty gas fraction | Option B - Cyclone to clean the whole amount of gas existing in the regenerator, replacing the third stage separator |