Automatic Backwash Filter Systems
Automatic Backwash Filter Systems
Catalyst Bed Protection and Guaranteed Uninterrupted Operation in Refinery Processes
At Dantechs Systems and Filter Solutions, we offer highly engineered products designed to protect reactor beds in the most challenging flow conditions within refinery and petrochemical plants and to minimise downtime Automatic Backwash Filter Systems. The consistent removal of solid particles from hydroprocessing (hydrotreater and hydrocracker) feed lines is the most critical factor in extending the service life of catalyst beds within reactors and reducing operating costs (OPEX).
Our systems automatically reverse the flow when a specified differential pressure (Delta P) limit is reached, thereby cleaning the filter elements with the process fluid itself. As all other elements continue the filtration process during this time, the process flow is maintained without any interruption, ensuring continuous 24/7 turnkey operation.
Our Automatic Backwash System Solutions
We offer two main technology segments designed to accommodate variations in crude oil and the solid load density of refinery processes:
1. Wedgewire Permanent Element Systems (4000 Series)
- Technology: Solid particles are captured on the surface of permanent, long-life wedgewire filter elements manufactured from stainless steel.
- Principle of Operation: When the automatic backwash cycle begins, the system reverses the flow direction for a single element at a time. Whilst the other cartridges continue to filter uninterrupted, the cleaned element returns to its original pressure drop value within seconds.
- Performance Limits: Capability to operate at extremely high temperatures, such as 750°F (~400°C). It is an excellent solution for high-temperature, medium-density solid loads such as heavy coker gas oil and residue.
2. Rotary Arm Systems (FR Series)
- Technology: A new-generation, high-efficiency automatic filtration technology utilising semi-permanent specialised mesh filter media.
- Principle of Operation: During backwashing, the integrated rotating cleaning arm inside the housing passes over each filter element, removing contaminants from the line.
- Advantages: Compared to traditional tubular filters, it consumes up to 10 times less backwash fluid (recovery loss). It delivers superior performance in flows containing low to very high solid loads, in coke-cutting water and in plant process water, up to a temperature of 500° F (~260°C). Its design, which can be easily overhauled on-site by field maintenance staff, reduces maintenance costs by a factor of 5.
Comparative Solution Matrix
To determine the ideal backwash package configuration required for your process, a comparison of the characteristics of our systems is provided below:
|
Technical Criteria |
Wedge Wire Permanent Systems (4000 Series) |
New Generation Swivel-Arm Systems (FR Series) |
|
Solid Load Capacity |
Low – Medium Solid Loads |
Low – Very High Heavy Solid Loads |
|
Maximum Temperature |
750°F (~400°C) |
500°F (~260°C) |
|
Recycling Loss |
Less than 2 per cent of the feed flow |
Ultra-low; less than 0.1 per cent of the feed flow |
|
Typical Applications |
Gas oil, Resid and Heavy Coker streams |
Hydroprocessing feeds, process and cooling waters |
|
Maintenance Model |
Periodic external cleaning & six-monthly valve maintenance |
Six-monthly on-site media inspection and rapid replacement |
|
Initial Investment Cost |
High |
Reasonable / Medium |