Petrochemical Plant Gas Coalescer Revision
Project Summary & Scope
This is a project to completely renovate existing filtration systems with a \"Zero Waste\" goal to adapt to the increasing production capacity of a large-scale petrochemical plant operating at international standards. It was planned for the plant to comply fully with environmental policies and achieve significant savings in energy costs.
Within the scope of the project, old generation filters operating under high pressure were dismantled, and replaced with two-stage coalescer units and fully automated backwash liquid filter systems specially designed by DanTechs engineering.
Challenges Faced
Realizing this massive transformation without stopping the production of the plant (zero unplanned downtime) was the most critical phase of the project. In addition, due to the aggressive nature of the fluids reacting chemically, unusual corrosion resistance was required in material selection.
Solution & Results Obtained
With detailed piping and bypass line designs, the integration process was completed while the plant was running, with zero downtime (live-tie-in). The corrosion problem was permanently resolved using special Duplex steel.
- The amount of liquid waste, which was 250 m³ daily, was reduced to zero thanks to recovery.
- The pressure drop (Delta-P) in the compressor line was optimized, providing 18% energy savings.
- Manual filter cleaning labor was eliminated, maximizing operational safety.
- The plant was awarded the international Green Environment Award.