Sintered Hot Gas filter element applications in the chemical and oil industries

The demand of separation of contaminants from the hot gas streams is increasing in the recent
industry. For the extensive requirement of pollution control and economical reuse of hot process
gases, an increasing count of applications conversion into temperature limits that is not suitable for
standard and polymeric media and where a conversion to metallic and other media is required.
Hot gas filtration using woven wire mesh is a proven technique. By using a broad range of high alloys
such as stainless steel 310 and stainless steel 316, Hastelloy, Inconel and resistant heating alloys, a
temperature limit to 1000oC in the diverse vigorous application media can be handled.
Catalyst Mesh Screens for Support and Filtration
Heanjia constructs wire mesh screens for the catalytic oxidation for the high temperature
applications up to 800oC to 950oC with a pressure limit from 1 15 bars. Our wire mesh is utilized as
a separation screen.
Bagfilters
Woven mesh media is used into the diverse types of filter elements which include flat elements or
supported tubes to the cartridge designs. Heanjia delivers durable filter media in the high functional
alloys for the standard bagfilter constructions. The general elements of various lengths can be
offered in the common and specific lengths. To offer highly durable performance against the fatigue
produce the backpulse, Heanjia has produced a patented and established seam solution to retain the
media on the bagfilter cage. Due to rare suitability and stability of standard bagfiler cages in all
applications, Heanjia delivers the specific mesh designs for the latest and traditional cages.
Filters for hot gas applications
Heanjia works with different kinds of woven filter media produced for various process conditions
and mechanical needs for applications with nominal mechanical needs. Because of their specific
structure, they offer superior dirt holding capacity and outstanding cleaning ability such as
backpulsing. To make them fit for the large mechanical pressures, they can be produced from high
performance alloy meshes that are sinter laminated. Selfstable elements utilized in the cartridge or
tube sheets can be produced.
For wide bagfilter applications, Heanjia supplies specialized filter mesh solutions that offer prolong
and heavy duty performance. These filters are made to handle fatigue caused by backpulse cleaning
and to offer a stable pore size structure. Heanjias filter elements for the hot gas filtration
applications are easily cleanable with standard pressure cleaning techniques and hence permit
diverse use of elements.
With the use of our state-of-art production tools, Heanjia can serve its customers with the multitude
of filtration solutions that are cost-effective and offer unique performance for your specific
applications.
Weaving and other material processing technologies is the root of our success. Since 1984, we have
been regularly including creativity and customer closeness. This dedication for technique and
outstanding solutions enables us to become the leading weaving company in the industry and

architecture. With experienced production techniques and integrated process experience, we

regularly test the latest fields of operations. Our mesh products are employed to produce efficiency
units, full installations and specific components in the wide variety of industrial sectors. Our firm
weaving techniques regularly sets the latest standards in the production of high precision metallic
meshes and heavy duty technical systems.
Solid weave production specialization
With weave technologies, produced in-house, we use highly fine wires and creative material
combinations. We use latest simulation technology to become able to optimally design the
performance of our mesh to meet the needs of specific process. Our extensive range of filtration
solutions and wide level machining and finishing processes ensure the prolong reliability of our
products while also offering seamless integration into industrial production procedures which
include heat processing, strip cutting, winding and welding, coating, calendaring, cleaning and
production in the clean conditions. Wide inspection procedures and tight company end to end
quality systems provide regular product features and wide procedures.
Sintered metal filters are used in the hot gas filtration applications in the diverse plants in the
chemical processes, petrochemical and power production units. These offer particulate holding
efficiency about 99.9%. The service temperature goes high up to 900oC. Considering the filtration
efficiency, essential factors are corrosion resistance, mechanical strength at the operation
temperature and cake production. These are critical factors for application s of hot gas filters in the
successful and economical manner. The issues related with the warm corrosion and strength at the
elevated temperature are overcome by using high performance alloys that are resistant to noble to
hot corrosion service media. They are high strength and resistant to wear during the fluctuated
temperature and loading.
Metal Mesh filters are produced with the desired strength at high temperatures, hot corrosion
resistance and hardness to withstand the thermal and mechanical stresses. Following are the
advantages of using sintered metal filters in the severe conditions at the high temperatures. The
filter service and functionality in the specific conditions are stated.
In the diverse applications involved in the chemical, petrochemical and power production plants
need hot gas filtration to secure the downstream apparatus for process security and to meet the
environmental standards. Filtration of gas released from the reactor at the elevated temperature is
essential, as cooling will either need a heat exchange or combining with cold air, at an included cost.
When combining with cold air, the dew point must be monitored to avoid condensation. Hot gas
particle filtration has been realized as a key fact for effective implementation of coal based
combined cycle power units for example integrated gasification combined cycle and hybrid cycles.
However cyclones and electrostatic precipitators are commonly employed for the particle separation
from a gas stream, fabric bag house filters, barrier or cross flow filters that offer separation
efficiency of 99.9% or larger. Fabric bags are commonly used at temperature limits from 90- 250oC,
Use of cyclones and precipitators need extra energy input. Back pulsed filters are static in use and
are fit for the specific pressure drip and gas flow conditions. The filters with consistent media
become economical as these systems result into nominal downtime, closed and automatic service
with nominal operator use required and minor maintenance. The adequate selection of filter media

with suitable opening, strength and corrosion resistance permit prolong filter service with excellent
efficiency for particle retention.
Understanding of the service filtration technique is the base of successful filter setup and
application. In case of gaseous media with nominal particulate contamination, filtration by holding
the particles in the depth of a porous material is adequate. The service of these filters will be based
on the particle retaining potential and the related decrease in pressure. In case of gases with large
dust loading, the filtration method is based on cake filtration. A cake is produced over the filter that
becomes the filtration layer and results in further drop in pressure. The pressure fall increases with
increase in particle weight. As soon as terminal pressure is attained, the filter element is drove back
to clean the filter to return it to the primary pressure drop. For the specifically chosen pore size in
the filters, the pressure drop can be recovered to the original level. Although in case of lodging of
particles in the porous media during the further flow, and wide load the filter element, the pressure
drop cannot fully recovered subsequent to cleaning.
The suitability of cleaning cycle and pressure drop recovery are a crucial factor for the cake features.
The cake strength is based on the dust particle morphology, distribution, electrostatic and chemical
interactions and extent of moisture and other vapors available in the cake. For the involvement of
elevated temperature, fine particles may bond and start to chemically interact with the filter media
thus complicating the cake release process. For effective filter design, it is crucial to consider the
above stated attributes to conduct a specific procedure.
Sintered metal filters
Sintered metal filers have been commercially used for above 40 years. They are constructed into a
variety of corrosion resistance and high strength alloys. The basic advantages of using sintered metal
filters include highs strength, hardness and pressure capability, corrosion resistance, cleanabiltiy and
prolong service life. With added strength, pressure handling and cleanability, sintered metal filters
provide a feature for regular use with back pulse cleaning for prolong periods. High toughness for
the high temperature services and resistance to creep, fatigue and hot corrosion make sintered
metal filters dominate among other filter elements.
Sintered filters are produced by pressing the mesh sheet and then high temperature sintering. The
pair of pressing and sintering states the pore size and distribution, strength and permeability of the
porous mesh. A benefit of metal filters is that they can be welded with other components to receive
high strength sealing joints. The sintered filters are used for gas filtration ratings about 0.5micro-m.
Resistance to temperature and hot corrosion
Following table describes the suitable highest service temperature for commercially used metal
filters in oxidizing, reducing or neutral conditions.
Porous Alloy
SS 316
SS 310
Hastelloy C276
Inconel 600

Highest service temperature, oC in different media

Neutral
Oxidizing
Reducing
500 oC
400 oC
500 oC
500 oC
500 oC
500 oC
550 oC
450 oC
550 oC
800 oC
800 oC
800 oC

Sulfidizing
350 oC
500 oC
250 oC
250 oC

Hastelloy X

925 oC

650 oC

925 oC

250 oC

The temperature limits state maximum limits for retaining high strength at the elevated
temperatures. Loss in strength at the high temperature is basically due to the internal softening of
alloy and additionally because of corrosive attack. In molybdenum based high performance alloys for
example Hastelloy X, the production of molybdenum oxide at 796oC in the extremely oxidizing
conditions up to 650oC. Heat resistant alloys are often fit for service at the high temperatures in the
reducing or carburizing conditions. The Nickel based alloys get intergranular corrosion in the
presence of sulfur media. Chromium, iron and silicon in these materials decreases the sensitivity to
such corrosion.
Filtration factors at high temperatures
a.
b.
c.
d.
e.
f.
g.
h.

Kinds of solids, reactive or inert, dry or stinky

Gas composition and dew point
Hard loading, particulate density, particle cake density and permeability
Size of particles, distribution, shape etc
Service pressure and temperature
Permitted pressure drop
Gas flow rate
Required filtration efficiency in terms of particle size or overall solids weight

For gas filtration at the temperatures below 200oC, the above factors are essential for construction
of specific filtration system. At service temperatures above 200oC, the reaction and bonding
between the dust particulates and interaction with the sintered metal filter improves. It can cause
complications in the elimination of produced cake during the blowback cycles. Before separation
through demisters to eradicate tar or oil vapor particles from the hot gas would offer specific
support in efficient performance of hot gas filter. The chemistry of gas and particulates should be
determined and compatible alloys must be selected to reduce the risk of cake production or reaction
with the filter elements.
Sintered metal hot gas filter designs
Heanjia provides various designs of sintered metal gas filters and gas-solids blowback filters.
Particle Holding filter- It involves filtration of warm air being released from heater at temperature of
800oC and eliminate the particles of size up to 0.5 micro-m, to secure the downstream apparatus. it
was comprised of Hastelloy X filter elements that offered prolong and consistent performance for
above 7 years and they needed ultrasonic cleaning subsequent to 10,000 hours of service.
The main cause of corrosion of Hastelloy X components was oxidation. These were initially plugged
with Molybdenum oxide. Alloy X consists of 8 10% Molybdenum as an alloying agent. Molybdenum
oxide melts at 796oC. At the service temperature of 815oC, molybdenum in alloy was slightly
interacting with oxygen and producing molybdenum oxide that meted and plugged with filter.
Thereafter, the application temperature for Alloy X filter elements in the oxygen based condition
was decreased to 650oC. Alloy 600 porous filter elements were preferred to substitute for Alloy X
elements.

Catalyst Trap Filter

It is used to reduce the damage level of expensive catalyst through the exit gas stream of a fluidized
bed reactor and avoid the catalyst particles from piercing the filtered stream. Traditional cyclones
generally are used to contain solids in the elevated temperature fluidized beds were not considered
adequately efficient for this procedure.
The gas limit chosen was 540oC, and condition was extremely oxidizing and carburizing. The gas
comprised of 75% weight organic vapor, 10% H2O, 10% carbon dioxide and 5% nitrogen. The
application pressure was 20 psig and face velocity was 4 ft/min. The average particle size was 8
micro-m with 2% particles of size below 1 micro-m.
Inconel 600 porous was selected for filtration and the filter element was strengthened with a
perforated internal core to decrease the stress corrosion damage. A complete filter area of 216 ft2
was utilized in filters. These are used to offer 365 days regular service and then the filter elements
are eradicated for chemical cleaning.
Dehydrator vent filter
A sintered metal hot gas filter was used on a fluidized bed dehydrator to eliminate the silica particles
from the effluent gas. Warm nitrogen gas at 900oC was utilized to dry silica particles in a fluidized
bed. The essential filtration efficiency was 98% at 1.3 micro-m particle. The application pressure
chosen was 10 psi. As the condition is nominally oxidizing, Alloy X porous was selected for warm gas
filtration for its great strength. The filter provides service as per the requirements. As the process is
not conducted regularly, the filter experiences significant thermal cycling. Due to its hardness, the
sintered metal filter absorbs the thermal stresses. If warm corrosion damage will take place, alloy
600 porous can substitute the Hastelloy X porous elements.
Future Performance
Stainless steel 310 filter is installed as a filter downstream of a hot gas filter in a power production
plant. It is organized to evaluate the service of the filter over an extended service from a hot
corrosion position. The service temperature varies from 280oC 450oC. The gas containing minor
magnitudes of hydrogen sulfide that causes sulfidation attack.
To determine consistency for a regular performance at high temperatures and corrosive conditions,
further work requires to be performed to evaluate the structural attributes of sintered metal filters
at high temperatures over a prolong period. An extensive database of elevated temperature
characteristics of porous metals in the oxidizing, reducing and sulfidizing gaseous conditions is
required. Wide mechanical testing must be performed as a function of temperature, environment
and heating cycle.
Sulfur bearing conditions are extensively severe. Traditional iron and nickel based alloys will not
perform sufficiently as sintered metal filters in sulfidizing conditions at high temperatures. Iron
aluminide alloys have been recognized as main candidates for high temperature applications in the
sulfidizing condition. Welding of iron aluminide alloys has been an issue, but solutions have been
found.

Entrainment filtration
The entrainment issue became critical in the petroleum industry demanded the wire mesh
entrainment separator. The multilayer wire mesh is installed on a single grid and comprised in place
by tie-down wires as a multilayer wire mesh is mounted among dual grids that are welded together
with spacer rods to keep a constant width kind of sandwich type. The wire mesh is about porous
providing nominal resistance to vapor flow. Light can be observed by mesh. The construction
materials for use in the production of wire mesh entrainment separators naturally vary is based on
the application.
The wire mesh filters have introduced a new technique for controlling liquid entrainment. The
benefits of double grid design over the single grid design have been noticed. Better equipment
performance ensures the lesser risk of equipment damage due to high quality stream flow.
Hot gas filtration requirement in oil-gas plants
The vapor phase filtration of biomass extracted pyrolysis oil described by enhanced bio-oil
characteristics by use of hot-gas filtration. The filter elements produced by Heanjia Super-Metals
offer excellent operability. Use of regular blowback filters describes an effective maintenance of
filter element pressure drop with the suitable limits and filter clogging doesnt occur.
Bio-oil received through hot gas filtration with sintered stainless steel mesh is of higher quality than
that received from traditional filtration elements.
Conclusions
Sintered metal hot gas filters are successfully used in the chemical process, petrochemical and
power plants for several years. Different alloys are obtainable that have the needed mechanical
strength and corrosion resistance to withstand the operation conditions. Most service requires to be
functioned to produce sintered porous materials that will withstand the sulfidizing condition at high
temperatures. This production will be critical to the successful use of sintered metal hot gas filters in
the coal combustion units.
Besides the development of suitable metallurgy for diverse corrosive conditions at high
temperature, the cake release nature at high temperature is also successful filter service. The
particle nature at high temperatures, their reactivity with the sintered metal filter surface and inter
particle bonding will specify the cake nature. Suitable solutions will require to be produced to
receive a cake that is readily dislodged while blowback. A firm mechanical design of the filter system
to serve at the high temperatures and handle the heat and pressure loads while filter operating cycle
will be needed.
Eventually, the sintered filters possess the needed corrosion resistance and mechanical strength for
withstanding the elevated temperature media; the filters lack hardness and decrease in a brittle
manner. The filters also need the ability to withstand immediate temperature variations and heat
shock. Sintered metal filters due to their intrinsic hardness overcome such limitations and if
designed suitably, should offer prolong performance without damage.

Heanjia Super-Metals has achieved wide expertise in the production of high performance sintered
mesh for filtration solutions. Using our state-of-art tooling, we can supply the filter elements in the
wide variety of custom sizes and specifications for the specific applications of our customers. Our
engineers work with our clients in each step of their application filter element production in order to
deliver the highly efficient products. Contact us today to discuss your hot gas filtration requirements.