Black Powder Contamination in the process water system.
Install BPS Magnetic Separator (Cost: $13,000 for (2X) B5SCFD118SCLFFLN4) between the desalter vessel and the water tanks, before Pentair filtration. Note BPS separators operate with less than 1 PSI DP with a large holding capacity of ferrous and non-ferrous contamination and an expected operational life of 16+ years. The individual Filters are isolated and cleaned daily, removing significant volumes of contamination each time.
The Black Powder contamination levels reduced by 95+ percent prior to the Pentair filter, extending the Pentair filter element change out to 45 Days. The housing differential pressure reads 25 PSI (current run is 30 days with only 2 PSI Pressure drops, so interval is extended).
Sixty one element change outs have been eliminated, realizing cost savings of
$793,000.00. The Pentair elements changed to 1-micron with projected change out every 45 days.
The collective base line savings for a 12- month period will be $1,200,000, eliminating the cost of removing process water for disposal.
The reduced filter element consumption of $793,000 equals a savings of $1,993,000.00 from an investment of $13,000 in BPS separation technology.
The MycelX unit that is now working reliably was an $800,000.00 investment, the savings are
$2,793,000.00. When factoring the labor, downtime, and exposure involved with change-outs, water hauling trucks and drivers, the savings increase again.
PS Magnetic Separators are an environmentally responsible solution because they are a cleanable, reusable technology. This $14,000 unit has an operating life of 15+ years. The ROI resulted after the initial 3 loading days eliminating downtime and maintenance providing a reliable LPG loading system. The BPS System cut 9 cleaning intervals to 0 as cleaning was complete in the down interval of 2 days between loading functions. This saved extended demurrage costs of $25,000/day/vessel and labor costs of $8,000.
March 29, 2017
Downstream, Hydrocarbon Fluids, Midstream, Process Water, Refinery