Midstream Operator – Coyanosa Texas, Mar 2022 Problem The operator identified high levels of black powder contamination in their condensate production. The contamination was reducing the quality and sale price of the condensate along with increased costs from conventional filter change-outs and shutdowns. The conventional filters were ineffective in removing nano-size particles of black powder …
Midstream Operator – Coyanosa Texas, Dec 2021 Problem Black Powder contamination under 5 microns in size was causing costly filter change-outs and reduced efficiency of the Amine system to remove H2S and Co2. Solution The customer installed a BPS Magnetic Separator (Figure-2) upstream of the coalescer elements with the goal to clean the black powder …
Black Powder wear contamination in reclaimed oil was gravity fed to the high pressure flash tanks, the de-mister sections of compressors and finally the coalescer.
Butane and Low Ethane Propane (LEP) feedstocks contain sub micron Black Powder contamination that leads to costly unplanned maintenance and repairs. Previously, the Black Powder was removed using inefficient conventional bag filters, requiring over 50 filter change-outs each month. In addition, these bag filters are ineffective at removing Black Powder particles under 10 microns. This enables contamination to flow through the loading process causing damage to pumps, compressors, cooling systems and loading equipment.
High levels of Black Powder contamination (iron oxide, iron sulfide, silica and salts) from feed stock were bypassing filtration, contaminating compressor lube oil and damaging pumps, bearings, and seal faces. Two filtration methods were in use – a cone strainer upstream of the pump and high pressure cartridge filters upstream of the compressor.
Off-loading Natural gas condensate (C5H12+), from the 1st stage of natural gas field compression.
Excessive Filter Costs and Offloading Stoppage.
Clean the Black Powder™ contamination from a 12,000 BBL crude oil slop tank with an estimated contamination level of 1 pound of Black Powder per barrel of oil. The Black Powder contamination analysis identified primarily iron oxides and iron sulfides ranging with an average particles size of 1.82 microns and range from 0.06 to 50.60 (see analysis).
All fuels employed in the Aviation industry require the highest possible cleanliness value that allows the cleanest burn resulting in the least amount of solids emissions possible. Clean fuel also reduces premature wear of fuel system components.
“Methane is an extremely potent greenhouse gas and is about 80 times more potent than carbon dioxide if it escapes into the atmosphere before being burned. Studies show that natural gas power plants could be worse for climate change than coal plants if their leakage rate rises above 4%.”
The MycelX Desalter system was failing due to Black Powder contamination, costing $100,000 USD per month in hydrocarbon contaminated water disposal. A Pentair system was installed upstream of the MycelX system, but was ineffective in removing Black Powder. In order to save costs, single use Pentair filters were changed from 10 microns to 30 microns filter size to extend change-out cycles to 7 days. The cost of each filter element change-out was $13,000 USD, including disposal.