Magnetic Separation Technology saves $390k a year

Midstream Operator – Coyanosa Texas, Mar 2022


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 contamination from the condensate and required replacement four to five times on the worst days and as few as three to four times a week (48 to 80 filters monthly), costing $500 per filter.


The customer installed a BPS magnetic separator in line before the traditional filter skid to improve the quality of the condensate and reduce the consumption and negative environmental impact of the single-use filters.


The BPS magnetic separator cleaned the black powder contamination from the condensate down to and below 1ΞΌ in size with high efficiency (see analysis).  

Significant Benefits:

  • Improved quality resulted in higher revenue
  • Reduced consumption and costly disposal of filters, unlocking savings of up to $390,000 yearly on average.
  • Reduced erosion of pipelines, meters and pumps.

ESG benefits:  

  • Reduced coalescer element consumption and disposal
  • Improved environmental footprint
  • Reduced opportunity for injury
Figure-1: A BPS Magnetic Separator Element with  5+ lbs of black powder contamination after 7 days running on the condensate system

Analysis Results

BPS had SEMx, a third-party lab, to complete EDS, PSD, and XRD tests on the solids captured on the Magnetic Separator Element (MSE).

EDS and XRD Analysis

XRD is used to identify the crystalline compounds found within the contamination. The results are summarized in Table 1.

Table 1 : Results of XRD Analysis

Mineral NameChem. FormulaWeight %
Calcium Aluminum SilicateπΆπ‘Ž2.75 𝐴𝑙5.5 𝑆𝑖18.5 𝑂483.7
Iron Sulfate Hydroxide𝐹𝑒1.5(𝑆𝑂4)𝑂𝐻2.9
Manganese Sulfide𝑀𝑛𝑆0.8

PSD Analysis Results

PSD analysis determines the sizes of particles within a solid’s contamination. Figure 2.  illustrates the particle size distribution of contamination found within the sample. The analysis determined that 47% of the particles were below 4 microns in size and 22% were less than one micron.

Figure 2: Particle Size Distribution for Solids Contamination

Figure 2: Particle Size Distribution for Solids Contamination

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