Saifilter specializes in designing and manufacturing custom filtration components for gasification. With years of experience in designing and producing gasification filter elements, our equipment efficiently filters solid waste generated during the gasification or pyrolysis process, such as corrosive carbon particles, resin, soot, etc. In addition to our primary products, our Filter Elements stand out as a prominent solution in our line-up, ensuring optimal performance in challenging environments.
Saifilter Gasification Filters allow normal, high-efficiency filtration at temperatures higher than traditional systems. They are 100% static-resistant and non-flammable. At the operating temperature of 350℃-800℃, the filtration efficiency is 99.99%, able to remove particles <1μm and the filtration emission value is as high as <5 mg/Nm³. Saifilter gasification filters can protect critical downstream components and comply with local environmental regulations.
Solid particles are derived from the gasification and pyrolysis processes. Depending on the specific operational stage of the system, corresponding methods can be chosen for filtration. Filtering particles at elevated temperatures enables downstream equipment to more efficiently recover waste heat. Typically, hot gas filtration follows several stages:
- Before the heat exchanger, a gasification filter or a cyclone separator can be used for filtration. At this point, the temperature of the syngas is typically between 800°C and 1,000°C.
- After passing through the gasification filter element or cyclone separator, before entering the heat exchanger, the temperature of the syngas drops to between 320°C and 650°C.
- After using the wet scrubbing system, the gas temperature generally drops to below 250°C.
Saifilter Gasification Filter elements can be used for both new systems and system retrofit upgrades. There are multiple installation designs available to suit your specific installation requirements. Depending on the operational conditions of different customers' applications, Saifilter manufacturers can provide four types of Gasification Filter elements. These elements use porous metal membranes, metal fibers, and metal powders as filtering materials to tailor the most cost-effective filtration solution.
Filter Elements for Hot Gas Filters
Standard Hot Gas Cleaning Filter
It is made of a single layer of metal mesh through a composite 200-500μm powder asymmetric stepped pore filter layer, with the metal mesh as a supporting carrier, rolled and vacuum high-temperature sintering. It belongs to surface filtration and is suitable for medium and low-pressure process equipment. The operating temperature is 300-800℃, and the gas filtration grade range is 1 to 20 µm absolute value.
High Pressure Flow Restrictor
It is made of multi-layer metal mesh through a composite 50-200μm powder asymmetric stepped pore filter layer, with the multi-layer mesh as a supporting carrier, rolled and vacuum high-temperature sintering. It is a surface filtration, suitable for use in high-pressure process equipment, with an operating temperature of 300-450°C and a gas filtration grade range of 1 to 20 µm absolute.
Hot Gas Porous Powder Filter
It is manufactured by pressing alloy powder into a porous tube filter element and then sintering it under vacuum at high temperature. The combination of pressing and sintering operations determines the pore size distribution, strength, and permeability of the porous media. The operating temperature is 400-1000℃. Gas filtration grades range from 0.1 to 100 µm absolute.
Hot Gas Sintered Metal Felt Filter
It is a metal filter element that is deeply processed by sintered metal fiber felt as filter material. It has different filtration gradients and can be used for surface filtration or depth filtration. Operating temperatures are 300-1000°C and gas filtration levels range from 1 to 80 µm absolute. Depends on alloy choice.
Application of porous hot gas filtration elements in chemical production
Application of porous hot gas filter candle in polycrystalline silicon production
- Efficient Particle Removal: Ensures clean and high-quality syngas.
- High-Temperature Resistant: Suitable for the high temperatures of gasification processes.
- Varied Designs: Different materials and designs based on needs.
- Diverse Pore Sizes: Selectively removes contaminants based on size.
- Improved Syngas Quality: Ensures Syngas meets quality standards for downstream applications.
- Protects Equipment: Reduces maintenance costs and extends equipment lifespan.
- Enhanced Efficiency: Guarantees the overall efficiency of the gasification process.
- Environmental Benefits: Reduces emissions of particulates and other pollutants.
- Operational Safety: Ensures the safe operation of gasification systems.
In Line Equipment Protection:
- Pressurized Gasification - Syngas Cleaning
- Biomass Gasification
- Heat Exchanger Protection
- Catalyst Life Extension
Atmospheric Pollution Control:
- Incineration of industrial, clinical and chemical waste
- Incineration of animal caracasses
- Soil remediation
- Cement and brick manufacture
- Metallurgical processing - ferrous and non-ferrous
Gasification filters are essential components in gasification systems, used to remove impurities such as dust, ash, and harmful substances from the synthesized gas before it is used or further processed. These filters play a crucial role in ensuring that the gas produced is clean and of high quality, which is essential for both environmental and equipment safety.
Gasification filters work by utilizing physical barriers such as ceramic or metal filters or using chemical processes to remove contaminants from the gas stream. Depending on the specific design and materials, these filters can capture particulates, absorb harmful chemicals, or separate substances through various means like sieving, adsorption, or absorption. They are usually installed in different stages of the gasification process to ensure maximum purification.
Using gasification filters in a gasification system is vital to:
Protect downstream equipment from potential damage caused by particles or corrosive components present in the raw gas.
Ensure the production of high-quality syngas, which is essential for optimal performance in applications such as electricity generation or synthetic fuel production.
Minimize environmental pollution by capturing pollutants that might otherwise be released into the atmosphere, thus helping in complying with environmental regulations.
Enhance the efficiency and longevity of the gasification system by reducing the wear and tear on the machinery.
Maintaining and cleaning gasification filters involves:
Regular inspection to identify any signs of wear, damage, or blockage.
Following the manufacturer's guidelines regarding cleaning procedures, which might include backflushing or using specific cleaning agents to remove accumulated particles.
Monitoring the pressure drop across the filter to detect any abnormalities that might indicate clogging or other issues.
Replacing the filters at recommended intervals or when they no longer function effectively ensures the optimal performance of the gasification system.
Ensuring that the waste removed from the filters is disposed of correctly, following local and federal regulations to prevent environmental contamination.
Different types of gasification filters are available, designed to address various challenges in filtering syngas. These may include:
Particle Filters: Used to remove solid particles like ash and dust from the gas stream.
Ceramic Filters: Typically used to remove fine particles and withstand high temperatures.
Activated Carbon Filters: Employed to absorb volatile organic compounds and other contaminants.
Metal Filters: Designed to withstand high pressures and temperatures, often used in harsh environments.
Baghouse Filters: Utilize fabric bags to capture particles, suitable for removing larger quantities of dust and other solids.