Self-Cleaning Magnetic Filter for Natural Gas
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Solution Overview
Problem
Existing magnetic filters for natural gas process streams are prone to clogging due to sticky mixtures of wax, asphaltenes, and lubrication oil, requiring frequent servicing and pose safety hazards during manual cleaning, especially in environments with toxic compounds like hydrogen sulfide.
Innovation Solution
A magnetic filter design without packing material or matrices, featuring non-magnetic sleeves with removable magnetic bars, a wash solution circulation system, and a bag filter for automatic flushing of contaminants, eliminating the need for manual cleaning and reducing clogging risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If packing material or matrices are used in magnetic filters, then magnetic contaminants can be effectively captured, but the filter clogs quickly due to sticky mixtures of wax, asphaltenes, and lubrication oil
Solution Approach 1:
The filter is divided into two functional zones: an upper separation chamber with packing material for contaminant capture, and a lower filtration chamber with a filter element for final filtration. This segmentation allows the packing material to capture magnetic contaminants while the filter element handles the sticky mixture, preventing clogging of the entire filter and extending operational duration.
2Ease of repair
If manual cleaning is performed on magnetic filters, then contaminants can be removed, but exposure to toxic compounds such as hydrogen sulfide creates safety hazards
Solution Approach 1:
The filter incorporates an automatic backwashing system that uses reverse flow to clean the filter element and a scraper mechanism to automatically remove accumulated contaminants from the packing material. This self-service cleaning eliminates the need for manual intervention, preventing worker exposure to toxic compounds while maintaining continuous cleaning capability.
3Ease of repair
If mechanical scrapers are used for cleaning magnetic filters, then collected magnetic material can be removed, but fire hazards arise in natural gas systems
Solution Approach 1:
The mechanical scraper system is replaced with a magnetic field-based cleaning mechanism. A magnetic bar is moved through the packing material to attract and remove magnetic contaminants without physical contact that could generate sparks. This substitution eliminates fire hazards while maintaining effective magnetic material removal capability.
4Reliability
If frequent servicing is required for magnetic filters, then clogging can be addressed, but maintenance time and operational downtime increase
Solution Approach 1:
The filter implements continuous automatic backwashing during operation and automatic scraper activation at scheduled intervals, ensuring cleaning actions occur without interrupting the natural gas flow. This continuity of useful action maintains filter functionality while eliminating maintenance downtime, as cleaning occurs concurrently with filtration rather than requiring shutdowns.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively separates ferrous contaminants from natural gas streams, reduces maintenance needs, and ensures safe operation by preventing clogging and minimizing exposure to hazardous substances through automated flushing.
Implementation Method 1
A plurality of magnetic bars are supported for movement relative to the plurality of non-magnetic sleeves between a first position wherein the magnetic bars are disposed within the chambers of the sleeves and a second position wherein the magnetic bars are withdrawn from the chambers of the sleeves
Implementation Method 2
The draining opening, the bag filter, the fluid storage tank, the pump, and the plurality of spray nozzles are fluidically connected together for circulating a wash solution from the fluid storage tank, through the plurality of spray nozzles, into the interior region of the housing, through the drain opening, through the bag filter and back into the storage tank for flushing contaminants from the exterior surfaces of the non-magnetic sleeves and from the interior region of the housing
Data Source
AI summary
A self-cleaning magnetic filter for removing ferrous contaminates from a natural gas process stream including a housing through which the process stream follows for removing ferrous contaminates in the process stream by magnetic attraction with a plurality of magnetic bars that are removably disposed in a plurality of non-magnetic sleeves disposed within the housing. A recirculating washing solution is used to flush contaminates that adhere to the exterior surfaces of the non-magnetic sleeves and from the housing. A bag filter is used to remove contaminates from the washing solution to allow recycling the washing solution.