Hot Gas Filtration

Hot Gas Filter Systems

Enhance efficiency with advanced Hot Gas Filters for coal, biomass gasification, and more. Operating over 260°C (500°F), these filters are made of sintered metal powders, which provide fine pore sizes and tortuous flow paths to remove particles. Our hot gas filtration systems ensure continuous operation, optimizing waste heat utilization. 

  1. Easy to clean
  2. Compact and space-saving design
  3. Minimal heat distortion at high temperatures
  4. Effective filtration at high temperatures
    Resistant to corrosion from sulphur-containing gases

Hot gas filters are used in incineration, coal and biomass gasification, and fluid catalytic cracking units in refineries, ensuring efficient particulate removal in high-temperature environments. They are also used in Syngas filtration and removal of fly ash from hot gas streams.


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What is a hot gas filter system?

Hot gas filter systems are designed to remove particles and dust from gases and air. These filters are built with durable materials like Stainless Steel 316/316L, Hastelloy C22/C276X, Inconel alloys, Titanium, and Iron-aluminium alloys, ensuring they last long in aggressive environments. These filter cartridges have a large filtration area, are easy to install, and are cost-effective to operate.

Filter Media Used in Hot gas Filtration Solutions

Filtration of gases whose temperature exceeds 260 degrees Celsius, wherein conventional cloth-based filter media cannot be used, is termed as 'hot gas filtration'. Hot gas filtration media, typically ceramic or metal-based, must endure high temperatures and harsh chemicals while trapping particles efficiently. With strong heat resistance, corrosion protection, and intricate pore structures, they ensure effective filtration and smooth airflow. Ideal for industries like waste disposal, metal refining, and chemical production, these filters come in forms like filter bags and filter cartridges, adhering to strict standards for prolonged equipment life.

Ceramic Filters :

Ceramic filters for hot gas filtration are common, and are engineered to withstand extreme conditions, making them suitable for gasification processes. They possess the following features:

  • Efficiently operates at temperatures up to 1000° C
  • Robust composition for high thermal stability
  • Chemically compatible with sulphur-containing fumes

Metallic Filters :

Metallic filter elements serve as vital substitutes for ceramics in applications requiring high temperatures. Metallic filters, made from strong, porous metals, handle high temperatures better than ceramics, mainly because they can handle thermal gradients or transients better owing to their higher thermal conductivity and ductility. Different alloys offer varying temperature resistance: stainless steel for 420°C, and special alloys like FeCralloy reaching 800°C for hot gas filtering. These filter elements are chosen for applications requiring high temperatures due to their features such as,

  • Durable: Does not break during installation owing to higher ductility than ceramics
  • Weldable: Customized end-caps possible
  • Thermally conductive: Handles thermal shocks
  • Reliable: No failure from repeated blowback

Types of Metallic Filters Used in Hot Gas Filtration

Metallic Fiber Felt :

  • Constructed from fine metal fibers, these filters provide excellent filtration efficiency and high porosity.
  • Ideal for applications requiring high dirt-holding capacity and good thermal conductivity.

Powder Sintered :

  • Made by sintering metal powders into a solid porous structure.
  • Offers uniform pore size distribution for consistent filtration performance.
  • Highly resistant to thermal and chemical degradation, suitable for harsh environments.
  • Can survive repeated blowback cycles owing to the robustness of the filter media

Multilayered Sintered :

  • Consists of multiple layers of sintered metal, combining different pore sizes for enhanced filtration efficiency.
  • Effective for applications requiring high filtration accuracy with a low pressure drop, albeit with reduced strength compared to powder-sintered media.

Pleated Mesh :

  • Constructed from woven metal mesh that is pleated to increase the surface area.
  • Offers low-pressure drop and high flow rates, ideal for applications with high particulate loads.
  • Easily cleanable, but can tear in the long term from repeated blowback.

Our Sintered Powder Filters for Hot Gas Filtration

At Kumar Process Consultants, we specialize in offering high-performance sintered powdered filters needed for hot gas filtration applications. Constructed through a precise bonding process of metal particles at high temperatures, our filters feature a robust and porous structure that excels in both filtration efficiency and durability. They prevent particle shedding to ensure process purity, offer high resistance to extreme temperatures and pressures, and are easy to maintain through back-flushing with compressed air/gas. 

Our hot-gas filters are made from materials such as stainless steel, hastelloy C22/C276, titanium, and nickel-based alloys, ensuring exceptional corrosion resistance in harsh environments. Utilizing cold isostatic pressing and sintering, they provide long-lasting performance, superior mechanical strength, and easy installation for minimal downtime, making them a reliable choice for industrial filtration needs.

Iron-Aluminide Filters for Hot Gas Filtration

At Kumar Process Consultants, we specialize in offering iron-aluminide filters, the premier solution for hot gas filtration. Crafted from durable iron-aluminide alloys, these filters are renowned for their exceptional resistance to high temperatures and corrosive environments. Their unique properties ensure they maintain structural integrity and high performance even under extreme conditions, making them ideal for applications requiring reliability and longevity. A nanometer-scale thick ceramic layer creates a blue tinge on the filters, differentiating them from the gray of stainless steel or FeCrAl alloys.

Iron-Aluminide Filters includes below key features:

  • Unique metallic material with an adherent nanoscale ceramic layer - ductility of metals with the corrosion resistance of ceramics
  • Excellent resistance to sulphur-containing gases at high temperatures
  • Support materials options: SS310, SS316, Hastelloy C276, etc.
  • For use in syngas filtration, flue gas filtration, coal gasification
  • Diameter: up to 180 mm
  • Length: up to 2500 mm with joints

Hot Gas Filters Applications

At Kumar Process Consultants, we specialize in offering iron-aluminide filters, the premier solution for hot gas filtration. Crafted from durable iron-aluminide alloys, these filters are renowned for their exceptional resistance to high temperatures and corrosive environments. Their unique properties ensure they maintain structural integrity and high performance even under extreme conditions, making them ideal for applications requiring reliability and longevity. A nanometer-scale thick ceramic layer creates a blue tinge on the filters, differentiating them from the gray of stainless steel or FeCrAl alloys.

Biomass gasification and pyrolysis

We specialize in advanced filtration solutions crucial for biomass gasification and pyrolysis processes. These processes convert carbon-rich materials into valuable resources like syngas or synthetic natural gas (SNG), enhancing efficiency over direct combustion. Our hot gas filtration systems are designed for Integrated Gasification Combined Cycle (IGCC), Pressurized Fluidized Bed Combustion (PFBC), and handling pelletized Municipal Solid Waste (MSW). They withstand high temperatures, ensuring syngas purity, preventing equipment fouling, and optimizing efficiency throughout key stages:

  • Pre-Heat Exchanger Filtration: Removes solid particles at 800°C to protect critical components and maximize energy efficiency.
  • Post-Heat Exchanger Filtration: Purifies syngas at 320°C to 650°C for downstream uses like catalysis or fuel production.
  • Cooling Stage Filtration: Filters contaminants below 250°C to meet environmental standards and enhance safety.

Waste incineration and pyrolysis

We specialize in advanced filtration solutions for waste incineration and pyrolysis, transforming diverse waste types (medical, municipal solid waste, sewage sludge, plastics) into energy or chemicals. Hot gas filters are crucial for cleaning flue gases in incineration, covering areas up to 1000 m². This technology reduces harmful pollutants. Filtration during pyrolysis processes, operating at temperatures ranging from 350°C to 500°C, effectively purifies gases produced during plastic breakdown.


Fluid catalytic cracking units in refineries

Refineries employ hot gas filters in FCC (Fluid Catalytic Cracking) units to clean exhaust and protect equipment. These filters capture fine particles at high temperatures (500-600°C), meeting emission standards and safeguarding machinery. They operate at gas speeds of 90-150 m/h, cover large surface areas (500-1000 m²), and incorporate numerous elements (1000-2000). Additionally, they function as vent filters for catalyst storage, enhancing efficiency and ensuring environmental compliance.


Coal to Gas Filtration

Our advanced filtration solutions efficiently separate solids from hot gases, ideal for coal gasification. Our ceramic and metallic filters effectively clean aggressive gases by removing solids, operating from 232°C to 800°C. Our Gas Solid Separation (GSS) systems ensure long-lasting performance in high-temperature environments like IGCC and PFBC processes. 

Advantages of Hot Gas Filtration

  • Removal of fly ash using filtration instead of wet scrubbing, increasing process efficiency by up to 3% 
  • Protection of downstream equipment like heat exchangers from fouling due to fly ash, increasing heat recovery and overall process efficiency
  • High filtration temperatures prevent condensation of tars in biomass gasification, preventing choking of filtration media.

FAQs

What is a hot gas filter?

A hot gas filter removes solid particles from extremely hot gases in industries like refineries, chemical processing, and waste incineration. It ensures equipment integrity, environmental compliance, and process efficiency in high-temperature environments.

What is the process of gas filtration?

Gas filtration involves passing gas through a filter medium to remove particles and contaminants. The process ensures cleaner gas suitable for various industrial applications, maintaining equipment integrity and meeting regulatory standards.

What is the working principle of a gas filter?

Gas filters work by passing gas through a porous material that captures particles and contaminants, allowing purified gas to pass through for industrial use or environmental compliance.