Hot Gas Filtration

Hot Gas Filter

Hot gas filters are essential for removing particulate matter and contaminants from high-temperature gas in various industrial applications. Operating efficiently at temperatures above 260°C (500°F), these filters are critical for industries like power plants, steel mills, chemical processing, and incineration plants, where hot gas is produced. Hot gas filters are an integral part of any high-temperature gas filtration system, offering robust and reliable performance for a wide range of industrial processes. Whether for incineration, gasification, or waste heat recovery, hot gas filtration are essential for maintaining optimal operation and environmental compliance.

  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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Hot Gas Filter Manufacturer - Kumar Process Consultants

Kumar Process Consultants offers advanced Hot Gas Filters designed for high-efficiency filtration of particles and dust in gas, even under extreme temperatures and pressure conditions. These filters are engineered to ensure reliable performance in various industrial sectors, including coal gasification, cement kilns, flue gas, and biomass gasifications.

Our hot gas filters provide efficient sub-micron filtration in gas at elevated temperatures and high-pressure environments. This ensures that particulate matter is effectively removed, enhancing the efficiency of downstream equipment and enabling more effective heat recovery.

The hot gas filtration is equipped with an automated cleaning mechanism, utilizing back-pulsing to remove collected dust particles when pressure differential limits are reached. This ensures continuous filtration without interruptions, enhancing system uptime and operational efficiency.

Our filters are made from high-quality, durable materials such as Stainless Steel 316/316L, Hastelloy C22/C276, Titanium, and Iron-aluminum alloys. With large filtration areas and an easy installation process, Kumar Process hot gas filters provide a cost-effective solution for industrial filtration needs. The long service life and low maintenance requirements further contribute to their cost-efficiency.

Connect with us to inquire about the high quality hot gas filter needed for filtration of gas particles.

Filter Media Used in Hot Gas Filtration Solutions

Filtration of gas exceeding 260°C, where conventional cloth-based filters fail, is referred to as hot gas filtration. In these cases, hot gas filters typically use ceramic or metal-based filter media that can withstand high temperatures and harsh chemicals while effectively capturing particles. With superior heat resistance, corrosion protection, and complex pore structures, these hot gas filtration systems ensure smooth airflow and efficient filtration.

Ceramic Filters :

Ceramic filters are commonly used in hot gas filtration systems and are engineered to handle extreme conditions, making them ideal for gasification processes.

Key features include:

  • Efficient operation at temperatures up to 1000°C
  • High thermal stability due to robust composition
  • Chemical compatibility with sulfur-containing fumes

Metallic Filters:

Metallic filters serve as essential alternatives to ceramic filters for applications requiring high temperatures. Metallic filters, constructed from strong, porous metals, offer better performance in thermal gradients or transients because of their superior thermal conductivity and ductility. Alloys such as stainless steel (420°C) and FeCralloy (800°C) are commonly used.

These hot gas filters provide:

  • Durability: Resistant to damage during installation due to higher ductility than ceramics
  • Weldability: Customizable end-caps for specific needs
  • Thermal conductivity: Effective handling of thermal shocks
  • Reliability: No failures from repeated blowback

Types of Metallic Filters in Hot Gas Filtration

In hot gas filters, several types of metallic filters are available, each offering unique benefits for various industrial applications.

Metallic Fiber Felt :

Metallic Fiber Felt filters are made from fine metal fibers, providing excellent filtration efficiency and high porosity. Their structure allows for a high dirt-holding capacity and efficient heat transfer, making them well-suited for applications requiring effective particle capture and good thermal conductivity.

Multilayered Sintered Filters :

Multilayered Sintered Filters are composed of multiple layers of sintered metal filter with varied pore sizes, delivering enhanced filtration precision. These filters are highly effective in applications that demand high filtration accuracy and a low pressure drop. Although they offer excellent performance, they may be slightly less durable than powder-sintered media, especially under intense pressure conditions.

Pleated Mesh Filters :

Pleated Mesh Filters consist of woven metal mesh arranged in pleats to maximize surface area, allowing for high flow rates and low-pressure drops, which is ideal for environments with high particulate loads. These filters are easily cleanable; however, repeated cleaning through blowback can lead to gradual tearing, making them suitable for applications where regular maintenance and replacement are manageable.

Sintered Powder Filters for Hot Gas Filtration

As a leading hot gas filter manufacturer, Kumar Process Consultants specializes in offering hot gas filtration systems using high-performance sintered powder filters. These filters are constructed through a precise bonding process of metal particles at high temperatures, resulting in a durable and porous structure that excels in both filtration efficiency and longevity. Our hot gas filters are used for extreme temperatures and pressures, they ensure process purity by preventing particle shedding and are easy to maintain with back-flushing.

Features of Our Sintered Powdered Filters

  • Provides uniform pore size distribution, ideal for consistent filtration.
  • Resistant to thermal and chemical degradation, ideal for harsh environments.
  • Survives repeated blowback cycles, offering a robust filtration media.
  • Produced by sintering metal powders into solid porous structures.

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 sulfur-containing gas 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 Filter Applications

We offer high quality hot gas filtration solutions for below industrial applications.

Biomass Gasification

Our filters support biomass gasification and pyrolysis, converting carbon-rich materials into valuable resources like synthetic gas (syngas). They play a key role in IGCC, PFBC, and MSW processing. The filters operate at critical stages: pre-heat exchanger filtration at 800°C, post-heat filtration between 320°C and 650°C, and cooling stage filtration below 250°C to meet environmental standards.


Waste Incineration

Designed for waste incineration and pyrolysis, our hot gas filters clean gases from medical and municipal waste, sewage sludge, and plastics. Covering up to 1000 m², they operate between 350°C and 500°C, effectively reducing pollutants and ensuring cleaner emissions.


Catalytic Recovery Filtration

Our filters support exhaust gas filtration in refineries, protecting equipment in FCC units and meeting emission standards. Operating between 500°C and 600°C and handling velocities of 90–150 m/h, they cover up to 1000 m², capturing particles and serving as vent filters for catalyst storage.


Coal-to-Gas Filtration

For coal gasification, our ceramic and metal filters separate solids from hot gas at 232°C–800°C, handling aggressive gas conditions in IGCC and PFBC applications. Their robust design enhances gas purity and extends equipment lifespan.

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

How long does a hot gas filter last?

The lifespan of a hot gas filter varies by application but typically ranges from 1 to 5 years, depending on operating conditions and maintenance.

What is the use of a hot gas filter?

A hot gas filter removes particulates and contaminants from hot gases in high-temperature applications, protecting equipment and ensuring cleaner emissions.

Why can a hot gas filter be used in catalyst recovery filtration?

Hot gas filters capture fine catalyst particles, enabling recovery and reuse, which reduces material costs and minimizes waste in catalytic processes.

What is the difference between hot filtration and vacuum filtration?

Hot filtration removes impurities from hot solutions to prevent crystallization, while vacuum filtration uses reduced pressure to speed up filtration, often for solid-liquid separation.

What is the working principle of a gas filter?

A gas filter works by trapping particles within a porous medium, allowing clean gas to pass through while contaminants are captured.

What are gas filters made of?

Gas filters are typically made of materials like sintered metal, ceramic, or woven metal mesh, designed to withstand high temperatures and corrosive gas.