--- title: "Case Study: 7 times increase in on stream life for HGO filtration" description: 7 times increase in filter lifetime for HGO filtration image: https://www.amazonfilters.com/hubfs/AI-Generated%20Media/Images/petrochemical%20plant%20highlighting%20Naptha%20hydrotreating%20unit.jpeg --- [+44 (0) 1276 670600](tel:+44%20(0)%201276%20670600) [![Amazon Filters Logo](https://www.amazonfilters.com/hubfs/amz01/Global/Logos/amazon_filters_logo_color.svg) ](https://www.amazonfilters.com) Products [All products](https://www.amazonfilters.com/products) [Filter cartridges & capsules](https://www.amazonfilters.com/products/filter-cartridges-and-capsules) [Filter housings](https://www.amazonfilters.com/products/filter-housings) [Custom filter housings](https://www.amazonfilters.com/products/custom-filter-housings) [Retrofits](https://www.amazonfilters.com/products/replacement-retrofit-filters) [OEM](https://www.amazonfilters.com/products/oem-filters) Applications [Pharmaceuticals and 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](https://cta-service-cms2.hubspot.com/web-interactives/public/v1/track/click?encryptedPayload=AVxigLJROGIbyd30Lwhh%2FYtr45fh49c69UGdbjroNByqjaHkwQnD1dJegkKPeUL5Ed3mtwVjwJmuPIFOAuo%2Bh6%2Fed7YyhCeHNFTFOhOTJwj3zgr3f2KVzf1cDTArQklXAfGWVTjH4UrPuxcxV8GiteJS%2FScYhfZbIXuFDZb33Lh0WVHl7ePOfgH0M9FTZSIb&portalId=6888762) [+44 (0) 1276 670600](tel:+44%20(0)%201276%20670600) Case study # Retrofit solution results in 7 times on stream life for HGO filtration  ![](https://www.amazonfilters.com/hubfs/case-studies/tag-icon@3x.svg) Oil & Gas [Download PDF](https://www.amazonfilters.com/case-study-7-times-increase-in-on-stream-life-for-hgo-filtration#openFormModal) ![](https://www.amazonfilters.com/hubfs/case-studies/close.svg) #### Product **High Flow SupaMesh** #### Client Private Refinery #### Application Pre-treatment of Heavy Gas Oil (HGO) #### Location Singapore #### Value Added Longer Life (x7) , Lower OPEX  #### Sector Crude Oil Refinery ## ***HGO (Heavy Gas Oil) Filtration*** HGO is a critical yet problematic intermediate. It is typically routed to FCC (Fluid Catalytic Cracking) units , Hydrotreaters and Hydrocrackers. The HGO is contaminated with corrosion products, inorganic solids, metals and coke precursors, all of which impact on the efficiency of downstream treatment processes. - Catalyst Fouling  - Pressure Drop Increase - Frequent filter changeouts or cleaning  - Heat exchanger fouling All of which have the consequence of **increased OPEX**. Amazon Filters have a proven track record in substantially reducing OPEX through a combination of fluid analysis and the introduction of the most appropriate filtration technology. At this client in Singapore, Amazon Filters helped improve heavy gas oil filtration performance at a long-established refinery facing persistent short filter life of their 100 micron cartridges. By assessing the contamination profile, reviewing vessel internals, and retrofitting the existing filter housing to accept Amazon **SupaMesh** cartridges, the site moved from frequent (sometimes daily) cleaning interventions to a filter service life of around seven days under the same process conditions. ## Understanding the Problem The client suspected that the problems were associated with an additional feed stream that had a high percentage of wax solids. Detailed particle size and TSS analysis was performed on the feed streams at varying temperatures. This proved that the solid wax component was removed at the process operating temperatures and that the short filter life was down to the dirt holding capacity of the filters installed.  ![PID](https://www.amazonfilters.com/hs-fs/hubfs/PID.png?width=700&height=389&name=PID.png) *Process Flow Diagram showing position of filters protecting downstream FCC catalyst beds.  * The existing filtration system consisted of a 2 housings in duty / standby configuration . Each housing containing 36 x 40" metal mesh filters (single cylindrical wrap design). While this is a low cost filter format it has major drawbacks when on stream life and dirt holding capacity are critical. This is due to the low effective surface area of each filter combined with the fact that they use only a single layer of mesh. The total surface area of the 36 filters only provided a filtration surface area of approximately 4.7 sqm. The original installation and filters are shown below. ![COMPETITVE HGO Filter](https://www.amazonfilters.com/hs-fs/hubfs/COMPETITVE%20HGO%20Filter.png?width=659&height=189&name=COMPETITVE%20HGO%20Filter.png) When the filters reach an operation differential pressure of 1.2 Bar they are removed and cleaned for re-use. The removal and cleaning of 36 filters is and arduous and time consuming task.  ## The Solution Two key areas of improvements were identified.  - Substantially extending the on stream life of the filter system - Minimising the maintenance time required for filter change out  Both of these needed to be achieved with minimum disruption to the process. A review of the existing housing design revealed that the filter sheet (where the filters are located) was a bolted on feature. This provided the opportunity to change to a more efficient filter format without the need to replace the filter housing itself.  A new assembly was designed which could be simply lowered and installed into the existing housing. This featuring only 4 off [**SupaMesh**](https://www.amazonfilters.com/products/filter-cartridges-and-capsules/stainless-steel-filters) HighFlow cartridges to replace the 36 originals.  ![retrofit highlow supamesh with installation](https://www.amazonfilters.com/hs-fs/hubfs/retrofit%20highlow%20supamesh%20with%20installation.png?width=734&height=329&name=retrofit%20highlow%20supamesh%20with%20installation.png) The **SupaMesh** HighFlow filters utilise a pleated construction maximising the available filtration surface area per filter. These 4 filters cartridges provided a 30% increase in surface area compared to the 36 original filters. They also incorporate multiple filtration layers, unlike the original single layer mesh. This maximises dirt holding and consequently on stream lifetime. ## The Results  The new retrofit basket assembly was lowered into the existing housing on site, followed by the installation of the 4 **SupaMesh** HighFlows.  ![d9f26df7-acf5-434a-90ea-619d9869ad81](https://www.amazonfilters.com/hs-fs/hubfs/d9f26df7-acf5-434a-90ea-619d9869ad81.jpg?width=268&height=358&name=d9f26df7-acf5-434a-90ea-619d9869ad81.jpg)![a2562bf4-352a-4912-aeb1-2d4dc7536e85](https://www.amazonfilters.com/hs-fs/hubfs/a2562bf4-352a-4912-aeb1-2d4dc7536e85.jpg?width=267&height=356&name=a2562bf4-352a-4912-aeb1-2d4dc7536e85.jpg)![S9101B filter installation (2)](https://www.amazonfilters.com/hs-fs/hubfs/S9101B%20filter%20installation%20(2).jpeg?width=266&height=355&name=S9101B%20filter%20installation%20(2).jpeg)   The new filter operated along side the original filters in the duty / standby configuration. Over a 6 month evaluation period the new **SupaMesh** installation has consistently delivered up to 7 times the operational life of the originals.   The retrofit solution delivered a clear operational improvement, using the same vessel and without changing the broader process conditions.   - Reduced cleaning frequency from as often as twice per day to around once every seven days.  - The change out and cleaning time for the 4 filters was substantially lower than with 36. The consequence is a freeing up of maintenance resource to concentrate on value added projects. - Retained the existing vessel shell through a retrofit approach (eliminating capital spend and reducing engineering and installation time) - Improved operational reliability for heavy gas oil filtration - Lowered maintenance intervention requirements for the site team - Understanding the reasons for poor performance through fluid analysis is a powerful tool - Be open to introducing new formats or specifications of filters'. Trust the experience of your filter provider - Try to look at the OPEX costs rather than individual piece part costs of filters. It can be very misleading - Installing the correct specification filters in this case resulted in lifetime increasing 7 fold  ![KEY TAKE AWAYS (1)-2](https://www.amazonfilters.com/hubfs/KEY%20TAKE%20AWAYS%20(1)-2.png) ## Let's **get started** We'll make sure you're getting the best out of your filtration system [ Talk to sales ](https://www.amazonfilters.com/talk-to-sales) Applications - [Pharma and healthcare](https://www.amazonfilters.com/industry/pharmaceuticals-and-healthcare) - [Energy](https://www.amazonfilters.com/industry/energy/) - [Water](https://www.amazonfilters.com/industry/water-filtration) - [Food and beverage](https://www.amazonfilters.com/industry/food-and-beverage) - [Chemicals and coatings](https://www.amazonfilters.com/industry/chemicals-coatings) Products - [All products](https://www.amazonfilters.com/products) - [Filter cartridges & capsules](https://www.amazonfilters.com/products/filter-cartridges-and-capsules) - [Filter housings](https://www.amazonfilters.com/products/filter-housings) - [Customised filter housings and skids ](https://www.amazonfilters.com/products/customised-filter-housing-and-skids) - [Retrofits](https://www.amazonfilters.com/replacement-retrofit-filters) - [OEM](https://www.amazonfilters.com/industry/oem-filters)   Legal - [Privacy policy](https://www.amazonfilters.com/legal/privacy-policy) - [Copyright](https://www.amazonfilters.com/legal/copyright) - [Trademark](https://www.amazonfilters.com/legal/trademark) - [Disclaimer](https://www.amazonfilters.com/legal/disclaimer) - [Conditions of sale](https://www.amazonfilters.com/legal/conditions-of-sale) About - [About us](https://www.amazonfilters.com/about-us) - [Global network](https://www.amazonfilters.com/our-global-network) - [Careers](https://www.amazonfilters.com/company-information/careers) - [Compliance](https://www.amazonfilters.com/compliance) - [Blog](https://www.amazonfilters.com/blog) - [News](https://www.amazonfilters.com/company-information/news) - [Contact us](https://www.amazonfilters.com/contact-us) Contact Amazon Filters Ltd. 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