--- title: "Case Study: Cost Effective Pre Filtration for Naptha Hydrotreater" description: Significant Cost reduction on pre filtration for Naptha hydrotreater 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 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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 # Cost Effective Pre Filtration for Naphtha Hydrotreating  ![](https://www.amazonfilters.com/hubfs/case-studies/tag-icon@3x.svg) Oil & Gas [Download PDF](https://www.amazonfilters.com/cost-effective-pre-filtration-for-naptha-hydrotreater#openFormModal) ![](https://www.amazonfilters.com/hubfs/case-studies/close.svg) #### Product **VisClear II** #### Client National Petrochemical Plant #### Application Naphtha Hydrotreater Catalyst Protection #### Location Malaysia #### Value Added Longer Life, Improved Efficiency, Lower Pressure Drops   #### Sector Petrochemical ## ***The Impact of Prefilter Specification on OPEX*** ## Introduction Naphtha hydrotreating is a crucial process in the petrochemical industry, serving the purpose of removing impurities such as sulphur, nitrogen, and metals from naphtha feedstock. Effective filtration is essential for ensuring the longevity of the catalyst and the efficiency of the hydrotreating process. However, several filtration issues can arise, compromising the quality of the treated naphtha and the overall performance of the plant. This case study focuses on the importance of working with a knowledgeable supplier who can both improve the efficiency of the process while delivering reduced OPEX.  Switching from a string-wound format to our [Visclear II meltbown filter](https://www.amazonfilters.com/products/filter-cartridges-and-capsules/depth-filters/visclear-ii) improved the quality of filtrate ( additional catalyst protection in the hydrotreater) while also extending lifetime by 7 times.   Before we look in detail at this particular application here are some areas that are important to look at with respect to filtration. ## Types of Filtration Issues ## **Particulate Contamination** Particulate contamination is one of the primary filtration issues in naphtha hydrotreating. Solid particles, such as catalyst fines, rust, and insoluble organic compounds, can clog filters, reducing flow rates and causing pressure drops. These particles can originate from upstream processes, equipment corrosion, or degradation of the catalyst. **Water Contaminants** Water can be a significant challenge in naphtha filtration. It can cause emulsification with hydrocarbons, leading to difficulties in separation. Water ingress can stem from upstream processes, equipment leaks, or condensation. Effective coalescing filters (**SupaSep LLP**) are necessary to manage water contamination, but they can be overwhelmed if water levels are excessively high. **Organic Contaminants** Organic contaminants, including heavy hydrocarbons and polymeric substances, can foul filters and impede the hydrotreating process. These contaminants can originate from various sources, such as upstream processing units, feedstock variations, or thermal degradation. Their presence can lead to reduced catalyst activity and increased maintenance requirements. **Impact on Process Efficiency** Filtration issues can significantly impact the efficiency and effectiveness of the naphtha hydrotreating process. Clogged filters can lead to increased pressure drops, reduced flow rates, and higher energy consumption. Additionally, insufficient filtration can result in catalyst poisoning, lowering its activity and shortening its lifespan. Consequently, the process may require more frequent shutdowns for maintenance and replacement of filters and catalysts, leading to increased operational costs. ## Consequences of Poor Filtration Choices  Filters are consumable products, and as such the focus for procurement departments is often 'we need to reduce the piece price of this filter'. The consequence of this short sighted approach can lead to multiple problems in production. Here are just a few: - Additional maintenance costs due to more frequent filter change outs - Lost production time. It isn't a quick process to change out filters in a 65 round housing. Up to half a days production could be lost  - Inconsistent performance of filters making it difficult to predict the in-service life or plan for scheduled filter changes  - Cost of stock holding a much higher number of filters - The environmental cost of additional waste  - Poor quality filtrate leading to contamination of catalyst beds on hydrotreater and subsequent substantial maintenance costs ## The Problem  The client initially approached us due to poor delivery times from the incumbent supplier and just wanted us to quote for a like-for-like replacement of the existing low cost string-wound filters. They didn't want to increase consumable costs. We will see later how wrong this type of decision can be! Our approach as a company is always to try and improve the filtration process in terms of on-stream life , filtrate quality and OPEX.  Retrofitting like-for-like, although low risk, essentially negates any chance of process and OPEX improvements. However, in this case it was urgent that the client secured a reliable supply of [oil and gas filters](https://www.amazonfilters.com/industry/energy/oil-and-gas-filtration) to keep the process going. When supply issues are a real problem it is understandable decision.   Our **SupaWind **string-wound cartridge was supplied as a direct retrofit. Whilst performance was equivalent to the original system (filter lifetime 2-4 days when the hydrotreater was running at peak capacity) we felt this was not a viable solution long term.   ![particle report](https://www.amazonfilters.com/hs-fs/hubfs/particle%20report.png?width=699&height=900&name=particle%20report.png) ## Understanding The Problem It is not possible to recommend an improved filtration solution without first understanding the problem. To facilitate this, our specialist Oil & Gas partner in Malaysia ([Diamond Offshore](https://www.diamondoffshore.com.my/)) conducted a comprehensive particle analysis of the process fluid in conjunction with a tear down of the filter following blockage in service. This showed a wide particle distribution and pointed to the requirement for a filter with a superior graded density filtration media i.e. very open structure on the upstream side to maximise dirt holding while providing excellent filtration efficiency through the final layers of media downstream.  ![WhatsApp Image 2025-02-25 at 6.51.03 PM (1)](https://www.amazonfilters.com/hs-fs/hubfs/WhatsApp%20Image%202025-02-25%20at%206.51.03%20PM%20(1).jpeg?width=450&height=800&name=WhatsApp%20Image%202025-02-25%20at%206.51.03%20PM%20(1).jpeg) ## The Solution Filters manufactured by advanced meltblown technology are ideally suited for use in fluid streams where the particle size distribution is wide. In this case, the **VisClear II** filter was installed as it has the added advantage of being extremely robust due to being manufactured with slightly larger diameter fibres than our [SupaGard](https://www.amazonfilters.com/products/filter-cartridges-and-capsules/depth-filters/supagard) range. Due to the elevated temperatures of 100oC nylon meltblown media and hardware was specified.  The filters were installed into the process and checked for condition after 3weeks (compared to 2-4 days with the string-wound variant).  Typically the procedure would have been to change the filters on pressure drop, which is set at 1.0 bar. In this case the filters had been operating for just over 3 weeks and the customer was concerned that bypassing maybe occurring as the results were so good. The filters were removed when the differential pressure was 0.3 bar (still substantial on-stream life left in the filter). They were inspected and found to be fully integral while still affording excellent protection to the catalyst beds within the hydrotreater. The improved performance of the  **Visclear II** has demonstrated not only adequate protection to the hydrotreater but more importantly a 7 times increase in lifetime with associated significant savings in filters consumables and reduction in labour / maintenance costs.  ![shutterstock_2374700419 (1)](https://www.amazonfilters.com/hs-fs/hubfs/shutterstock_2374700419%20(1).jpg?width=500&height=285&name=shutterstock_2374700419%20(1).jpg) - It is a common theme throughout our case studies but .. It is a false economy to install low cost/low specification filters in any system - 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  ## 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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