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Magnetic separator technology is the key to minimizing compressor downtime. More than 80 percent of centrifugal gas compressors manufactured today are equipped with dry gas seals. Dry gas seals are a non-contact seal with a running gap of approximately 3 to 4 microns in size between the primary and mating seal rings. Buffer gas is used as a sealing and working fluid for the running gap and any contaminants carried into the gap can cause degradation of performance and eventually failure of the seal. Through chemical analysis, Black Powder has been found to be one of the most damaging contaminates in buffer gas causing seal damage.
"To minimize compressor downtime it is imperative to remove black powder from buffer gas before it can cause damage to the seal," says Roger Simonson, president of One Eye Industries Inc. "Without proper filtration, the result is increased downtime and massive operational loss. Investing in filtration will improve up-time and reduce maintenance costs"
Black powder, consisting mainly of a mixture of iron oxides and iron sulfides, is a solid contamination found in finished product pipelines. Materials such as flash rust from hydro-test water, post internal pipeline corrosion, and carryover from gas gathering all collect to create Black Powder contamination, which may be wet and have a tar-like appearance, or dry and be a very fine powder, sometimes like smoke.
"The removal of black powder contamination from buffer gas will significantly reduce seal damage and may act as a monitoring tool for scheduling maintenance," says Simonson. "Focusing on filtration will improve product purity and quality which will significantly increase value. Application of magnetic separator technology on compressors will improve product quality, production costs and reduce premature wear on process equipment."
Black powder can cause a range of problems, including product contamination, erosion wear in compressors, filter clogging and equipment contamination for consumer products, erosion and sealing problems for valves, and flow reduction. Achieving the level of filtration needed with the use of traditional filters is cumbersome and costly.
"We have designed a system to remove black powder ranging from 100-plus microns to sub-micron sizes," says Simonson. "Protecting seals from contamination should be the primary focus in order to keep your compressor running."
Developed by One Eye Industries Inc., the Black Powder Magnetic Separator System was designed to be a solution to compressor failure caused by black powder contamination in seals. Utilizing rare earth technology, OEI's patented magnetic design, enables highly efficient separation of ferrous and in many applications non-ferrous particles (due to static adhesion) in buffer gas. The design creates multiple powerful compressed magnetic fields that en-circle the magnetic separator element. This technology has enabled for a larger and stronger magnetic field surface area that projects three times further than traditional magnetic fields significantly increasing separation efficiency. The Magnetic Separator elements operate at full strength up to 300 degrees Fahrenheit (150 Celsius) and are highly resistant to vibration and offer over 10 years of service life.
Black Powder Magnetic Separator System highlights:
· Minimal flow restriction
· Removes contamination ranging from +100 microns to sub-micron sizes
· Enhances traditional filters
· Positive return on investment
· Environmentally friendly and HSE compliant (health, safety and environmental management system)
· Extends component life
· Easily cleaned
· Protects bearings, seals, injectors and pumps
· Can be used to schedule/predict maintenance service
About One Eye Industries Inc.
Over the past 14 years, One Eye Industries have designed and manufactured the most advanced environmentally friendly industrial separation and filtration systems on the market. Specializing in magnetic separation for black powder contamination and filtration for rotating equipment, the company’s filters can be used in applications such as lube oil, hydraulics, fuel, transmissions and coolants. One Eye Industries welcomes custom projects with quick turnaround times.