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Filtration and Separations Technologies for Petroleum Refining Understanding Root Causes... Finding Solutions
Filtration and SeparationsTechnologies for Petroleum Refining
Understanding Root Causes...Finding Solutions
2
Pall helps refiners identifyproblems and apply solutions
Refiners are constantly looking to increaseproduction capabilities, reduce costs, andgenerate increased revenues and profits. Toaccomplish this goal, refiners regularly searchfor new ways to improve efficiency, whilecontinuing to deliver high–quality products atprofitable prices. Pall can play a key role inthis continuous improvement process. Ourproducts and services help optimize productivity,reliability, quality, safety, and environmentalprotection, while reducing overall operatingcosts.
Pall understands the importance of improvingthese key business components. Success herecan directly impact a refiner’s bottom line.
The first step to continuous improvement isto identify problem areas and understand theroot cause. After proper detection and documentation, Pall works to develop asolution to the problem that best utilizes ouradvanced separations and filtration technology.
We put decades of experience and know-howto work to design and implement long lastingsolutions that enable refiners to:• Meet tighter clean fuels product specifications• Meet tougher environmental regulations• Maintain or increase refinery throughput• Lengthen run time• Reduce maintenance
Pall Corporation maintains its position as theworld leader in filtration and separations technology with a steady stream of innovative,high-quality products backed by excellentservice and support. We invest heavily inR&D and technical service to provide therefining industry with exceptional returns ontheir investment.
Our filtration and separations solutions havebeen successfully deployed within refineriesthroughout the world.
Total Fluid ManagementSM
Pall follows a comprehensive, Total Fluid Management approach to identifying and solving contaminationproblems.
Our advanced technologies andservices help refiners:• Increase production• Reduce unscheduled downtime• Meet environmental emission
standards• Reduce corrosion rates, lengthen
plant life, and improve safety• Raise product yield and conversion• Minimize product reprocessing• Enable capacity expansion with
minimum capital expense• Help to debottleneck existing
plants during revamps or cleanfuels upgrades
• Help to utilize opportunity crudes• Enable refiners to meet tighter
product specifications • Lower energy costs• Lower maintenance costs• Protect catalyst beds
Pall offers a full range of high-qualityfiltration and separations systemsthat meet the unique requirementsof the diversified refineries that weserve. We design and manufacturenearly all of our media, elements,vessels, and fully integrated separationssystems. By supplying the broadestarray of polymeric, inorganic, metallic,and ceramic media available, Pall isable to select the optimal filter mediumto meet specific process requirements.
In rare cases, where Pall does nothave an appropriate product, wework with the customer to develop anew, customized product that can
solve the problem. We are eager totake on new challenges and are committed to keeping up withevolving market demands.Pall offers worldwide technologyconsultation and support throughour Scientific and LaboratoryServices (SLS) department. SLS is aworldwide network of scientists andengineers experienced in investigatingand solving various and often complex problems encountered influid clarification and separationprocesses. In addition, a specializedgroup of scientists and engineers issolely dedicated to customers in thepetroleum refining industry. Pall hasstate-of-the-art laboratories locatedthroughout the United States,Europe, and Asia.
All Pall manufacturing facilitiesadhere to uniform manufacturingprocedures and have been grantedInternational Standards Organization(ISO) certification to ISO 9001. Thisensures that Pall filtration and separation products and systems will perform exactly as specified, no matter where they are installed.
Root cause analysis and Total FluidManagement are the principles onwhich we base our success in thepetroleum refining industry. We lookforward to applying our knowledge,technology, and experience to helpyou achieve a higher level ofprocess control and efficiency inyour operations.
Separation ofSolids from LiquidsPages 9-15
Separation ofSolids from GasesPages 16-20
Separation of Liquids and Solids from GasesPages 21-22
Separation ofLiquids from LiquidsPages 23-24
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SLS test facility.
Contents
1 In applications where different options are listed, Pall Corporation willassist project engineers in determining the best filtration solution fortheir situation.
Filtration and SeparationRecommendations
4
The process diagram and corresponding charts illustratetypical applications within a refinery. Processes are detailedwithin the drawing and include major applications. Thenumbered items coincide with the recommendedfilter/separation application tables below. Note: should aparticular concern or filtration/separation application arisethat is not addressed in this brochure, please contactyour local Pall representative for assistance.
Particulate Filters/Backwash Filters1
Application Problem Benefits
Liquid hydrocarbon and Reduced solvent losses and foaming;Aromatics particulates cause foaming improved energy consumption;
and fouling problems. reduced maintenance, labor, and disposal costs.
Solid particulates plug and Improved conversion efficiency deactivate catalyst bed and and profitability; fewer catalyst
Catalyst foul feed exchanger; water can change-outs; improved Protection deactivate some catalysts. conversion/yield; lower
maintenance, labor, and catalyst costs; longer cycle times; lessbackwash fluid reprocessing; extended campaign life.
Refinery final products contain Improved product quality; fewer particulates and water. reprocessing and contamination
Final Product costs; lower maintenance and Filtration disposal costs.
Catalyst fines reduce value of Improved product quality andslurry oil. revenue; reduced critical nozzle
Fluid Catalytic erosion; increased yield; reduced Cracking Unit coke formation in FCC reactor; Slurry Oil less backwash fluid to reprocess;
higher profitability of FCCU.
Amine foaming. Amine losses prevented; sulfurplant operation improved.
Rich / AmineLoop
1
2
3
4
Liquid/Gas Coalescers1
Application Problem Benefits
Hydrocarbon carryover into Minimized or eliminated Amine and amine plant causes foaming, production losses due to sulfur Sulfur excessive amine losses, and plant trips; reduced environmentalRecovery Unit can lead to either reduced license level exceedance; stable
amine plant capacity or impact amine plant operations; and the ability to meet final product increased amine plant capacity.sulfur specifications in fuels. Amine plant upsets; sulfur plant trips; and environmental emissions above license limits.
Fuel gas composition changes Reduced or eliminated routine Refinery rapidly and contains burner cleaning program;Fuel Gas condensable hydrocarbons; improved furnace fine tuning;
liquids and solids will foul, plug reduced fuel gas usage;burners and combusters; low reduced greenhouse gasNOx and ultra low NOx burners emissions; safer furnaceare especially sensitive to operation and on-spec NOxplugging. emissions.
Liquid hydrocarbons and solid Reliable hydrogen compressor Hydrogen contaminants such as corrosion operation; significantly reduced Compressor products or ammonium chloride maintenance and repair costs.Protection in hydrogen gas streams can
lead to premature failure of reciprocating compressor suction and discharge valves, and piston ring failure resultingin H2 compressor downtime and excessive unscheduled maintenance and in some cases can cause lost production.
6
7
8
Liquid/Liquid Separators1
Application Problem Benefits
Off-spec products; high salt or Improved product quality/on-specFinal clay tower usage; corrosion in products; fewer reprocessing andProduct storage tanks. contamination costs; lower Filtration maintenance and disposal costs;
free up tank storage; improved cash flow and fewer delayed shipments.
Water may contain caustic and Improved conversion efficiency Catalyst other solid particulates; plug or and profitability; fewer catalyst Protection deactivate catalyst bed. change-outs; lower maintenance,
labor, and catalyst costs.
Caustic or amine carries over Improved profitability; lower Treating into product stream causing reprocessing costs; reduced
off-spec product; carried-over maintenance and labor costs.caustic can disarm sensitive catalyst.
Desalter upsets can cause oil Less emissions from water Desalter carryover to waste treatment treatment plant; allows debottle-
plant and upset water treatment necking of desalter and reduced plant operation and emissions corrosion rates in CDU overhead; to the environment; desalter improved FCC catalyst yield and upsets or crude charge rate longer FCC catalyst life.increase can cause brine carryover to CDU and result in high corrosion rates in crude overhead; salt in FCC feed can reduce FCC catalyst yield and shorten catalyst life.
Liquid hydrocarbon ingress; More stable Amine systemAmine Unit foaming incidents; upsets at operation, reduced foaming,Protection sulfur plant. longer A/C life; less sulfur plant
trips.
10
11
12
13
14
Blowback Filters1
Application Problem Benefits
Existing equipment is unable to Tougher environmental license Reduced meet tightening emission levels limits met continuously and FCC Particulate required by environmental plant shutdown and/or capacity Environmental authorities for particulate and reduction averted; turbo expander Emissions micro-particle matter. Poor reliability improved dramatically.
reliability of turbo expander and inability to meet desired FCC campaign length of 3-5 years between major repairs or overhaul of turbo expander.
Poor reliability of CCR recycle Reliable CCR operation and CCR gas compressor; high production of H2 and reformate.Recycle Gas maintenance costs; loss of
expensive reformer catalyst.
9A
9B
5
5
Refinery Filtration and Separation Applications
H2
Acid Gas
8
HYDROGEN PRODUCTION
SULFUR RECOVERY
7 Gas
LPG
Naphtha
6
AMINE
Atm
osp
here
Dis
tilla
tio
n Va
cuum
D
isti
llati
on
2 11
C
HYDROTREATING
Fuel Gas
Sour Gas
Sour Gas
7 6
Kerosene & Middle Distillates
2
11
2 11
11
2 ISOMERIZATION
HYDROTREATING 2
11
Fuel Gas
7
H2
Fuel Gas
7
8
HYDROTREATING
Sour Gas DEHYDROGENATION
9A 9B
7
7
Off Gas
Fuel Gas
Fuel Gas
Flue Gas
Gas Oil
132 11
FLUID CATALYTIC CRACKING
9A
To FCC
Coker Gas Oil
COKER
2 11
Fuel Gas
7
Fuel Gas
7
7 Fuel Gas
LUBE OIL PLANT
8
H2 8
5 14
H2 8
Sour Gas
8 MRU
CrudeOil
13
13
Brine
Desalter
6
Sulfur
Re�nery FuelGas
LPG
Gasoline
Benzene, Toluene, Xylene
Gasoline Solvents
Jet Fuel Kerosene
Petrochemical Feedstock GasolineHigher Ole�ns
Gasoline
Gasoline
Gasoline
Slurry Oil
Jet Fuel, Diesel
Coke
3 10
7
3 10
3 10
3 10
3 10
3 10
3 10
3 10
3 10
4
3 10
Stack TAIL GAS TREATING
Fuel Gas H2
12AMINE
11
7
ISOMERIZATION
CATALYTIC REFORMING
8
Fuel Gas 7
1 AROMATICS EXTRACTION
Fuel Gas Benzene
HYDROTREATING
7
12
Fuel Gas
H2
HYDROCRACKING
7
8
CAUSTIC TREATING
MeOH
MTBE
ALKYLATION
2 112
12
2
5
H2 8
Lube Oil Basestock 3
3
9B
7
Understanding Root Causes . . . Then Applying Filtration andSeparations Technology
Open here to review filtration applications found in refineries.
t
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With an extensive portfolio of filtration and separation products,Pall can help refineries improve fluidquality and increase profitability byoptimizing the performance of theirprocessing equipment. Many of Pall’sproducts were developed specificallyfor the refinery industry, in collaboration with our customers.
Our close relationship with refinersand process licensors has helpedPall understand current and futureneeds. Our awareness and dedicationto this market has fueled our productdevelopment programs and sharpenedour technical and scientific skills. As aresult, Pall is continually introducingnew products to help improve theproduction and efficiency of ourcustomers’ operations.
Pall’s advanced technologies include:
Products that Meet Refiners’ Needs
Pall’s filter media.
Separation ofSolids from Liquids
Separation ofSolids from Gases
Separation of Liquidsand Solids from Gases
Separation ofLiquids from Liquids
At the heart of every filtration andseparation system is the mediumwhich performs the separation. Pallmanufactures 21 distinct families ofmedia, providing over 150 grades ofpolymeric, inorganic, metal, andceramic filter products and phaseseparation systems. This allows Pallto supply high-quality products withthe appropriate medium and gradefor specific refinery applications.
Details of each technology can befound in the sections that follow.
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A variety of filtration methods can be used for solid/liquid separationsdue to the differing concentration ofsolids in liquid streams. For highsolids loading, a backwash systemmay be the optimum filtration solution, while disposable filterswould be used for lower solids loading applications. In some cases,removal of solids may require a combination of backwash technologyfollowed by a disposable filter forpolishing. Regardless of the amountof solids present in the liquid, Pallcan provide a product or combinationof products to achieve optimumperformance and economy.
Pall originally developed backwashtechnology in the 1960’s in response tothe needs of hydrogenated chemicalproducers. This technology was introduced to refiners and started togain acceptance in the late 1980’swhen refiners needed to upgrade thevalue of slurry oil in Fluid CatalyticCracking (FCC) units by removingcatalyst fines.
Today Pall’s advanced backwashtechnology is used in other refiningprocesses for the purpose of extendingthe life of fixed bed catalyst reactorsand improving conversion inhydrotreaters and hydrocrackers.Pall’s backwash systems offer significant benefits over conventionalwedgewire systems that can be usedto protect fixed bed catalyst reactors.
Separation of Solids from Liquids
Pall’s backwash systems have extremely low operating and maintenance costs comparedto other technologies such as electrostatic separators and hydrocyclones.
Separation of Solids from Liquids
Backwash Filters
• PSS® sintered powder stainlesssteel filters• PMF™ metal fiber filters• Rigimesh® sintered woven wiremesh filters• AccuSep® sintered stainlesssteel filters
Disposable Filters
• Profile® II depth filters• Ultipleat® filters with Profiledepth filter media• Marksman™ pleated filters• Nexis® melt blown filters • Claris® melt blown filters• Duo-Fine® pleated filters withmicrofiberglass media• Hi-V® resin bonded filters • Pleated filters with Epocel®
medium, Ultipor® GF Plus medium, HDC® II medium• Profile Coreless melt blown filters • Ultipor HT filters • High Flow filters
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Backwash SystemsA backwash system is designed toremove and/or collect suspendedsolids from a liquid process streamwhile periodically regenerating itself.A porous filter medium with suitablepore size will efficiently collect solidson its surface, where they form a permeable cake. During backwash, a reverse flow will be initiated at a predetermined filter pressure dropand/or time interval, discharging thecollected solids to recovery. The filterwill then be returned to full forwardflow. Its pressure drop just after backwash will remain essentially constant through backwash cycles.
The efficient operation of Pall backwashsystems require high standards in vesseldesign, tubesheet assembly, piping,instrumentation, and valve selection. Atthe heart of the system is Pall’s filtrationmedia. With a variety of porous filtermedia available, both metallic and nonmetallic, and backwash techniques,Pall’s backwash systems are designed and optimized for specific refineryapplications.
For example, many hydrotreaters usebackwash filters to remove solidsfrom the feed and protect the feedexchanger and catalyst bed. In thepast, wedgewire media was used forthis purpose. However, this media onlyprovides about three to five percentvoid volume in this application.Replacing the wedgewire elements in the filter vessel with Pall Rigimeshelements provides approximatelyseven times higher void volume andtwice the filter area. An upgradeshould be based on a need for finerfiltration and higher throughputs priorto backwash cycles. Retrofits andnew, scaleable systems are available.
Rigimesh medium — approximate void volume =30%.
Typical wedgewire element — approximate voidvolume =4%.
Backwash Systems vs. Other Technologies
Rigimesh Medium vs. WedgewireBenefits of Pall’s
Backwash Systems
• Longer run times between fixedbed catalyst change-out• Higher throughputs• Lower differential pressure• Longer cycle time betweenbackwash regeneration• Lower utility costs• Significantly reduced backwashfluid reprocessing cost (up toseven times less backwash fluidto reprocess)• Payback in less than one year• Extremely low cost of operationvs. wedgewire systems
Pall Backwash Electrostatic Wedgewire Hydrocyclones Sand BedsSystem Separator
Efficiency High Medium and Low Medium LowVariable
Solids-Loading High Medium Low High HighCapability
Operating and Very Low High Very High Low LowMaintenance Cost
Backwash Fluid <2% >10% 2-20% 6% 1-2%Requirement vs.Throughput
Sensitivity to None Very High None None NoneFlow Rate Change
Temperature Range High Low High Medium High
Reliability and Safety High Medium Low Medium Mediumof Operations
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Benefits of Pall’s Gas AssistBackwash Systems
• Longer catalyst life• Reduced incidence of “off-spec” product• Low reprocessing and/or disposal costs due to low volume of backwash fluid• Low maintenance cost forvalves and control equipment• Infrequent “out-of-vessel” element cleaning
Gas Assist Backwash MethodThe gas assist backwash method isused when process flow rates arehigh or continuous, and uninterruptedflow is required. For backwash, onevessel is isolated and the downstreamside of the vessel is pressurized witha controlled quantity of filtered airor other suitable gas. The vesseldrain port is rapidly opened, resultingin a hydraulic pulse that “bumps” thecollected solids from the filter surface.Forward flow is restored to the vesseland the remaining filter vessels arebackwashed sequentially.
During gas assist backwash, theexpanding gas bubble forces theliquid through the elements in thereverse direction (inside-out) at avelocity as high as seven times thenormal forward flow velocity. Thiseffectively dislodges the accumulatedcake from the elements, while significantly reducing the volume ofliquid required. Thus, the concentrationof the solids discharge is high.
Refineries receive a high return on investment after installing Pall’s backwash filters to protect catalyst beds and to remove catalyst fines from FCCslurry oil.
ProcessOut
BackwashGas In
ProcessIn
Solids Recovery
• One or more vessels
• Isolate one vessel for backwash
•A compressed volume of gas provides a high-velocity reverse flow of liquid remaining in vessel
Gas Assist Backwash System
Separation of Solids from Liquids
Combining the gas assist backwashwith the high dirt-holding capacity ofPall’s backwash media results in longcycle times between backwashingand reduced reprocessing costs whichsubstantially improve unit economicsover the life cycle of the equipment.
AccuSep Sintered MetalFilters
AccuSep sintered metal filters aremade of sintered stainless steel, in a seamless tubular format. AccuSepelements are produced by a proprietary process which creates ahigh void volume in a strong andvery uniform medium. The mediumis relatively thin, resulting in a structure that is up to three timesmore permeable than most conventional pressed sintered metal tubes.
Metallic Backwash Filters
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PSS Porous Metal Filters
Manufactured of sintered stainlesssteel powder, the PSS “S” mediumoffers exceptionally uniform permeability and absolute removalefficiencies.
PSS elements are seamless in construction with a very high void volume (up to 60% in some grades).This provides very high dirt-holdingcapacity and low pressure loss, especially in very fine grades, whichpermit design at high flux to helpreduce capital costs.
In addition to the standard productmade from 316L stainless steel, we supply PSS medium in Inconel2, nickel, nickel molybdenum, and aluminide alloys.
PMF Metal Fiber Filters
PMF filters are manufactured of finediameter 316L stainless steel fibersthat are sintered at their points ofcontact to produce a uniform,strong, tapered-pore medium. Thismedium provides remarkably highdirt-holding capacity, with one ormore inner layers providingabsolute-rated filtration.
Rigimesh Stainless SteelWoven Wire Mesh Filters
Pall’s proprietary process permits theuse of finer-diameter wires in themanufacturing of Rigimesh stainlesssteel woven wire mesh filters. Theresult is low pressure drops, morepores per unit area, and better dirt-holding capacity than other wovenmetal filters.
The medium is sintered for improved tensile, yield, shear, and fatiguestrength. Rigimesh filters maintain a uniform pore size and exhibit nomedia migration, even under hightemperature and pressure conditions.
2 Inconel is a registered trademark of SpecialMetals Corporation.
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10000
5000
2000
1000
500
200
100
50
20
10
5
2
1
Filtration Ra
tio Beta
5 10 15 20 25 30Particle Size (µm)
Effic
iency %
99.99
99.98
99.9
99
50
W2
W1
Filtration beta ratio of Profile II filters (P200) and two competitive polypropylene depth filtersrated at 1 µm nominal.
Performance Comparison - Profile II Filters vs. Competitive Depth Filters
Separation of Solids from Liquids
P200
Filtration Beta Ratio Comparison -Profile II Filters vs. Competitive Depth Filters
Liquid DisposableFiltersWhen the solids concentration is relatively low (10 ppm), Pall’s disposable filters will efficiently andeconomically remove solids from liquid streams. Disposable filters canbe used to remove solids from finished refinery products and fromsolvents such as amine and sulfolane.
Pall’s disposable filters are characterized by high dirt-holdingcapacity and lot-to-lot uniformity.Our filters provide long service lifeand improved protection for equipment and personnel. They aredesigned to prevent both unloadingof trapped particles and mediamigration. The filters are self-aligningin Pall’s vessels, with positive sealing to eliminate fluid bypass.
Benefits of Pall’sDisposible Filters
• Gradient of pore sizes for full utilization of the filter• Strength and durability to withstand changing processconditions• Chemical and thermal compatibility with process conditions to ensure long life• Absolute-rated3 for reliable,reproducible performancebacked by documented performance data• Cost-effective, nominally-ratedfilters are available for less critical applications
3 An absolute rating is defined as Bx=5000as measured utilizing the widely acceptedmodified OSU F-2 test.
Filter Brand
Particle Size Profile II Filter W1 W2(µm) (P200) Wound Filter Spun Depth Filter
20 µm Absolute 1 µm Nominal 1 µm Nominalß20 = 5000 ß1 = 1 ß1
Percent Removal Efficiency
0.5 NA NA NA
1 NA NA NA
2 <50% <50% <50%
4 75% 75% 50%
10 95% 95% 87.5%
25 >99.98% 96.7% 93.3%
50 >99.98% 98% 96%
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Liquid Disposable Filters
Profile II FiltersProfile II filters are available inpolypropylene, nylon or polyphenylenesulphide (PPS) media. These elementshave an upstream continuously gradedpore section and a downstreamabsolute-rated section, which increasesservice life many times.
These filters are suitable for a widerange of applications, involving bothcorrosive and non-corrosive fluids.Profile II filters are ideal for prefiltrationand final filtration.
Epocel FiltersEpocel filters have a pleated, high-areaconstruction which provides long servicelife and consistent production. Constructedof epoxy-resin-impregnated cellulose,this fixed-pore construction eliminatesunloading and media migration. Epocelfilters provide a broad range of chemicalcompatibility and are recommended forthe clarification of a wide range of fluidsand gases.
Ultipor GF Plus FiltersThe Ultipor GF Plus medium consists of resin-bonded glass fibers supportedby upstream and downstream polymericsubstrates. This unique constructionprovides for a strongly bonded, migration-free, high dirt-holding capacity medium.Ultipor GF Plus filters are used successfullyin a variety of refinery applications.
HDC II FiltersHDC II filters are constructed of allpolypropylene pleated media. These filtersfeature a high area, high dirt-holdingcapacity, and extended service life. HDCII filters are ideal for use in applicationswhere economy and reliability are crucial.
Claris FiltersClaris filters are polypropylene meltblown filters. Claris filters feature an E-core, Extruded Fibrous Core, structurewhich provides excellent strength. Theirgradient pore structure enhances theirdirt-holding capacity. Claris filters featurean all polypropylene construction for easyand safe filter incineration and disposal.
Hi-V FiltersHi-V filters are resin-bonded disposablefilters designed for highly viscous fluids.Hi-V filters use wound resin impregnatedfibers that are four to six inches in length,much longer than typical molded filterswhich use fibers of less than one-eighthinch.
Hi-V filters feature high flow rates, highcontaminant-holding capacity, no centercores, and reliable, consistent filtration.
Profile Coreless FiltersProfile Coreless filters are absolute-ratedfilters used to filter gases or liquids. Theyhave high capacity, low cost, and areideal for applications such as amineloop filtration, compressor protection,or final product filtration. The corelessconstruction allows for easy and safe filter incineration and disposal.
Profile UP FiltersThe unique Ultipleat (U) crescent-shapedconstruction of the Profile (P) depth filterprovides longer life than most pleatedpolypropylene filters. Optimized for theremoval of gels and other viscous fluids,the Profile UP depth filter providesexcellent chemical compatibility withlow extractables. These filters are theappropriate choice for a wide range ofapplications in the refining industry.
Ultipleat High Flow FiltersUltipleat High Flow filters are coreless,large diameter, single open-ended, pleatedfilters with an inside-to-outside flow pattern.These filters utilize Pall’s proprietary,crescent-shaped pleats and are availablein a range of materials. The UltipleatHigh Flow filters come in diameters of152.4 mm (6 in) and lengths from 508-2023 mm (20-80 in). Ultipleat High Flowtechnology enables the use of considerablyfewer filters and smaller housings forhigh flow rate applications.
Ultipor HT FiltersUltipor HT filters are pleated, high areaelements designed for long service life.The unique medium structure is a high temperature composite. The filtersare qualified for use up to 218˚C/425˚Fwith compatible fluids.
Designed specifically for high temperatureapplications and well suited for manyrefinery applications, these high temperature filters are used to processtough oil fractions, containing fine suspended solids typically found inprocesses related to desulfurization andfuels upgrading. Filter operability athigh temperatures can often mean elimination of intermediate tanks forproduct cooling and save energy onproduct reheating costs upstream of thehydroprocessing units.
Nexis FiltersNexis high-efficiency depth filters aremanufactured using an advanced,microprocessor-controlled, Co-locatedLarge Diameter (CoLD Melt™) productionprocess. This proprietary process allowsthe creation of multiple filtration zoneswithin a single filter cartridge. The benefitsinclude: efficient contaminant removal,long service life, and improved strength.
Duo-Fine FiltersDuo-Fine filters are high-capacity pleatedfilters with microfiberglass media. Themicrofiberglass media provides exceptionaldirt-holding capacity for long service life.
Duo-Fine filters are available in a varietyof core options to satisfy a wide-rangeof temperature compatibilities.
Marksman FiltersMarksman filters are available as high-capacity, pleated, depth filters orhigh-capacity melt blown filters. Thesefilters feature a large 152.4 mm (6 inch)diameter, high surface area, and highflow capacity. Marksman filters areavailable in a variety of grades and sizesto meet specific application requirements.
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Separation of Solids from Liquids
16
Separation of Solids from Gases
Pall continually develops state-of-the-art technology for solid/gas separationto deal with aggressive environments,extreme temperatures, and high contaminant concentrations. Pall hasworked with both refiners and processlicensors to develop blowback systems that efficiently separatesolid particulates from gas streams.
A filter medium with sufficientlysmall pores is selected for this application. Solids form a permeablecake on the filter’s surface that is dislodged at a predetermined pressuredrop (a function of cake thicknessand compressibility) by initiating areverse pulse (blowback). The dislodged solids are purged from the filter system, where they may bereturned directly to the process forreuse, or removed from the processstream and sent to a storage or collection unit. The filter is thenreturned to full forward flow and toan initial pressure drop that remainsessentially constant through repeatedblowback cycles.
Pall’s blowback systems use eitherporous metal composite or ceramicfilters. The comprehensive capabilitiesof Pall’s blowback systems are high-lighted in the chart to the right.
Blowback Systems vs. Other Technologies
Pall’s blowback filter system in operation.
Blowback Filters
• PSS sintered powder stainless steel filters• PMF metal fiber filters• Rigimesh sintered woven wiremesh filters
Gas ParticleDisposable Filters
• Pall pleated filters with UltiporGF Plus medium, HDC II medium, or Epocel medium• Ultipleat filters with Profiledepth filter media• Profile II filters• Profile coreless filters
Pall Blowback Cyclone Baghouse Scrubber ElectrostaticFilters Precipitator
Efficiency of Solid Separation >99.99% 98% 99.9% 99% 99%from Gas Stream
Separation Efficiency Varies No Yes No Yes Yeswith Solids Loading
Relative Operating Medium Medium Medium High LowPressure Drop
Maximum Operating 899˚C 1093˚C 232˚C 232˚C 482˚CTemperature (1650˚F) (>2000˚F) (450˚F) (450˚F) (900˚F)
Sensitivity to Changes Insensitive Very Some Very Very in Flow Rate Sensitive Sensitivity Sensitive Sensitive
Precooling Required Upstream of No No Yes Yes YesSolid Separation Device
Solids-Loading Reduction Prior No No Yes Yes Yesto Final Separation Required
Reliability and Safety of High High Low Medium MediumOperation
Blowback Filters
PSS Porous Metal FiltersManufactured of sintered stainlesssteel powder, the PSS “S” mediumoffers exceptionally uniform permeability and absolute removalefficiencies.
PSS elements are seamless in construction with a high void volume(up to 60% in some grades). Thisprovides high dirt-holding capacityand low pressure loss, especially infine grades, which permit design athigh flux to help reduce capital costs.
In addition to the standard productmade from 316L stainless steel, wesupply PSS medium in Inconel, nickel, nickel molybdenum, and aluminide alloys.
PMF Metal Fiber FiltersPMF filters are manufactured of finediameter 316L stainless steel fibersthat are sintered at their points ofcontact to produce a uniform,strong, tapered-pore medium. Thismedium provides exceptionally highdirt-holding capacity, with one ormore inner layers providingabsolute-rated filtration.
Rigimesh Stainless SteelWoven Wire Mesh FiltersPall’s proprietary process permits theuse of finer-diameter wires in themanufacturing of Rigimesh stainlesssteel woven wire mesh filters. Theresult is low pressure drops, morepores per unit area, and high dirt-holding capacity.
The medium is sintered for improved tensile, yield, shear, and fatiguestrength. Rigimesh filters maintain auniform pore size and exhibit nomedia migration, even under hightemperature and pressure conditions.
Dia-Schumalith® CeramicFiltersDia-Schumalith ceramic filters arebetter suited for applications requiring higher temperatures andgreater corrosion resistance thanmost sintered metal alloy filters. The silicon carbide support bodyand alumina membrane of the Dia-Schumalith filter ensures a low differential pressure at high flux rates.
Dynalloy® Stainless SteelFiltersDynalloy filters are made of depth-type, stainless steel fibermedia manufactured under strictISO 9001 quality control measures.
Fabrication begins with the manufacturing of discrete micronsize fibers. A uniform mat of thesefibers is constructed in a randomlylaid orientation. The mat is compactedand sintered (metallurgically bonded)to provide strength and integrity.The result is a high void volume,closely controlled pore size mediaideal for corrosion-resistant applications.
17
Separation of Solids from Gases
18
Epocel FiltersEpocel filters have a pleated, high-area construction which provideslong service life and consistent production. Constructed of epoxy-resin-impregnated cellulose, thisfixed-pore construction eliminatesunloading and media migration.Epocel filters provide a broad rangeof chemical compatibility and are recommended for the clarification of a wide range of fluids and gases.
Ultipor GF Plus FiltersThe Ultipor GF Plus medium consistsof resin-bonded glass fibers supportedby upstream and downstream polymeric substrates. This uniqueconstruction provides for a stronglybonded, migration-free, high dirt-holding capacity medium. UltiporGF Plus filters are used successfullyin a variety of refinery applications.
HDC II FiltersHDC II filters are constructed of allpolypropylene pleated media. Thesefilters feature a high area, high dirt-holding capacity, and extendedservice life. HDC II filters are idealfor use in applications where economy and reliability are crucial.
Gas Particle Disposable Filters
Ultipor HT FiltersUltipor HT filters are pleated, higharea elements designed for longservice life. The unique mediumstructure is a high temperature composite. The filters are qualified for use up to 218˚C/425˚F with compatible fluids.
Profile Coreless FiltersProfile Coreless filters are absolute-rated filters used to filter gases orliquids. They have high capacity, lowcost, and are ideal for applicationssuch as amine loop filtration, compressor protection, or final product filtration. The coreless construction allows for easy andsafe filter incineration and disposal.
Profile II FiltersProfile II filters are available inpolypropylene, nylon or polyphenylene sulphide (PPS)media. These elements have anupstream continuously graded poresection and a downstream absolute-rated section, which increases servicelife many times.
These filters are suitable for a widerange of applications, involvingboth corrosive and non-corrosivefluids. Profile II filters are ideal forprefiltration and final filtration.
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Jet Pulse Blowback MethodThe jet pulse blowback methodeliminates the need for large vesselisolation valves. Full forward flow is maintained at all times. Groups of elements are blown backsequentially by directing a high-pressure pulse of gas into the throatof each element. The pulses lastbetween 0.1 and 1.0 seconds, at twoto three times the process pressure.During this period, the flow to theelements being cleaned is reversedmomentarily by a high-pressure jetpulse. The shock wave set up bythe reverse pulse, enhanced by theventuri in the element throat, effectively removes the accumulatedcake from the elements.
Pall’s blowback filters are used to remove catalyst fines from vent gas.
•One or more vessels
•Full forward flow maintained
•Groups of elements blowbacksequentially
•Forward flow overcome by high-pressure pulse in reverse flow.
Short duration (0.1 to 1.0 seconds)
Pall’s Blowback System
Process Out
Solids Recovery
Process In
Blowback Gas
Separation of Solids from Gases
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Pall’s blowback systems are used in many applications. A few of themore common ones are listedbelow.
Catalytic ReformingPall’s blowback systems are used in catalytic reforming units where catalyst is continuously regeneratedto protect against erosive wear andfouling of the recycle gas compressor.These systems filter the elutriationgas that is recycled back to theregenerator. For this application,Pall’s PSS porous stainless steel filters (rated one micron in gaseousservice) with jet pulse (blowback)in-situ cleaning are used. PSS filtershave been installed successfully atrefineries throughout the world.
Catalytic CrackingBlowback systems used to removecatalyst fines from FCC flue gasallow the refiner to:• Meet emission guidelines• Fully protect downstream process
equipment.
The current permissible particulateemission for a fluidized-bed catalyticcracker (FCC) globally is <50 mg/Nm3.This mark is moving to <40 mg/Nm3
for the world, and in some cases aslow as 10 mg/Nm3 for given countries.
Depending upon the economics ata specific refinery, there are severalblowback options:
A) Where turbo expanders are in service – a hot gas filter is recommended upstream of theexpander to maintain maximumpower recovery and extend turbineblade life.
In hot gas applications (up to850ºC/1560ºF) as related to coal gasifiers and fluid bed coal combustors
with an even more corrosive and hotterenvironment than FCC,Pall’s PSS porous stainlesssteel filters or Dia-Schumalith ceramic filters have proven tobe efficient and reliable.Unlike cyclones, theremoval efficiency ofPall blowback filtersremains constant duringvariations in gas flow rate.
B) If turbo expandersare not used – PSSclean-in-place blowbackfilters are recommendedto consistently meet emission guidelines.
The removal efficiencyof PSS filters remains constant during flowsurges (upset conditions)and is not affected bychanges in the electrostaticcharge of the particulatematter, as is the case with electrostatic precpitators.
C) If third- and fourth-stagecyclones are in place, replacing thefourth-stage with PSS filters willimprove solids capture, which maybe sufficient to meet emissionguidelines with minimum capitalinvestment.
The use of fourth-stage blowbackfilters has proven to be the mostcost-effective way to meet <50 mg/Nm3
emissions in FCC flue gas applications.
D) FCC hopper vent filters can beused to reduce fugitive emissionsduring catalyst loading/unloadingand transfer.
Dehydrogenation ProcessesPSS porous stainless steel filtersprocess the catalyst regenerator off-gas at dehydrogenation plantsoperating fluid bed reactors. Pall’sblowback system reduces particulate emissions in a singlestep, to levels at or below regulatoryguidelines. Older plants had usedtwo stages of cyclones followed byflue gas scrubbers to reduce suchparticulate emissions.
Filter tubesheet assembly installation
Pall’s SepraSol™ liquid/gas (L/G) coa-lescers have been used in refineriesand gas processing plants for morethan thirty years. Pall’s liquid/gascoalescers provide maximum liquidand solid removal at low saturatedpressure drops to reduce mainte-nance and operating costs associat-ed with contaminated gas. Theelement’s highly effective filtrationarea and glass fiber resin-bondedpleated cartridge construction is surrounded by non-woven polymericsupport and drainage layers. Thecoalescer is rated at 0.3 µm (99.99%removal efficiency) for solid particles,and produces downstream liquidaerosol concentration as low as0.003 ppmw. These specificationsensure long service life, minimizedoperating costs and minimal laborrequirements, as well as greatlyimproved equipment reliability.
Pall’s liquid/gas coalescers merge,or coalesce, small droplets of liquidinto larger drops. A gas is forced toflow through several layers of filtermedia, each layer having a progressively larger mean poreopening. As droplets compete forthe open pores, they coalesce, andthe process continues until the larger drops continually collect and drain into a collecting sump.
Pall’s liquid/gas coalescers removevirtually all liquids in gas streams(down to 0.003 ppmw liquid in the effluent gas). In addition, Pall’s liquid/gas coalescers have a proprietaryoleophobic/hydrophobic treatmentthat ensures efficient removal andquick recovery from process upsetsthat send slugs of liquid downstream.
Separation of Liquids and Solids from Gases
Liquid/Gas Coalescers vs. Other Technologies
Pall’s liquid/gas coalescers remove liquids and solids from hydrogen and fuel gas, protectingturbo machinery and combustion equipment.
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Separation of Liquids and Solids from
Gases
Liquid/Gas Coalescers
• SepraSol liquid/gas coalescers• SepraSol Plus liquid/gas coalescers• SepraSol Double Open-endedliquid/gas coalescers
SepraSol High Mist Vane Cyclonic Knock-outEfficiency L/G Eliminator Separator Separator DrumCoalescer
Smallest Liquid <0.1 5 10 10 300Droplet EfficientlyRemoved (Micron)
Relative Operating Low Medium Medium Medium LowPressure Drop
Sensitivity to Low High Medium Medium MediumIncreased Liquid Loading
Sensitivity to Medium High Medium Medium MediumIncreased Flow Rate
Sensitivity to Low High High High Low “Turn-Down”
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Chemically treating the medium can significantly increase the flow per cartridge.
Liquid
Droplets
in Air
FlowDrops Fall
Due to
Gravity
Small Liquid Droplets Coalesce to Form Large Drops
COALESCING
Coalescing Mechanism
Small droplets coalesce to form largedroplets.
DropsFallDue toGravity
Effect of Chemical Treatment on Coalescer Performance
Treated ElementUntreated Element
0% 25% 50% 75% 100%
Dow
nstre
am O
il Co
ncen
tratio
n (p
pmw
)
Percent Maximum Flow Rate
0.020
0.010
0.000
LiquidDropletsin GasFlow
≈ ≈ ≈
5.00
Pall’s liquid/gas coalescers are usedin many applications. A few of themore common ones are listed below.
Hydrogen Recycle GasCompressor ProtectionPall’s liquid/gas coalescers areinstalled in front of hydrogen compressors to prevent costlyunscheduled downtime. Refinershave been able to extend regularmaintenance schedules by installingliquid/gas coalescers upstream ofthe compressors. Because refineryhydrogen streams are particularlyprone to changes in purity and liquidconcentration, Pall’s oleophobic/hydrophobic treatment is extremelybeneficial in this application.
Burner ProtectionLiquid and solid contamination infuel gas streams is a universal problemfor refineries. By removing suchcontaminants, liquid/gas coalescerssignificantly reduce the maintenanceassociated with plugged burner tipsin process furnaces. Low NOx andUltra Low NOx burners are evenmore susceptible to plugging. Becausethe concentration of liquids in fuelgas can change instantaneously, Pall’soleophobic/hydrophobic treatmentagain is particularly beneficial.
Lube Oil RecoveryMost compressors have an oil lubricating system. Lube oil is oftendischarged into the process gas inaerosol form. A liquid/gas coalescerplaced at the discharge of a compressorwill recover the lube oil and preventcontamination of downstream catalyst,desiccant, and activated carbon beds.
Molecular Sieve / PSA ProtectionMost mol sieves or PSA’s used fordrying process streams are sensitiveto free water which increases regeneration frequency and reducesthe life of adsorbents. SepraSol L/G
Liquid / Gas Coalescers for Optimum PerformancePall’s liquid/gas coalescers perform with maximum removal efficiency andeconomy that reduces equipment downtime, labor and maintenance costs.Pall’s unique filter medium provides single-stage coalescing, separating liquid aerosols smaller than 0.1 micron in size. Pall’s proprietary coalescertreatment improves the drainage of liquids through the coalescer, enablingthe use of smaller assemblies and minimizing up-front capital costs. Thetreatment also lowers operating costs by operating at a lower liquid saturatedpressure drop and by recovering quickly from process upsets.
coalescers are recommended toprotect mol sieves / PSA’s on isomerization units, polypropyleneunits or in hydrogen plants forhydrogen purification.
Gas Treating Processes / SulfurRecoveryIn amine treating units, foaming canbe initiated by liquid hydrocarboncontaminants in the feed gas.Installation of a liquid/gas coalescerupstream of the amine contactor
can reduce the costs associatedwith foaming such as reduced processing capacity and increasedamine losses. Liquid/gas coalescerscan also recover any amine that iscarried over into the acid gas goingto the sulfur plant or the sweet gas.By reducing upsets in the amineplant, the sulfur plant can be protected from upsets and the number of trips or incidences ofoff-spec sulfur can be reducedalong with a reduction in environmental emissions.
Separation of Liquids from Liquids
Pall’s AquaSep Plus and PhaseSep coalescers are the most cost-effective technology for liquid/liquidseparation compared to other methods, including tank settling, electrostatic precipitation, saltdrying, sand filtration, and coalescing by mesh pads.
When refinery customers alerted Pallto recurring problems with hazy fueland caustic carryover, Pall workedwith them to provide a long-termsolution. As a result, Pall developedtwo new products – the AquaSep®
liquid/liquid coalescer and thePhaseSep® liquid/liquid coalescer.Pall consulted with its customersduring every step of the productdevelopment cycle to ensure that thenew products would meet their needs.
Today, AquaSep Plus coalescers andPhaseSep coalescers are installed inrefineries throughout the world andare used in a variety of applicationsincluding:
• Removal of water from gasoline,diesel, kerosene, and jet fuel
• Protection of catalysts and adsorbentsfrom water contamination
• Removal of carried-over causticfrom caustic treating processes
• Removal of carried-over aminefrom LPG
• Removal of H/C from amine• Protection of salt driers and clay
towers
Pall’s AquaSep Plus coalescer andPhaseSep coalescer are multiple-stagesystems. These systems first removeparticulate matter, then coalesce andseparate the water or liquidcontaminant from a hydrocarbonstream. An AquaSep Plus coalesceror PhaseSep coalescer can removeentrained water to a level at orbelow 15 ppmv.
Pall’s PhaseSep liquid/liquid coalescerhas been demonstrated to reducethe sodium concentration downstreamof a caustic treating unit to below0.5 ppmw of sodium. In addition,
Liquid/Liquid Coalescers
• AquaSep Plus liquid/liquid coalescers• PhaseSep liquid/liquid coalescers• Small flow liquid/liquid coalescers• Lucid™ liquid/liquid separators
Pall’s liquid/liquid coalescersdo not disarm in the presenceof surface active agents in thefuel.
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Separation of Liquids from Liquids
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Unique Stack DesignPall’s AquaSep Plus coalescers andPhaseSep coalescers are stacked ontop of a separator element. Thisproprietary stacking method optimizesthe flow distribution from the coalescer to the separator, ensuringthat each separator has equal flow.In conventional two-stage systems,the separators are located at differentdistances from the coalescer, causingunequal distribution of flow to theseparator. Also, conventional two-stage systems require several coalescerelements for each separator. Pall’sstack design results in an overallsmaller assembly size and a longercoalescer/separator life.
Low Interfacial Tension (IFT)The ability to remove waterimproves as the IFT between thetwo phases increases. The IFTeffectively measures the stability ofan emulsion or dispersion. The IFTis a critical factor when consideringliquid/liquid coalescence becausethe largest possible stable dropletsize that will form by the coalescenceprocess will be dictated by IFT. Asystem with a high IFT (> 20 dyne/cm)can sustain a large stable coalesceddroplet size. Systems with low IFT(i.e., water in fuels with additives < 20 dyne/cm) form smaller stablecoalesced droplets and require ahigh-efficiency coalescer/separator.
DisarmingSurfactants in fuels have a tendencyto form fuel/water hazes and candegrade the performance or disarmconventional glass fiber coalescers.Pall’s liquid/liquid coalescers do notcontain glass fiber, instead they areconstructed of polymeric material usinga unique proprietary process. This resultsin a long, reliable, low-maintenanceservice life when compared to conventional liquid/liquid coalescers.Pall’s liquid/liquid coalescers areimmune to disarming caused by surface active components likenaphthenate or sulfonate carryover,or the addition of corrosion inhibitors,dispersants, and static dissipators.
AquaSep Plus and PhaseSep Liquid/Liquid Coalescer
Liquid/Liquid Coalescers vs. Other Technologies
AquaSep Plus/PhaseSep liquid/liquid separation system with coalescer/separator stack in a vertical housing.
PrefilterAquaSep Plus/
PhaseSepCoalescer
Separator
Outlet
DrainInlet
AquaSep Plus Liquid/Liquid Coalescers andPhaseSep Liquid/Liquid CoalescersAquaSep Plus liquid/liquid coalescers and PhaseSep liquid/liquid coalescerswere developed to efficiently separate very stable liquid/liquid dispersionsand provide high-fluid quality and value. They are compatible with highlyacidic and basic fluids. The high-performance stack design allows an evenflow distribution which permits a high flow rate in a smaller assembly. Also,the long life of the cartridge results in fewer change-outs, which reducesmaintenance and disposal costs.
Pall AquaSep Salt and Conventional Pack Bed Electrostatic TankPlus/PhaseSep Desiccant Coalescers Tower Precipitator SettlingSystem Tower
Lowest Interfacial AquaSep Plus: <2 dyne/cm >20 dyne/cm >20 dyne/cm >10 dyne/cm >20 dyne/cmTension Efficiency 3 dyne/cmSeparated PhaseSep:
<2 dyne/cm
Relative Operating and Low High Medium Low High LowMaintenance Costs
Effect of Additional Low High Low Low High LowDispersed Liquid onOperating Costs
Effect of Surface Active None None Reduced Reduced Reduced ReducedChemical on Efficiency Efficiency Efficiency Efficiency Efficiency
Effect of Additional Low Medium Low High Medium MediumDispersed Liquid on Efficiency
Sensitivity to Low Medium Medium Low High LowTemperature Changes
Relative Maintenance Low High Medium Low High Low
About Pall Corporation
For more than 60 years, PallCorporation has been solving complex contamination problemsfor diverse customers around theworld. With revenues of more than$2.7 billion, Pall is the largest andmost diverse filtration, separations,and purifications company in theworld. Our products and servicesallow customers to meet regulatoryrequirements and increase outputwhile reducing total cost of ownership.Our enabling technologies helpmake customers’ products better,safer and even possible.
Pall continues to develop newproducts and systems to further its cutting-edge phase separationtechnology. Pall’s core competencyin coalescing technology has helpedreduce operating and maintenancecosts at refineries.
We invite you to learn more aboutour technology, products, and services. For more information contact your Pall representative or visit us on the web at:www.pall.com.
Pall is dedicated to helping customers minimize their carbon footprint, maximize recycling and waste reduction,and ensure the most efficient utilization of naturalresources and raw materials. We are applying the sameknow-how and dedication to our own operations.
We team with customers in ways specific to their industries,providing them with technologically advanced products andengineered process solutions that improve and strengthentheir businesses while reducing their environmental
impacts. Customers worldwide look to us to help them purify and conservewater, consume less energy, and minimize emissions and waste. Pall is committed to ENABLING A GREENER FUTURESM. To find out more aboutour green initiatives, visit us on the web at www.pall.com/green.
Environmental protection
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© Copyright 1995, 2011, Pall Corporation. Pall, , AccuSep, AquaSep, Claris, CoLD Melt, Dia-Schumalith,Duo-Fine, Dynalloy, Epocel, HDC, Hi-V, Lucid, Marksman, Nexis, PhaseSep, PMF, Profile, PSS, Rigimesh,SepraSol, Ultipleat, and Ultipor are trademarks of Pall Corporation. ® Indicates a Pall trademark registered inthe USA. , Total Fluid Management, and ENABLING A GREENERFUTURE are service marks of Pall Corporation.
Fuels and Chemicals
25 Harbor Park DrivePort Washington, NY 11050 +1 516 484 3600 telephone+1 888 873 7255 toll free US
Portsmouth — UK+44 (0)23 9230 3303 telephone+44 (0)23 9230 2507 [email protected]
Visit us on the Web at www.pall.com
Pall Corporation has offices and plants throughout the world. For Pall representatives in yourarea, please go to www.pall.com/contact
Because of technological developments related to the products, systems, and/or servicesdescribed herein, the data and procedures are subject to change without notice. Pleaseconsult your Pall representative or visit www.pall.com to verify that this information remainsvalid. Products in this document may be covered by one or more of the following patentnumbers: EP 0 930 926; US 5,443,724; US 6,332,987; EP 1 165 205; US 6,342,283; US 6,662,842; US 7,473,360; EP 0 830 191; US 5,591,335; US 5,653,833; US 5,681,469;US 5,690,782; US 5,730,820; US 5,733,581; US 5,741,395; US 5,783,011; EP 0 930 926;US 5,480,547; US 6,332,987; EP 0 433 661; EP 0 667 800; EP 0 982 061; EP 1 380 331;US 5,543,047; US 5,690,765; US 5,725,784; US 6,113,784; US 7,083,564; US 7,318,800;EP 0 470 485; US 5,252,207; US 5,552,048.
PR-900b Produced in the USA. December 2011
