Magnetic Separator Systems
Introduction
Black Powder Solutions’ (BPS) Magnetic Separator Systems are inline, full-flow systems for removal of ferrous and non-ferrous contamination (Black Powder™) from fluid and gas systems.
These systems employ a Magnetic Array within an engineered pressure vessel that maximizes dwell time and particulate removal capability with minimal pressure drop (~0 psi ΔP in a clean system). Each system is engineered to achieve 99%+ efficiency in removing Black Powder contamination of all ferrous particles by accounting for design parameters such as flow rate, pressure, temperature, viscosity, medium and others. BPS Magnetic Separator Systems have the option of manual and semi-automatic cleaning systems, require minimum of consumables, require no fuel or power (manual cleaning) and have a 15+ year operating life.
We will work with you to utilize our existing Separators, or create a custom unit to best fit your footprint, environmental requirements, and maximize the quality of your product to increase value.
BPS Magnetic Separator Systems require cleaning rather than filter disposal. Each system offers long life service and utilizes minimal consumables. The high loading capacity allows for extended maintenance intervals of 1.5 – 3x depending on the density of the contamination in the particular system.
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Extended life of critical operating systems
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Reduction in downtime and lost production due to higher efficiency contamination capture
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Reduction in downtime and lost production due to extended service intervals
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Improved product quality
| ORDERING | |
|---|---|
| Engineering Certification | ASME, U-Stamp, CRN, PED, CE, other as requested |
| Design Code | Available upon request |
| Area Classification | Class I, Div I, Div II |
| Warranty | 1 Year |
| OPERATING | |
|---|---|
| Maintenance Interval | 6–24 Months (average) |
| Operating Life | 15+ Years |
| Material Construction | |
|---|---|
| Material | 304 SS, 316 SS, Duplex, Carbon Steel, exotic alloys |
| Configuration | Single, Duplex, Offset, Inline Ports, other as requested |
| Modular Design | Scaled to flow and contamination requirements |
| Cleaning Mechanism | Manual, Semi-automatic, Fully-automatic |
| Inlet / Outlet Size | |
|---|---|
| Low | 1” (Equivalent) |
| High | 72” (Equivalent) |
| Vent / Drain Size | |
|---|---|
| Low | 1” (Equivalent) |
| High | 12” (Equivalent) |
| Operating Data for a Single Magnetic Separator | |
|---|---|
| *Based on a 2″ OD Magnetic Separator Element *Duplex Magnetic Separator Systems are available to accommodate higher flow rates |
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| Flow Rate - Liquid | ≤ 200,000 bopd |
| Flow Rate - Gas | ≤ 300 mmscfd |
| Design Pressure | Low: ≤ ANSI 150 High: ≤ ANSI 2500 |
| Design Temperature | Low: Cryogenic Service Upper Temp. Limit (Magnetic Element Array): < 600 ºF |
| Efficiency | > 99% + |
| Clean Pressure Drop | < 0.5 psi |
| Vibration Resistant | Yes |
| Magnetic Separator Element | Patented technology |
| Black Powder Separation | < 0.5 μm — 500 μm |
Cleaning of the internal Magnetic Element simply requires the use of a cloth or glove to wipe contamination for disposal, or into a sample jar for laboratory analysis. As with all contamination analysis, BPS recommends performing Particle Size Distribution (PSD), X-Ray Diffraction and Energy Dispersive X-Ray Spectroscopy (XRD/EDS) tests to determine particle composition, size, metallurgy and concentrations
The Manual Cleaning System is a full standalone system. The user removes the Magnetic Element from the vessel and installs it in the cleaning station. The Magnetic Element is lifted through the scraper plate allowing the contaminants to be collected in the containment bag.
The motor and the gear box attach to the davit arm. The large and small blind flange are at the top of the vessel. The small blind flange is removable, giving easy access to the internal screw and coupling. Rotation of the screw cap by the motor and gear box allows the BPS Scraper Plate to move up and down along the rods.
This system utilizes a PLC to control pneumatic actuated valves to divert flow into the magnetic separator and again to bypass for cleaning operations once scheduled or contamination loading capacity is reached. The PLC then activates the motor which is always be connected to the extension drive through a packing gland or mechanical seal eliminating the need to remove the small semi-auto access blind flange. The motor drives the BPS scrapers assembly up and down the Magnetic Separator Elements.