FIELD OF APPLICATION – PETROCHEMICAL AND GAS INDUSTRY

Petrochemistry and the gas industry span everything from the extraction and transit of natural gas through refineries and polymer production to biogas plants. The whole chain shares one silent enemy: black powder – a mixture of iron oxides and sulfides formed by the corrosion of steel pipelines – along with fine metal impurities in media, granulates and lubricants.

This is a pressurized, explosion-prone industry: equipment must withstand pressures in the range of bar to tens of bar, high temperatures and ATEX zones. That is precisely why we manufacture our separators with full pressure certification – welding qualifications per PED 2014/68/EU, EN ISO 3834-2, EN 13480, EN 13445 and EN 1090 – and in explosion-proof and double-jacketed designs.

Did you know…? Up to half of the black powder particles in gas pipelines measure just 3–5 micrometers and a significant portion is even smaller – conventional cartridge and basket filters fail to capture them and quickly clog up. A magnetic separator captures particles as small as 1 µm and operates without any consumable material.

Introducing magnetic separation into petrochemical and gas operations protects compressors, pumps and catalysts, stabilizes process loops and eliminates the cost of single-use filtration inserts. This has a positive impact on the profitability and efficiency of the operation.

WHERE IN PETROCHEMISTRY AND THE GAS INDUSTRY WILL YOU FIND OUR MAGNETIC SEPARATORS?

Black powder separation from oil pipelines, product pipelines and process streams

Black powder – magnetite, hematite and iron sulfides from pipeline corrosion – travels with crude oil, products and gas to terminals, metering stations and refineries. It erodes fittings, distorts flow measurement and degrades the product; fortunately, most of its mass is ferromagnetic.

The following equipment is most often used for black powder separation:

The MSP-BP separator with neodymium cores and an induction of up to 18,700 G is mounted between pipe flanges upstream of pumps, heat exchangers, metering points and loading terminals – it captures particles from 1 µm and, along with them, non-magnetic contaminants (asphaltenes, paraffin) bound to the ferromagnetic fraction. Pressure designs are welded per PED 2014/68/EU and EN 13480/13445.

From practice: the magnetic filter MSP-S 150 N with 16,000 G in a DN150 pipeline ended the repeated damage to the pump's mechanical seal caused by particles from cavitation and erosion – zero pressure loss, cleaning during full operation (case study 2 April 2026). For vertical pressure pipelines we supplied the filter MSP-VT 250 N CRAB for DN 250, up to 120 °C and 25 bar (case study 19 February 2025).

Advantages of the MSP-BP black powder separators:

• Magnetic induction up to 18,700 G, capture of ferromagnetic particles from 1 µm
• No single-use inserts – zero operating costs, zero pressure loss
• Pressure design with a full certification package PED / EN 13480 / EN 13445

Catalyst protection in refineries (FCC, hydrocracking, reforming)

Iron from the feed is irreversibly deposited on the surface of catalyst particles – it blocks pores, forms nodules, impairs fluidization and increases coke formation. Premature replacement of the catalyst charge is one of the most expensive items in refinery maintenance.

The following equipment is most often used to protect catalysts:

The separators are installed in the feed upstream of the reactor – the magnetic stage removes the iron oxides and sulfides that the desalter does not capture. The MX-MC matrix separator also polishes out sub-micron and weakly magnetic particles. A poisoned catalyst = lower yield and premature replacement of a charge worth millions – magnetic protection of the feed extends catalyst life and provides flexibility when purchasing heavier feedstocks.

Amine loops, glycol dehydration and process liquids

Iron sulfide is the main solid impurity in amine solutions and TEG glycol – colloidal FeS stabilizes foam, and foaming is one of the most common causes of an amine unit upset: off-spec gas, losses of both amine and glycol, and higher chemical consumption.

The following equipment is most often used in process loops:

Magnetic filters are placed on the rich amine upstream of the regenerator and on the rich glycol – continuous removal of FeS limits foaming and stabilizes unit operation. For hot media we supply double-jacketed designs (verified up to 150 °C) and, for higher contamination, the MSP-AC automatic cleaning without stopping the loop.

From practice: the MSP-S 50 N OCTOPUS filter ensured the purity of liquid ammonia in chemical production – microparticles from the wear of pipes and fittings caused deposits and complaints; after installation the problem disappeared with no reduction in flow and no pressure loss (case study 31 October 2025). Foaming amine = off-spec gas and an idle unit!

Polymer production – granulate and powder in pneumatic conveying

Petrochemical production of PE, PP, PVC or PET ends with pelletizing and pneumatic conveying to silos and dispatch. Wear of pelletizing-head knives, screws and machine fragments mean contaminated granulate – and a complaint from an automotive or food-grade customer.

The following equipment is most often used in polymer production:

The MSP-S pipeline separator (flange connection, operation at 6–10 bar, double-jacketed protection of the magnetic cores) is fitted into the pneumatic conveying downstream of pelletizing and upstream of the silos; grate separators go into gravity chutes and ML chute magnets into pipelines of poorly flowing materials – in our case study the ML 250 N protects a rosin resin crusher (8 February 2024). Final inspection is provided by the METRON 05 PowerLine detector (up to DN 630, conveying speed up to 30 m/s) and QUICKTRON gravity detectors in ATEX design. A separate page, Plastics and Rubber Industry, is dedicated to granulate processors.

Granulate sorting and removal of angel hair

The friction of granules against the walls of pneumatic conveying pipes creates angel hair and streamers – thin plastic threads and agglomerates that clog filters, hoppers and valves and lead to the rejection of entire deliveries of granulate.

The following equipment is most often used for granulate sorting:

A check vibrating screen is placed downstream of the pneumatic conveying and upstream of silo filling or packaging: it removes threads, dust and agglomerates and calibrates the granulate to the required fraction. We supply screens in ATEX and FDA designs; the multi-frequency X-line handles even difficult and dusting materials. Angel hair in a silo = clogged conveying and a returned delivery.

Compressor and regulating stations, gas transit and biogas

At compressor and regulating stations, metering points and pig receivers, black powder damages compressors, fouls gauges and distorts custody-transfer measurement. In biogas plants, meanwhile, metal impurities in the substrate erode pumps, agitators and screw presses.

The following equipment is most often used in the gas industry and biogas:

Magnetic filters are installed at the inlets of compressor and regulating stations, at metering lines and downstream of pig receivers, where after pigging they capture the released black powder before it reaches the compressor. In biogas plants, magnetic separation protects the substrate inlet – in our case study the MSP-SC 80 N ORCA flow separator removed pipeline wear from a stream of liquid fermented biomass (11 January 2024).

Lubricants, hydraulic oils and auxiliary circuits

In the lubrication and hydraulic circuits of turbines, compressors and pumps, ferromagnetic wear forms the majority of suspended particles – it degrades the oil, bearings and seals. Magnetic filtration is the simplest way to clean the circuits continuously.

The following equipment is most often used in auxiliary circuits:

Magnetic filters are placed in the bypass branches of lubrication circuits and in the return lines of hydraulics; MSF magnets (9,000 G) double the efficiency of existing bag filters without any intervention in the technology. The benefit: longer service life of oils, bearings and fine filters, and fewer service interventions.