Frequently Asked Questions
Black Powder results from both chemical and bacterial reactions within hydrocarbon systems. Bacterially, sulfate reducing bacteria and acid producing bacteria are dependent on the reaction of water and iron to form the hydrogen sulfides that cause oxidization and in turn Black Powder. Chemically, the three primary catalysts of Black Powder contamination are moisture, H2S, and temperature or pressure variance. Within pipeline transmission systems, ever present moisture catalyzes bacterial and chemical corrosion of the carbon steel walls within pipelines and storage reservoirs. In refineries, process plants, and storage reservoirs, if H2S is present, it will corrode all carbon steel components creating more Black Powder. Severe temperature and pressure changes occur throughout the pipeline at city gates, processing plants and refineries, precipitating iron oxides, iron sulfides and sulfur from the hydrocarbon gas or liquids. These particles have an affinity for themselves and throughout the rest of the pipeline process will reach measurable levels instantly causing clouds of Black Powder in the flow.
As most of transmission lines, transport systems and storage reservoirs are manufactured with soft carbon steel, all stages of a pipeline are vulnerable to erosion of pipeline components in the transmission line by exposure to Black Powder. Iron sulfides and iron oxides significantly damage components from the origin of the pipeline to the final product delivery because prior to precipitation, they are at and below sub-micron levels, therefore undetectable when passing through sensors and meters. Black Powder, at this size, damages pump seals, meters, valves, and compressor components because it plates out and wears on exchangers, trays, orifices and valves. These compromised components and instrumentation, lead to flow restriction and disrupted pressure boundaries.
Black Powder Solutions provides proactive management practices to reduce the contamination levels, mitigating the overall negative impact Black Powder has on pipeline operational integrity. The solution to this problem is to employ Magnetic Separation technology in strategic locations throughout the pipeline system, refineries, chemical plants, city gates and loading facilities.
Over the past 15 years’, significant improvements in rare earth magnetic technology have created the ability to use magnetic fields as a filter or separator medium which is environmentally and user friendly, highly efficient and cost effective.
Black Powder Solutions designs and manufactures Black Powder Separators in a modular format for full flow gas and hydrocarbon fluid pipelines that remove ferrous and non-ferrous Black Powder contamination. This is accomplished by two methods:
(1) Entrapment of the iron particles mixing with the non-ferrous during flow.
(2) Naturally occurring static charge created by the flow of gas or fluids through pipes, referred to as static adhesion. The ferrous and non-ferrous particles are charged and marry up when they contact in flow. When exposed to BPS radial magnetic fields, they attract and trap to the Magnetic Separator rod surface.
In natural gas and oil pipelines, binder materials such as paraffin’s, glycols, and asphaltenes marry up with fine ferrous and sand particles trapping to the magnetic fields when passing through the Black Powder Separators.
The Black Powder contamination trapped on the magnetic separators is easily removed and stored in mineral bags. When the composition is primarily iron sulphides, there is opportunity for auto-ignition (smolders and flames), precautions must be taken to saturate the Black Powder with a chemical to neutralize it.
Removing and monitoring the quantities of the Black Powder in strategic locations along the transmission lines will lessen the erosion factor and may act as a monitoring tool for pipe wall life cycle.
Prime locations for the employment of Black Powder Separators to reduce contamination levels is loading and offloading of product at port facilities, prior to LNG plants, refineries, gas chemical plants, metering stations and power plants. Cleaner product entering these facilities will improve production and lower operational costs by reducing premature process equipment component wear.
Yes, this technology offers a full inline system approach which is custom designed to specific applications.
- Designed to operate with minimal flow restriction.
- Patented radial field magnetic separation technology removes Black Powder to sub-micron levels in full flow.
- Designed in a modular form to allow increase and decrease of flow volumes.
- Long life service with minimal consumables.
- Removes ferrous and non-ferrous Black Powder contamination.
- An environmental alternative which is cleanable and reusable for years.
- Black Powder density may vary upon application.
Yes, we offer Dual State Magnetic Separator Cone Strainer.
Yes, High and low pressure pumps available, no element for minimal flow restriction, ASME U-Stamp, PED and CRN certified vessels.
Yes, Double separator design incorporating a magnetic separator as the primary design and a pleated stainless steel cloth element as the final separator.
Applications: Light weight viscosity fuels
Yes, Triple coalescing separator as the primary design, with a magnetic separator as the secondary, and a stainless steel cloth element as the final separator.
Applications: Natural Gas
Yes, we offer Magnetic Basket Strainer Separator.
This BPS design separates Black Powder to sub-micron levels protecting valves, meters, and compressor seals. Cleaner gas results in better combustion and less emissions. The unit is easily cleaned and returned to service and requires a yearly PM with minimal consumable components (flange gaskets).
Applications: Fueling engines for mobile and stationary equipment, furnaces, power plants
Features: Oversized housings to allow maximum employment of the magnetic separators to ensure the most efficient filtration
Yes, we offer BPS Magnetic Y-Strainer
For applications with restriction of space on equipment . The Y-Strainer traps both ferrous and non-ferrous contamination to sub-micron range.
Applications: Cryogenic, and high pressure
Features: Available in stainless steel, and bronze. Flanged access allows for cleaning at –320°F.
Yes, we offer BPS High Pressure Scrubber.
It is designed for hydraulic applications with system pressures up to 6000 PSI. Its increased separation capability removes both ferrous and non-ferrous contamination down to sub-micron levels without flow restriction.
Applications: High pressure, low flow, low viscosity
Features: Reduces the need for horsepower to move the hydraulic fluid through the line.
