Metallic Filters

Advantages of sintered metallic filter elements over ceramic filter elements for syngas treatment

Philip Findlay

Commercial and Technical Manager

January 24, 2025
7 min

Syngas, a gas produced from the pyro-gasification of carbonaceous materials such as biomass, municipal waste and fossil fuels, is crucial in clean energy production. However, syngas requires purification prior to downstream processes, such as fuel cell operation, chemical synthesis and as an alternative fuel source for heating and power generation. Traditionally, ceramic filter elements have been used in syngas treatment systems but present limitations. This blog studies the technical advantages of CFL sintered metallic filter elements, specifically Carbis Filtration Limited’s (CFL) SintAbond^® series, over ceramic filters for syngas treatment.

Challenges of ceramic filter elements in syngas treatment

Ceramic filter elements have been traditionally used in syngas treatment systems. However, they present several limitations that can impact the overall performance and efficiency of such systems:

1. Limited temperature tolerance

Ceramic materials are highly heat-resistant but can be susceptible to thermal shock. This occurs when a ceramic filter is subjected to rapid temperature changes, such as when hot syngas is introduced after a period of inactivity.

This can lead to cracking or even complete failure of the filter element. Prolonged exposure to high temperatures can degrade the structural integrity of ceramic filters which can reduce filtration efficiency and increase pressure drop across the filter.

2. Inconsistent pore size distribution

Ceramic filters often exhibit variations in pore size distribution across the filter element. This can lead to inconsistent filtration performance, allowing smaller particles to pass through in certain areas while larger particles are trapped in others.

Inconsistent pore size distribution can reduce the overall filtration efficiency of the ceramic filter, leading to increased levels of impurities in the treated syngas.

3. Limited thermal shock resistance

As indicated earlier, ceramic filters are vulnerable to thermal shock, which can cause cracks to form within the filter material. These cracks can propagate, leading to filter failure and potential system downtime. Repeated exposure to thermal shock can significantly reduce the lifespan of ceramic filters, increasing maintenance costs and operational disruptions.

4. Lower mechanical strength

Ceramic materials are inherently brittle, making them susceptible to breakage under mechanical stress, such as pressure fluctuations or physical impacts. The fragility of ceramic filters necessitates careful handling and increased maintenance efforts, including regular inspections and replacements.

5. Chemical corrosion susceptibility

Syngas often contains corrosive components such as sulfur compounds and alkali metals. Such substances can react with the ceramic material, leading to degradation and reduced filter performance. Chemical corrosion can shorten the lifespan of ceramic filters, requiring more frequent replacements.

6. Limited cleaning options

Ceramic filters are often delicate and sensitive to harsh cleaning methods. Aggressive cleaning techniques can damage the filter structure, compromising its integrity. The limited cleaning options for ceramic filters can reduce their reusability, increasing the overall cost of ownership.

Advantages of CFL SintAbond® filters over ceramic filters

CFL SintAbond® filter elements, manufactured from metallic materials fused through a high-temperature process, offer several advantages over ceramic filters in syngas treatment:

1. Superior thermal shock resistance

Sintered metal filters possess excellent resistance to rapid temperature changes, making them ideal for the harsh thermal environments of syngas processing. This reduces the risk of filter failure and ensures system reliability.

2. Enhanced mechanical strength

The robust construction of sintered filters makes them highly resistant to mechanical stress and high-pressure differentials. This translates to increased durability and reduced risk of breakage during operation.

3. Improved corrosion resistance

Sintered metallic filters are available in various corrosion-resistant alloys such as alloy 800 and C276, specifically designed to withstand the aggressive nature of syngas components. This enhances filter life and minimises maintenance needs.

4. Effective cleaning

Sintered filters can be effectively cleaned without degradation using a range of measures, including backwashing, sonication, or even thermal regeneration. This allows for efficient removal of accumulated impurities and maintains optimal filtration performance.

5. High-temperature tolerance

Sintered filters can operate efficiently at significantly higher temperatures than ceramic elements. This is particularly advantageous for syngas treatment systems where hot gas filtration is required.

6. Reduced fouling

The regular porous structure of SintAbond® filters minimises fouling and facilitates efficient cleaning via backwashing and other methods. This minimises downtime and maintenance costs associated with fouled filters, leading to a more cost-effective syngas treatment process.

Why CFL SintAbond® filters?

1. Enhanced filtration efficiency

The precise pore size distribution of SintAbond® filters allows them to capture a broader range of particulate contaminants from the syngas with superior efficiency. This results in cleaner syngas, ensuring optimal performance of downstream processes.

2. Reduced system downtime

The robust design and cleanability of SintAbond® filters minimise the need for frequent replacements and cleaning, leading to reduced downtime for the syngas treatment system. This translates to increased operational efficiency and productivity.

3. Improved system uptime and reliability

The enhanced durability, temperature tolerance, and cleanability of SintAbond® filters contribute to improved system uptime and reliability. This minimises the risk of unexpected disruptions due to filter failure, ensuring smooth and consistent syngas treatment.

4. Versatility

SintAbond® filters are available in a range of metallic materials and pore sizes, allowing for customisation to suit specific syngas treatment requirements. This flexibility enables engineers to make a filter selection for optimal performance in diverse syngas applications.

Why choose Carbis Filtration for your syngas treatment needs?

Carbis Filtration (CFL) provide reliable engineered solutions, enhancing and optimising industrial processes incorporating our sintered filter technology.

1. Advanced sintering processes

CFL utilises cutting-edge vacuum sintering technology, ensuring the highest quality and integrity of our SintAbond® filters.

2. Wide range of filter options

From SintAbond™ PMET, offering precise micron ratings, to SintAbond™ MESH for exceptional strength, CFL provides a diverse selection to meet specific syngas treatment requirements.

3. Customised solutions

CFL engineering team design bespoke filter systems, filter elements and specialist filter internals, customised to suit the clients specific application.

4. Material expertise

CFL offers a variety of high-performance metallic materials such as 310SS, titanium, alloys 600, 800 and C276, guaranteeing excellent thermal and corrosion resistance for syngas applications.

Conclusion

Sintered filter elements, such as the SintAbond® series from CFL, provide improved performance over traditional ceramic filters in syngas treatment applications. Engineered to withstand thermal cycling and abrasive particulates, making them highly reliable in demanding syngas production environments. In addition, the corrosion resistant properties of CFL SintAbond® filters, extend operational life, reducing maintenance frequency and total cost of ownership. Our innovative approach to filtration and separation combines precision engineering with material science, delivering customised solutions. With decades of experience and a commitment to continuous improvement, Carbis Filtration provides the tools and expertise necessary to optimise syngas purification systems.

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