Solving Solvent Loss and Foaming in Acid Gas Removal

2025-04-29

A large refinery operating a complex acid gas removal solvent was experiencing severe operational issues: 

• High foaming events disrupting process stability 
• Frequent filter changeouts every 2 weeks 
• Up to four full inventory turnovers per year of expensive solvent due to contamination and degradation 

At the time, the refinery was using 10µm nominal polypropylene depth filters on the lean side (20% slipstream). These were proving ineffective in protecting the solvent loop from solid contamination. 

Forensic Analysis: Root Cause of Filter Failure 

IntegraLabs performed a destructive analysis on existing spent filters. The findings were clear: 

• The outside surface of the cartridge had a thick cake layer of solids. 
• Solids had broken through the full depth of the media, reaching the downstream side. 
• The polypropylene media showed swelling and structural breakdown—evidence of channeling, allowing unfiltered solids to bypass the filter matrix entirely. 

 
Field Validation: Independent Testing by the Customer 

To benchmark system performance, the refinery conducted its own solids sampling upstream and downstream of the filters: 

Sample Location	Solids (mg/l)
Upstream	166.0
Downstream	56.0

This revealed a removal efficiency of less than 75%, validating the lab findings and confirming a need for improvement. 

The Jonell Solution: Pleated Cotton Cartridge Upgrade 

Jonell proposed a pleated cotton filter cartridge featuring: 

• 6x greater surface area than the depth filter 
• 99.98% removal efficiency of 20µm and larger particles 
• Direct retrofit compatibility (same vessel, no piping changes) 
• Lower media velocity, reducing channeling and promoting better cake formation 
• As a natural polymer, this material is intrinsically not affected by hydrocarbon present- the fibers will not swell, so  no impact on reducing the dirt hold capacity 

The new filters were installed and run for 5 weeks—more than double the service life of the original setup. 

Updated solids analysis: 

Sample Location	Solids (mg/l)
Upstream	130.0
Downstream	4.0

Efficiency exceeded 90%, with dramatically cleaner effluent and no evidence of media degradation. 

Key Results 

• Foaming incidents significantly reduced 
• Service life increased from 2 weeks to 5 weeks 
• Solvent loss reduced, preserving product value 
• Improved solids removal efficiency (>90%) 
• No capital modifications required—same vessel, better media 
• Cost savings for the customer on direct filtration expenditure realized annualized economies of saving of over $75,000- this figure is currently re-evaluated to include solvent loss cost, spent cartridge cost as well as labor and other factors. 

Takeaway 

This case underscores the value of filter media selection matched to process conditions. Jonell Systems’ combination of field support and lab analysis not only diagnosed the problem but enabled a validated, plug-and-play upgrade—saving the refinery time, money, and solvent. 

Want similar results? Contact Jonell Systems to schedule a contaminant analysis or filtration audit. We’ll help ensure your filter media is precisely