Application of alternative HYDAC filter element in petroleum and petrochemical fields

Technological breakthrough under the wave of domestic substitution: Lifelte filter to crack the "stuck neck" problem in the petroleum and petrochemical industry. In the roar of crude oil mining equipment, a filter with a diameter of less than 20 centimeters is silently guarding the lifeblood of the entire production line. In the face of the long-term monopoly of Germany's HYDAC filter, Henan Xinxiang Lifeldt Filter Co., LTD. (hereinafter referred to as "Lifeldt") broke the barriers with seven years of technological breakthroughs, and its independently developed alternative products set off a "localization storm" in the petroleum and petrochemical field, not only filling the technical gap, but also reshaping the industry supply chain pattern with the dual advantages of cost and efficiency.

Technical breakthrough: From "followers" to "game breakers" in the petroleum and petrochemical industry, the filtration equipment needs to be demanding: hydrogen sulfide and heavy metal particles mixed in crude oil need to be accurately intercepted under high temperature and pressure, and the filter element needs to withstand the extreme temperature difference of 420bar pressure and -40℃ to 120℃. HYDAC filter is known for its metal mesh lamination and precision welding process, but it has also become a pain point for domestic enterprises due to high import costs (unit price generally exceeds 5000 yuan) and long supply cycle (4-8 weeks). Starting from the material gene, the Liffert technical team pioneered the "multi-layer composite filter" technology: the 316L stainless steel sintered mesh is fused with imported modified fibers to find a balance between 1-25 micron filtration accuracy and 15% increase in flux. Laboratory data show that the filtration efficiency of the LFT-HP series filter in the kerosene medium is 99.99%, the pressure drop is 22% lower than that of similar products, and the life span is extended to 3000 hours. "We disassembled hundreds of HYDAC samples and found that although the spiral welded structure is excellent, there is still room for optimization in the flow channel design." Wang Lei, chief engineer of Liffert, revealed that the team used fluid dynamics simulation software to reconstruct the internal flow line of the filter element, reducing the fluid resistance by 20%, and this detail improvement reduced the energy consumption of the equipment by 8%.

The double disruption comparison of cost and efficiency shows that the Lifeldt alternative equalled or surpassed HYDAC in core metrics: filtration accuracy coverage of 1-25 microns, operating pressure of 450bar, and initial pressure drop of 0.1MPa. The cost advantage is particularly significant: the mainstream model unit price is 30%-40% lower than HYDAC, and 7-15 days spot delivery is achieved. The person in charge of the purchasing department of Sinopec revealed that after the pilot replacement of the group in 2023, the procurement cost of the filter element was reduced by 35% and the comprehensive efficiency of the equipment was increased by 27%.

Practical test: Application revolution from land to deep sea Case 1: Refining and chemical device "filter revolution" In 2022, the catalytic cracking unit of a refinery in Shandong fell into a dilemma due to the frequent replacement of HYDAC filter (annual cost of more than 2 million yuan). After replacing the Liffert LFT-RP series filter with a unit price of 2600 yuan, not only the filtration accuracy is improved to extend the catalyst life by 15%, but also the real-time warning of the filter status is achieved through the intelligent monitoring system, and the annual maintenance cost is reduced by 40%. Factory equipment supervisor Li Gong sighed: "Before changing the filter element like dismantling 'time bomb', now the system automatically prompts the replacement time, and the production plan is more controllable." Case 2: "Long-term protection of offshore platforms" A drilling platform in Bohai Sea hydraulic system was shut down for maintenance every month due to corrosion of the filter element, and the average life of the HYDAC filter element was only 8 months. The Liffert LFT-MARINE series uses fluoro rubber seal and nickel-based alloy skeleton, which has been running steadily for 24 months in the seawater salt spray environment, indirectly recovering the output value loss of more than 3 million yuan. Cnooc Technology department evaluation: "Deep-sea equipment maintenance costs are high, the filter element life extension brings benefits far beyond expectations." Case 3: The "Low temperature key" of the LNG transport chain In the refrigerant system of the LNG transport ship at -162 ° C, the aging problem of the HYDAC filter seal material is frequent. Liefert's special low-temperature filter has been tested in liquid nitrogen immersion (-196 ° C), achieving "zero fault" operation on several international shipping vessels, and is certified by the Norwegian Register of Shipping.

Industry resonance: The supply chain change behind domestic substitution "Every 1% increase in the localization rate of petroleum and petrochemical equipment can save more than 1 billion yuan in import costs." Zhang Ming, secretary-general of the China Petroleum Equipment Association, pointed out that Lifelte's breakthrough not only alleviates the "stuck neck" dilemma, but also promotes the formation of a virtuous cycle of "technology-cost-service" in the industry. At present, its products have covered Sinopec, CNOOC and other leading enterprises, and entered the United Arab Emirates, Singapore and other international markets, overseas orders accounted for 18%. In the face of the global energy transition wave, Liffert is deploying the next generation of intelligent filters: integrated iot sensors and AI algorithms, which can predict the filter life in real time and optimize equipment operating parameters. Liu Jianjun, chairman of the company, said: "Our goal is not a simple replacement, but to use technological innovation to let China's manufacturing in the petroleum and petrochemical field to control more say."

Although the filter element is small, it is about the big picture In the seemingly small field of filtration equipment, Lifelter uses the combination of material science, structural optimization and intelligence to leverage the supply chain reconstruction of the petroleum and petrochemical industry. When a handful of domestic filter elements operate stably in refining towers, drilling platforms and ocean-going ships, they not only reduce costs, but also invisibly build a safety barrier for China's energy industry. The change caused by this technological breakthrough is writing a new answer for the global petroleum and petrochemical industry.