Expedited Overhaul and Enhancement of Syngas Filter Cassette for Kew Technology Ltd
Overview
Client
Kew Technology Ltd
Company
Carbis Filtration Ltd (CFL)
Timeline
Expedited execution in eight (8) weeks
Sector
Waste To Energy
Project
Expedited overhaul and enhancement of Syngas Filter Cassette
Product specified
SintAbond™ PMET filter elements, precision machined components
Objective
To meet clients high expectations with overhaul of filter internals with enhanced materials and components, to a tight schedule
Result
Enhanced durability, reduced downtime, and compliance with safety standards
Background
Kew Technology Ltd, a leader in sustainable energy solutions, relies on advanced syngas filtration technology to optimise their energy production processes. Their syngas filter cassette, an integral part of a commercial scale test plant, experienced a failure due to wear and tear of existing components. This led to operational inefficiencies, increased maintenance costs, and potential safety concerns.
To address these issues, Kew Technology Ltd approached CFL for technical support, and assistance with an expedited overhaul solution, to not only restore the unit to optimal functionality but also enhance its performance with superior materials and precision engineering.
Objectives
Expedite overhaul
Minimise downtime by expediting repair of the syngas filter internals.
Enhance durability
Replace defective components with superior materials to extend the service life of the filter internals.
Precision engineering
Achieve a high level of accuracy with critical components to ensure optimal performance.
Safety compliance
Ensure all repairs meet stringent safety standards, including testing and certification of lifting provision points and weld integrity.
Solution Provided by CFL
CFL proposed a comprehensive repair and enhancement plan, utilising SintAbond™ PMET filter elements, provision of precision machined interfacing components and high integrity welding of filter elements and components to filter cassette arranagment. The solution included:
Superior materials
Replace operation-critical filter elements with SintAbond™ PMET, known for its high wear resistance and superior performance in demanding applications.
Precision machining
Supply of critical components meeting tight interface tolerances.
Comprehensive testing
Mechanical verification of lifting provision. 100% penetrant testing of welds, and proof load test certification for lifting lugs, ensuring safety and compliance.
Implementation
1. Inspection
CFL conducted a thorough breakdown, inspection, and evaluation of the syngas filter cassette to fully identify defective components and assess the extent of repairs required. Key components identified for replacement included filter elements, venturis nozzles and filter element support structure.
2. Material selection
SintAbond™ PMET specified in 310 stainless steel was selected for its exceptional mechanical properties, enhanced durability and resistance to the harsh operational conditions and thermal stresses.
3. Precision machining and fabrication
Inhouse precision machining and fabrication of critical components, to ensure seamless integration and optimal performance.
4. Testing and certification
Mechanical verification of lifting lugs, testing and certification to meet safety standards, allowing the secure handling of the filter cassette during maintenance and operation. Penetrant testing of all project welds to ensure weld integrity.
5. Expedited delivery
Given the operational urgency, CFL prioritised the overhaul, reassembly process and testing to minimise downtime, delivering the equipment to the client on time in the agreed expedited schedule.
Results
Happy client, successful reinstatement of equipment on time, allowing resumption of critical operations.
Conclusion
Our ability to provide expedited overhaul and enhancement of the syngas filter internals for Kew Technology Ltd resulted in significant operational benefits. The implementation of SintAbond™ PMET filter elements, combined with our precision machining and high integrity fabrication skills, not only restored filter cassette functionality, but enhanced its durability and efficiency. Through comprehensive testing and certification, CFL ensure the highest of standards, safety, and reliability, this was key to providing Kew Technology Ltd with a robust solution.
Key Takeaways
Expedited overhaul
Rapid turnaround, minimising operational impact.
Superior materials
SintAbond™ PMET – Improved performance.
Precision engineering
Optimal functionality and integration.
Safety assurance
Comprehensive testing, certification, and compliance.
