Industrial high-temperature gas filtration technology enables the separation of solids from gases and purification of gaseous pollutants under elevated temperatures. By integrating mechanisms such as physical interception, chemical adsorption and catalytic conversion, this technology aims to remove solid particles and harmful gaseous contaminants from high-temperature gas steams in an effective manner. The goals are to enhance gas purity, ensure the safe operation of downstream equipment, and support the “dual carbon” (carbon peak and carbon neutrality) environmental goals. Against the backdrop of growing global attention to environmental and energy issues, high-temperature gas filtration plays a pivotal and even indispensable role in numerous high-end industries, especially when it comes to the efficient production in fine chemical industries.

Domestic Development Trends and Technical Frontiers

Although China was a late starter in industrial high-temperature gas filtration, it has now become a rising star. Since the 1960s, a diversified high-temperature filtration element system has taken shape, represented by materials such as ceramic powers/fibers and metal fibers/powders/woven wire mesh. Furthermore, China also embraced significant technological breakthroughs in areas including pulse blowback cycles for filter element regeneration, the structural design of large-scale filters, and fundamental filtration theory research.

Despite these achievements, the technology still faces a series of severe challenges on the path towards higher efficiency, greater reliability, and better cost-effectiveness:

Material Limits and Operational Condition Adaptability: As industrial processes nowadays operate at higher temperatures (e.g. reaching 800-1000℃ in advanced coal gasification or catalytic cracking processes), filter materials are required to be more resistant to high temperature, thermal shock and corrosion.

Capture and Regeneration of Fine Particles and Adhesive Substances: Traditional methods struggle to efficiently capture PM 2.5 and submicron particles, and dense filter cakes are easily formed, which is the main cause of pressure drops. Sticky substances like tar and low-melting-point metal salts in high-temperature gas can clog pores and resist removal by standard pulse blowback, which could cause the filter to malfunction.

Stability and Energy Consumption Control in Regeneration: Pulse blowback process faces a dilemma: excessive blowing damages brittle ceramic/fiber elements, while insufficient cleaning fails to remove dust. Intelligent adaptive control systems are needed to optimize cleaning efficiency, energy use, and component lifespan.

Intelligent Monitoring and System Integration: Large-scale industrial processes require highly reliable filtration systems, but real-time monitoring of clogging status, component health, and remaining life remains underdeveloped. Predictive maintenance and AI-based control systems are critical for future progress.

Balancing Cost and Service Life: High-performance materials (e.g. ceramic fiber composites) and precision manufacturing increase initial costs. Innovations in materials and structural design are essential to reduce lifecycle expenses while maintaining performance.

Shinkai’s High-Temperature Gas Filtrtaion Technology

To address these challenges, Shinkai offers an integrated filtration solution combing high-performance equipment with advanced process design:

1. Core Filtration Principle: Precision Physical Interception

Proprietary high-temperature vacuum sintering technology precisely controls the filter media’s microstructure:

High Precision: Uniform pore size ensures near 100% efficiency in capturing micron/submicron particles.
High Permeability: Thin, uniform metal membranes enable low initial pressure drops and high gas flux.
Synergistic Potential: The metal membrane can serve as a catalyst support for integrated catalytic or electrostatic filtration.

2. The Key to System Design: High Efficiency, Stability, and Long-term Operation

The design of a high-performance filtration system requires precise balancing of various performance indicators. Nanjing Shinkai’s system design focuses on addressing the aforementioned challenges:

Addressing Regeneration Challenges: Utilizes advanced online zoned pulse blowback technology. This technology allows for cyclic cleaning of individual or groups of filter elements without interrupting the overall system operation, which enables continuous operation of the filtration system. Optimized blowing parameters and airflow path design ensure thorough cleaning while minimizing mechanical impact on the metal membrane elements. In this way, it can resolve the conflict between regeneration stability and element lifespan.

Addressing Material Limits: Its core elements are made from various high-performance alloys (e.g. 316L stainless steel, titanium alloys. Inconel, Hastelloys), processed via high-temperature vacuum sintering (vacuum up to 10^-5 Pa). This endows the elements with exceptional high-temperature resistance (up to 900 ℃), corrosion resistance, and high mechanical strength (forward pressure resistance 50 bar), enabling them to perform in the most demanding industrial conditions.
Balancing Cost and Lifespan: The excellent regeneration performance of the metal membrane (no significant pressure drop increase after blowing) significantly extends the service life of the elements, reduce the frequency of spare part replacements, and thereby effectively lowers the system’s total lifecycle cost.
Ensure Safety and Environmental Protection: The system features a sealed space design, ensuring production safety and environmental protection, and meets strict gas emission requirements.
Excellent Performance and Broad Applications:

Nanjing Shinkai’s high-temperature gas filtration solution successfully addresses multiple challenges related to materials, regeneration, and cost through its precise physical interception principle and scientific system engineering design. Thanks to its high filtration accuracy, strong temperature and corrosion resistance, excellent regeneration performance, and continuous operation capability, this technology has been successfully applied in:

• Fine silicon powder filtration and recovery in polysilicon and organosilicon production
• Gas purification in coal chemical industry
• Catalyst recovery in catalytic cracking and continuous catalytic reforming units in petrochemical industry
• High-temperature waste gas filtration from boilers and incinerators
• Recovery and filtration of solids like polyethylene, magnesium oxide, and titanium dioxide

Reference:

[1] Ji Zhongli, Luan Xin, Miao Linfeng. Development of High-Temperature Gas Filtration Technology and Equipment [J]. Chemical Industry

Nanjing Shinkai

We offer a variety of products with different characteristics that cater to demanding operating conditions. Committed to technological innovation and R&D, we aim to provide precise solutions, including efficient and reliable customized filtration systems, for our clients to fix their pain points production, increase efficiency and improve workmanship. If you are struggling with filtration challenges, we look forward to in-depth cooperation with you, and you will enjoy our one-stop, full-process customized service. Our service covers:

Design and Selection of Core Filter Cartridges

Planning and Design of Overall Process Workflow

Matching Selection of Key Valves and Instruments

Layout Design of the Precision Pipeline System

Let’s work together to craft an optimal filtration solution for you!

www. Shinkaifilter. com

Hotlines:

025-66989518

025-66989516

Email: info@shinkaifilter.com