Case Study of Petrochemical Industry
（1） CNOOC's offshore oil field
A certain offshore oil field under CNOOC is facing severe challenges in oil-water separation during crude oil extraction. Due to the high water content of 30% -40% in the crude oil produced by oil wells and the extremely limited space on offshore platforms, traditional dehydration equipment is difficult to meet the requirements of efficient dehydration and compact installation.
After introducing the coalescence dehydration oil filter, the situation has been greatly improved. This oil filter adopts advanced coalescence separation technology, which can quickly coalesce small water droplets in crude oil into large water droplets. Through efficient separation filters, water and oil can be accurately separated. After processing, the moisture content of crude oil has been successfully reduced to below 5%, fully meeting the standards for pipeline transportation and subsequent processing.
After using the coalescence dehydration oil filter, not only did the transportation cost of crude oil decrease, but also the corrosion of subsequent processing equipment caused by high moisture was reduced, extending the service life of the equipment. According to statistics, approximately 5 million yuan is saved annually due to reduced equipment maintenance costs, while crude oil production is increased by 5% due to a stable dehydration process.
（2） Sinopec's refinery
A certain refinery of Sinopec has been plagued by the problem of unstable product quality in the diesel production process. The fluctuation of moisture and impurity content in diesel often results in products not meeting the latest national quality standards, which affects the market competitiveness of the products.
To solve this problem, the factory installed a coalescence dehydration oil filter. The oil filter plays a key role in the diesel refining stage, effectively removing water and impurities from diesel by adsorbing and coalescing water through the coalescing filter element and intercepting impurities through the separation filter element. The quality of the processed diesel is stable, and all indicators meet national standards, even surpassing the industry average in some key indicators.
Since the use of the coalescing dehydration oil filter, the market recognition of the factory's diesel products has significantly increased, with product sales growing by 15%. At the same time, the additional revenue brought by the improvement of product quality can reach 8 million yuan per year.
Case study of the power industry
（1） A large substation of State Grid Corporation of China
The main transformer of a large substation under the State Grid Corporation of China is responsible for important transmission tasks. However, as the operating time increases, the moisture and impurities in the transformer oil gradually increase, leading to a decrease in insulation performance and seriously threatening the safe and stable operation of the substation.
The substation adopts an automated coalescing dehydration oil filter system. The system can monitor various indicators of transformer oil in real time, and automatically start the oil filter for purification treatment when the moisture or impurity content exceeds the standard. Through the regular operation of the coalescence dehydration oil filter, the insulation performance of transformer oil is effectively restored and maintained.
After one year of operation, the frequency of transformer fault warnings has been reduced from 3-4 times per month to 2-3 times per year, greatly improving the reliability of power supply. At the same time, by avoiding economic losses caused by power outages, which can reach over 10 million yuan per year, and extending the service life of transformers, it is expected to reduce equipment replacement costs by about 3 million yuan in the next 5 years.
（2） Huaneng Thermal Power Plant
The hydraulic control system of the steam turbine in a certain thermal power plant of Huaneng is prone to contamination of hydraulic oil due to long-term exposure to harsh environments of high temperature and high humidity. The mixing of moisture and impurities leads to frequent malfunctions in the hydraulic system, such as valve jamming and slow hydraulic cylinder action, which seriously affects the normal operation and power generation efficiency of the unit.
The power plant introduces a coalescing dehydration oil filter to purify hydraulic oil online. The oil filter continuously works to remove moisture and impurities from the hydraulic oil, keeping it clean at all times. After a period of operation, the failure rate of the hydraulic system has significantly decreased, and the stability of equipment operation has been greatly improved.
According to statistics, the unplanned downtime of the unit has been reduced by about 70%, and the power generation efficiency has been improved by 8%. This not only ensures a stable supply of electricity, but also brings an additional annual power generation revenue of about 12 million yuan to the power plant.
3、 Case studies in the mechanical manufacturing industry
（1） Foxconn's precision manufacturing factory
Foxconn's precision manufacturing factory mainly produces components for high-end electronic products, with extremely high requirements for machining accuracy. During the machining process of the factory's CNC machine tools, impurities such as cutting fluid, moisture, and metal debris are mixed into the machine tool lubricating oil, resulting in deviations in the dimensional accuracy and surface quality of the machined parts, and a high scrap rate.
The factory has installed a coalescence dehydration oil filter in the lubrication system of the machine tool. The oil filter performs real-time filtration and dehydration treatment on lubricating oil, effectively removing pollutants. The lubricating oil treated by the oil filter can provide good lubrication and cooling effects for the machine tool, ensuring high-precision operation of the machine tool.
After using the coalescence dehydration oil filter, the scrap rate of parts decreased from 8% to below 3%, and the product quality was significantly improved. At the same time, the maintenance cycle of the machine tool has been extended by about 50%, and the economic benefits brought by the reduction of equipment maintenance costs and the improvement of product quality are about 6 million yuan per year.
（2） Sany Heavy Industry hydraulic equipment production workshop
The stability and reliability of the hydraulic system have always been the focus of attention in a hydraulic equipment production workshop of Sany Heavy Industry during the production process. However, due to the easy contamination of hydraulic oil, key components such as hydraulic pumps and valves are severely worn out, resulting in a high equipment failure rate, which affects production progress and product quality.
The workshop uses a coalescence dehydration oil filter to purify hydraulic oil. The oil filter can effectively remove moisture and impurities from hydraulic oil, prevent oxidation and emulsification of hydraulic oil, and extend the service life of hydraulic oil. At the same time, it reduces the wear of hydraulic components and lowers the equipment failure rate.
By using a coalescence dehydration oil filter, the average trouble free operation time of the equipment has been extended from 500 hours to over 800 hours, and the production efficiency has been improved by 18%. This not only accelerates production progress, but also reduces production costs, saving the enterprise about 9 million yuan in expenses annually.
These cases fully demonstrate the powerful application value of coalescence dehydration oil filters in different industrial fields. By effectively removing moisture and impurities from oil products, they have brought significant economic benefits and improved equipment operation stability to enterprises.
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