Figure 5 shows the comparative differential pressure (ΔP) performance of SynGuard media pack (green and brown) versus conventional surface-pleated media (dark blue) in an HVGO/HCGO/AGO feed containing semi-deformable contaminants. The lofted media pack matrix maintains a low, stable ΔP throughout extended service by adsorb - ing deformable clusters within the depth structure (depth loading), while the surface filter exhibits rapid blinding and premature pressure rise due to surface blinding and limited pleat utilisation. Conventional filtration showed a rapid increase in pres - sure drop consistent with surface loading and effective area collapse. In contrast, SynGuard media exhibited grad- ual and stable pressure evolution over time, consistent with progressive depth loading. Despite operating with a reduced effective surface area relative to conventional media, performance remained sta- ble. This reflects full utilisation of the media depth rather than dependence on surface area alone. The stabilisa- tion of pressure drop development translates directly into extended service life. Reduced rates of differential pressure increase delay changeout events, while improved utilisa- tion of the media volume increases contaminant holding capacity. Conclusion Contaminant systems in heavy hydroprocessing are gov- erned by the interaction between suspended solids and reactive hydrocarbon species, resulting in semi-deformable organic-inorganic agglomerates. In conventional filtration, these structures accumulate on surfaces, forming com- pressible deposits that drive rapid pressure drop devel- opment and limit downstream utilisation. This behaviour represents a fundamental constraint on processing heavier and more variable feedstocks. The approach presented here treats contaminant interac- tion, not particle size, as the controlling variable. By combin- ing multi-layer lofted media architecture with engineered surface energy, capture is shifted from surface accumula- tion to controlled depth loading within the media pack. This shift in mechanism alters system behaviour. Semi- deformable agglomerates are stabilised and retained within the filtration medium before reaching downstream equip - ment, resulting in more gradual pressure-drop evolution, extended service life, and reduced operating cost. As feed variability continues to increase, this interac- tion-driven framework provides a practical method for conditioning contaminant systems upstream of the reac- tor. Critically, it establishes media architecture and sur- face interaction as explicit design variables in heavy-feed hydroprocessing. These variables belong alongside VDU cut strategy, ARDS severity, guard-bed grading selection, and hydroprocessing catalyst choice in any serious feed conditioning or revamp discussion.7 Once semi-deformable organic-inorganic agglomerates dominate contamination behaviour, filtration design can no longer be treated as an ancillary specification. The temper - ature window, media architecture, and fibre surface energy of the feed conditioning system become primary inputs for
achieving stable reactor ΔP, protecting catalyst life, and operating profitably across changing blends of straight- run, resid-derived, and cracked streams. References 1 Ruiz Maldonado, X.E., Hoces Hurtado, R., Romero Vázquez, M.A., Opportunity crudes and refinery challenges during hydrocracking operations, Topsoe/Cepsa Technical Paper, 2016. 2 Müller-Steinhagen, H., Malayeri, M.R., Watkinson, A.P., Fouling of heat exchangers – new approaches to solve an old problem, Heat Transfer Engineering , Vol. 32, No. 3-4, 2011. 3 Watkinson, A.P., Fouling characteristics of a heavy vacuum gas oil, Heat Transfer Engineering , Vol. 18, No. 3, 1997. 4 Speight, J.G., The Chemistry and Technology of Petroleum, 5th Edition, CRC Press, 2014. 5 Sadeghbeigi, R., Fluid Catalytic Cracking Handbook, 3rd Edition, Butterworth-Heinemann, 2012. 6 Tileuberdi, Y., et al., A review of asphaltenes, Engineered Science, 2025. 7 Alboudwarej, H., et al., Advances in Residue Hydroprocessing and Catalyst Design, Albemarle/Ketjen Technical Publication, 2018. Leontina Tompea is Global Refining Vertical Market Leader at Jonell Systems, a Filtration Group company, responsible for market devel - opment and advanced filtration solutions across global refining (fossil and renewable) and integrated petrochemical operations. She has more than 25 years of experience across complex refining environ - ments globally and previously led cross-functional commercial and technical teams in refining and energy transition applications. Tompea holds a Bachelor of Engineering in polymer science from Traian Vuia University, Timisoara, and a Master of chemical engineering from Ryerson University, Toronto, focused on oil sands upgrading. Email: leontina.tompea@filtrationgroup.com Mac McGuire is the Lead Lab Technologist at IntegraLabs at Jonell Systems, a Filtration Group company. Her role includes chemical analysis, R&D, and experiment design for the refining and industrial filtration sectors. She previously conducted advanced materials char - acterisation research at Southern Methodist University (SMU) and the National Institute of Standards and Technology (NIST), contributing to several peer-reviewed publications. She holds an MS in chemistry from SMU and is completing a PhD in astronautical engineering at Capitol Technology University, which included work with NASA Jet Propulsion Laboratory. Email: mac.mcguire@filtrationgroup.com Carolyn Heyse is Vice President of Strategy and Solutions Engineering at Jonell Systems, a Filtration Group company. She leads commercial strategy, technical sales enablement, marketing, and new product development, including the launch of IntegraLabs, an industrial testing and R&D facility focused on filtration and contaminant analysis. Prior to joining Jonell Systems, she held senior strategy and commercial roles at Filtration Group across multiple industrial portfolio companies. She holds a BS in finance from the University of Kansas and an MBA from the University of Chicago Booth School of Business. Email: carolyn.heyse@jonellsystems.com Jimmy Wallum is Director of IntegraLabs at Jonell Systems, a Filtration Group company. He is a filtration specialist in oil and gas and pet - rochemical applications with 31 years of experience in filter design, laboratory and field testing, and test rig development. He studied chemistry, engineering, and manufacturing technology with a focus on
quality control at Tarleton State University. Email: Jimmy.wallum@filtrationgroup.com
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