Filter press pilot testing serves the purpose of collecting data necessary for accurately sizing a full-scale filter press system. This data includes various parameters such as cake solids, cake density, total processing time, processing time for each step, slurry feed solids, slurry pH, chemical conditioning dosages, and maximum operating pressure for each process step. Additionally, other data like filtrate suspended solids, slurry pH, and specific chemical analysis required by the process may also be collected.
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During the filter press pilot testing, the following steps are typically involved:
By conducting filter press pilot testing, businesses can gather essential data to determine the appropriate size and configuration for a full-scale filter press system. This ensures optimal filtration efficiency and productivity in various industrial processes.
The HPL300, HPL470, and HPL500 pilot filter presses are "sidebar" filter presses each with a manual hydraulic pump. These filter presses consist of a frame, hydraulic system, and filter plates with filter cloths. The HPL500 can use either 470 mm x 470 mm filter plates or 500 mm x 500 mm filter plates, while the HPL470 can only use 470 mm x 470 mm plates. The HPL300 uses 300 mm x 300 mm plates. Other equipment needed for a test includes pumps and mixing tanks with mixers.
There are two basic filter press configurations: recessed chamber and membrane. Both the HPL470 and HPL500 pilot presses are suitable for all testing for both configurations. A recessed chamber test requires the filter press, feed pump(s), and a mixing tank with a mixer. A membrane test requires all the equipment needed for a recessed chamber test, plus a source of compressed gas for membrane squeeze and the necessary equipment to control the membrane squeeze. The HPL300 is suitable for recessed chamber tests and basic membrane tests without cake washing.
The basic test starts with preparing the slurry or slurry as required and installing the correct plates and filter cloth in the filter press. Once the press and sample are ready, the pump is turned on and the press is filled. Filtrate will be seen when the press is filled, and timing and taking filtrate samples begin. The test continues until both the low flow and maximum pressure conditions have been reached for filtration.
For a recessed chamber test, the test is ended at this point. For a membrane test, it is continued with optional steps such as cake wash, membrane squeeze, and optional air blow down. Once the test is finished, the press is opened, the filter cake is removed, and cake samples are taken. During the cake release, it is important to note how the cake released and the overall surface condition of the filter cloth. Cake release is normally somewhat better on a larger press, but if there is poor release on the test unit, the release on the larger unit will also be poor.
During the test, it is essential to collect data such as cake solids, cake density, total processing time, processing time for each step, slurry feed solids, slurry pH, actual chemical conditioning dosages, and maximum operating pressure for each process step. Additional data that is often collected includes filtrate suspended solids, slurry pH, and specific chemical analysis required by the process.
In summary, the HPL300, HPL470, and HPL500 pilot filter presses are versatile equipment for conducting filter press pilot testing. They can be used for both recessed chamber and membrane configurations, depending on the specific testing requirements. The test procedure involves preparing the slurry, filling the press, and monitoring the filtration process until the desired conditions are reached. Collecting accurate data during the test is crucial for sizing a full-scale filter press system.
When it comes to selecting a filter cloth for your filter press, there are two main criteria to consider: the initial quality of the filtrate and cake release. The initial quality of the filtrate refers to how clean the filtrate is when it first passes through the cloth. On process applications, it is common to prioritize improved initial filtrate quality, even if it means slightly poorer cake release. On the other hand, for most waste applications, it is common to prioritize improved cake release, even if it means slightly dirtier initial filtrate. Ultimately, the selection of filter cloth involves a combination of experience and trial and error.
Another important factor to consider is the chemical compatibility of the fabric material with the slurry. Different fabrics have different levels of resistance to various chemicals, so it's important to choose a cloth that can withstand the specific chemicals present in your slurry. This is crucial to ensure the longevity and effectiveness of the filter cloth.
In addition to the filter cloth, there are also chemicals and filter aids that can be used to enhance the filtration process. Chemical conditioning involves adding chemicals to the slurry to improve filtration efficiency. However, it's important to note that for most process applications, chemical conditioning is not possible due to the risk of contaminating the product.
Some common chemicals used for chemical conditioning include ferric chloride solution, which is commercially available with a concentration of 36% and a density of 1.378 gm/ml. The proper dosages of these chemicals can be determined through testing.
Filter presses are widely used in various industries and applications for liquid/solid separation. They can be customized to meet specific needs, such as filtration capacity, number of chambers, filter plate size, and materials of construction. Industries that commonly use filter presses include food and beverage processing, chemical manufacturing, mining, power generation, aggregates, asphalt and cement production, steel mills, and municipal plants.
Overall, filter cloths play a crucial role in the filtration process of a filter press. By considering the criteria of initial filtrate quality, cake release, and chemical compatibility, you can select the right filter cloth for your specific application needs.
The chemicals used for chemical conditioning in filtration processes are determined through tests to determine the proper chemical dosages. It is important to note that for most process applications, chemical conditioning is not possible due to contamination of the product.
When using ferric chloride and lime for slurry, it is recommended to add the ferric chloride first and mix well before adding the lime and mixing well. Ferric chloride solution of known concentration and density is commonly used. A commercially available ferric chloride solution typically has a concentration of 36% and a density of 1.378 gm/ml.
Hydrated lime, chemical grade with an analysis of 90 - 95% as Ca(OH)2 or 68 - 72% available CaO, is usually made into a 10% w/w slurry to add to the slurry. The density of the 10% slurry is 1.08 gm/ml.
Filter aids are typically added as slurries, usually at a concentration of 10% w/w. Other inorganic chemicals may be added as either solutions or slurries, depending on the specific chemical being used.
When conducting tests, it is important to mimic the expected process conditions as closely as possible, especially with initial pump flow rates. However, this may be challenging due to the varying sizes of the feed pumps used.
The selection of filter cloths is based on two criteria: the initial quality of the filtrate and cake release. In process applications, it is common to prioritize improved initial filtrate quality over cake release. Conversely, in most waste applications, slightly dirty initial filtrate may be accepted for improved cake release. The selection of cloth is typically based on experience and trial and error. Additionally, the chemical compatibility of the fabric material with the slurry is an important consideration.
During the extraction of solvents, such as in ethanol extraction, the ideal water content ranges from 70% to 95%. Water additives serve as catalysts for oxidizing pathogenic cell membranes and can help reduce costs and combustion hazards. In the case of FCC grade solvents, which require pure water when dilution is needed, microfiltered water with a purity level of 0.2 micron and de-ionized water are used to ensure a product free of heavy metals, volatiles, pyrogens, and microbes.
When analyzing a product to ensure it meets desired specifications, several material characteristics are considered: flowability, compression strength, bulk density, crushing strength, chemical analysis, and gas sampling and monitoring. These characteristics help determine if the product meets the desired specifications and aid in the process scale-up. Process data, such as residence time, kiln slope, temperature requirements, kiln rotating speed, emissions, and feed rate, can also contribute to achieving the desired product specifications.
Condensate traps are used to remove condensed liquids from the vacuum suction line. They work through adsorption of vapors to material media or cooling surfaces placed in the vacuum line, or a combination of both. Regular servicing is required to drain the condensed liquids from condensate traps. Some traps have automatic drain systems and automatic pump shut-off when the traps reach and pass high-level points. Water traps can be clear or have sight glasses to indicate when draining is required.
Inlet filters with paper, poly, or activated carbon, along with water traps, help keep vacuum oil uncontaminated for longer periods of service. These filters are essential in avoiding particulates from entering the pump, which can score the walls and reduce efficiency. Additionally, particulates inside the pump can cause damage and lead to seizing, failure, and long repair times. It is recommended to have a backup pump or access to an experienced pump repair shop nearby.
To start the test procedure for the pilot filter presses, you need to install the cloth on the filter plates and put the plates in the filter press frame. Close the press and pressurize the hydraulic cylinder to the proper pressure. It's important to note that the procedure for the bench press is outlined in Section 6.4.2. Additionally, calibrate the pumps as required per manufacturer's instructions.
Remember, it is important to thoroughly clean the KBr plates after each procedure to prevent contamination of future samples.
High voltage is needed to generate temperatures greater than 500°C. With high voltage comes inherent dangers of electrocution, fire, and severe burns. Make sure the furnace is properly grounded and no loose wires are connected to the furnace, and wear all necessary protective clothing while operating. The furnace program should be stopped, or the furnace shut off before opening the furnace door. Note that material will not always glow or appear hot, but will cause severe burns with improper handling. The elements for the furnaces may be exposed and can be easily damaged if bumped or scraped. They are very expensive to replace. The furnace elements are operated at a high current and can be dangerous if touched.
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Of all the features a sintering furnace may offer, perhaps the most important one is safety. After all, these furnaces climb to extraordinarily high temperatures and they hold there for a long time. And they use high amperage to do it.
Once the equipment is designed and built, a great deal of testing is sometimes needed at the equipment manufacturer’s facility. Temperature uniformity surveys are undertaken to determine the characteristics of the chamber. In many cases, actual product samples are run through exacting process cycles using inert and active gases to simulate actual process conditions. These processes are supplemented and further refined at the user’s facility, with adjustments made until all of the desired properties are obtained in the final product.
One of the drawbacks of a standard glass pressure reactor is the potential explosions due to hard-to-predict excessive internal pressure and lack of relief mechanism. However, with proper safety implementation provided by the manufacturer, the operator can perform most reactions in a safe manner.
The drawbacks of a metal pressure reactor (bomb) are set-up, maintenance, and corrosiveness.
The HPL470 and HPL500 filter presses are "sidebar" filter presses with a manual hydraulic pump. They consist of a carbon steel frame with sidebars mounted on a skid. The follower, also known as the moveable head, has a moveable extension piece that allows it to be moved further out of the way during cake discharge. The extension piece has buttons on both ends to ensure proper alignment during the closing of the press with the follower and the hydraulic cylinder.
The HPL500 filter press has a manual hydraulic hand pump with a reservoir and hydraulic cylinder. The closing force is 400 bar ( psig). There is a valve on the hand pump that controls whether hydraulic fluid is going to the cylinder or returned to the reservoir. The press also has a locking ring on the cylinder to mechanically maintain proper press closure.
The HPL470 filter press also has a manual hydraulic hand pump with a reservoir and hydraulic cylinder. The closing force is psig. Similar to the HPL500, it has a valve on the hand pump to control the hydraulic fluid flow and a locking ring on the cylinder to maintain press closure.
The frontal piping of the filter press consists of bolt-on headers with center feed and four corner filtrate outlets. For corner feed membrane, the center feed is ignored, and the upper right-hand filtrate port is used for feeding.
During press operation, the proper cake thickness is selected, and the head, intermediate, and tail plates are installed, alternating the filtrate drainage ports. The press should be operated within the following restrictions: maximum pressure of 225 psig and a low flow flux rate not exceeding 15 l/m2-hr.
The recessed chamber plates used in the HPL470 and HPL500 filter presses are standard center feed plates. They have barrel-neck type cloths that are held in place by cloth ties.
To install the plates, they should be placed in the press in the proper order. A maximum of 4 chambers (5 plates) can be installed. If necessary, additional spacer plates can be added behind the end plate if the hydraulic cylinder strokes out.
The membrane plate stack used in the HPL470 and HPL500 filter presses consists of a series of membrane plates and "recessed" plates. The plates are alternated: recessed - membrane - recessed - membrane, etc. The membrane plates have a PP welded membrane.
For corner feed membranes, the slurry is fed into the upper right-hand corner of the plates. The cloths are individual sheets held in place using a locking ring assembly in the corner feed ports. An adapter plate is used to adapt the 500 mm press porting to the 470 mm plate porting of the membrane plates.
For center feed membranes, the slurry is fed into the center feed port. The cloths are barrel-neck types, except for the tail plate, which is a drape over type. Cloth ties are used to hold the cloth in place. An adapter plate is also used to adapt the press porting to the plate porting of the membrane plates.
During installation, the plates should be placed in the press in the proper order, with a maximum of 4 chambers (5 plates) being installed. Additional spacer plates can be added behind the end plate if needed.
During the operation of the membrane press, the press is filled conventionally with a feed pressure of 100 psig max. The membranes can be inflated using compressed gas or water, with a maximum inflation pressure of 225 psig. Only every other membrane plate needs to be inflated, even if a "full" membrane plate stack is used.
It's important to note that there are two basic filter press configurations: recessed chamber and membrane. The HPL470 and HPL500 pilot presses are suitable for testing for both configurations. Recessed chamber tests require the filter press, feed pump(s), and a mixing tank with a mixer. Membrane tests require all the equipment needed for recessed chamber tests, as well as a source of compressed gas for membrane squeeze and the necessary equipment to control the membrane squeeze. The HPL300 is suitable for recessed chamber tests and basic membrane tests without cake washing.
If you are interested in our products, please visit our company website:https://kindle-tech.com/products/hydraulic-diaphragm-lab-filter-press, where innovation has always been a priority. Our R&D team consists of experienced engineers and scientists who closely follow industry trends and are constantly pushing the boundaries of what is possible. Our laboratory equipment incorporates the latest technology to ensure that you can obtain accurate and repeatable results during your experiments. From high-precision instruments to intelligent control systems, our products will provide you with unlimited possibilities for your experimental work.
Depending on the choosen version, LAB200 is able to install filtering plates with recessed chambers or also mixed pack composed by recessed plate chambers and membrane squeezing plates.
Of course the use of plates with membrane squeezing requires the high pressure generation system to proper squeeze the natural rubber membranes of the membrane plates.
Because of this, the installation of a mixed plate pack (mixed plate pack means recessed plates and membrane plates together) is limited to the versions PLUS and TOP of the LAB200-CEFS/CPFS/EFS/PFS; because BASIC and STD do not install the high pressure generation system and because of this is not possible to use the membrane squeezing system.
As standard, all the plates (both membrane or recessed) installed in the LAB200-CPFS series are made of PP (Polypropylene).
PP is the most common material used all over the world also in industrial filterpresses.
In some applications, due to the kind of fluid or slurry that must be filtered, ore due to the T° of application, PP could be not be chemically compatible with the application.
For this reason, is also possible to install Stainless Steel AISI 304 or AISI 316 plates, with some limitations:
Limitation n°1:
Plates is AISI 304/316 have no chamber thickness (chamber thickness=0) and because of this is mandatory to use a spacer between two filtering plates to have a filtering volume
Limitation n°2:
Plates in AISI 304/316 cannot be supplied with membrane squeezing system
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