Air operated diaphragm pumps are used with filter presses to pump sludge from the bottom of the sludge holding tank into the filter press. These pumps are ideal because they can handle the slurry which is generally about the consistency of a milkshake.
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The diaphragm pump usually starts out slowly and gradually ramps up. Once the pump starts to slow back down, (30-60 seconds between thrusts), it is usually an indicator that the filter press is full. At this point, the feed pump should be turned off and the valves on the filter press closed as the operator prepares to operate the air-blow-down process.
The diaphragm pump can be manually turned up or an Automatic Pump Control system may be added. This starts the pump at 25 psi, then moves up to 50, 75 and finally 100 psi which is standard operating pressure for the pump.
Met-Chem provides diaphragm pumps in the following sizes: 1”, 1.5”, 2” and 3”. The material of construction ranges from cast iron, aluminum, polypro or stainless steel.
With the purchase of a new Met-Chem filter press, Met-Chem can mount your air operated diaphragm pump to the legs of your filter press. This option also includes a flex hose that connects the outlet of the diaphragm pump to the center feed pipe, an air filter, a regulator, and an oiler. We can also provide a mounted diaphragm pump for your existing press.
Automatic Filter Press Pump Control SystemThe Met-Chem Automatic Pump Control System is used in conjunction with an air operated diaphragm pump to automatically increase the feed pump pressure at predetermined intervals during the filter press filling cycle. If the pump runs at a higher initial pressure, the filter cake will become a packed layer of solids on the filter cloth. This will restrict the flow of the slurry thereby creating a very dense coating of the filter cake. This can cause the cloths to blind off and not allow further filtration. Starting at a lower feed pressure allows a soft layer of slurry particles to be deposited on the filter cloth. This initial layer becomes the filtering media which will enhance the filterability of the incoming slurry.
The automatic pump control system automatically and gradually increases the feed pressure in four stages during the filling cycle. These stages are adjustable to suit your slurry and solids concentration. However, it is commonly set at increments of 25 psi. (25, 50, 75, 100). By monitoring the feed pump flow sensor, during the final pressure stage, the operator will be able to determine the cycle completion.
The Automatic Pump Control System also incorporates a low hydraulic pressure safety shut down the device. If there is not enough hydraulic clamping pressure present, the system will completely shut down, eliminating any possible leaking from between the filter plates.
The pump control system allows your filter press to run at its optimum efficiency creating dryer filter cakes, reducing disposal costs, reducing operator time and increasing the life of your filter cloths and feed pumps.
This system can be incorporated with a new filter press from Met-Chem, a used unit or even your own existing press.
Spare Parts KitMet-Chem is pleased to offer our spare parts kit which includes our 5 piece center feed pipe assembly, a head, tail, and 2 intermediate filter press cloths, and 100 foot of gasketing material. These are essential items for the operation of the filter press. A cracked pipe, ripped cloth, or torn gasket can happen anytime and having these items in your stock will ensure you will be back up and running in no time.
Center Feed and Manifold Filter Press UpgradesA center feed pipe assembly on a filter press should be able to last many years the same way any other type of plumbing will. However, if the material of the center feed pipe assembly is not strong enough to handle the corrosiveness of the solution running through the press then the center feed pipe assembly can corrode.
For cases of corrosive material or high temperatures, Met-Chem is pleased to offer upgrades from our standard center feed pipe and manifold. We are able to upgrade to CPVC, Carbon Steel, 304 or 316SS Stainless Steel, and Titanium. Met-Chem can also provide additional manifold upgrades such as automatic valves
The center feed pipe is what connects the filter press to the product that needs to be filtered. The center feed pipe assembly consists of five different parts. The first part is the lock nut which fastens on the center feed pipe and connects to the outside of the press. The pipe, which is the second part, goes through the head of the filter and all the way through the head plate of the filter press. The third part of the center feed pipe assembly is a gasket which ensures the assembly is watertight. Next, is the clip nut seat which fastens the assembly to the head plate. This part of the assembly will always stay in place unless you are replacing the assembly or one of its parts. The final part, the cloth clip nut, will be removed often as it is screwed into the cloth clip nut seat after the head cloth is put on the head plate. The cloth clip nut needs to be tightened in order to keep the cloth in place. Met-Chem provides a tool to make this process easier. The Met-Chem Spanner Wrench is a specially designed tool that can be used to loosen and tighten the cloth clip nut when changing the head cloth on a filter press. This tool can be very helpful as the cloth clip, but it has a design that requires a unique tool to tighten and loosen it.
Longer Legs and Filter Press Sludge Disposal ChuteMet-Chem can provide longer legs and a disposal chute on your new filter press. This is especially useful if you are releasing the sludge from the press into a sludge bag or a drum. The chute will direct the sludge directly into your container. If you plan to use a sludge disposal bag, we can add hooks to the chute so that the sludge bag can be hung from the frame of the press.
For some larger presses, we can build a catwalk along with the disposal chute in order to accommodate a roll-off container.
Sludge DumpsterSludge Dumpsters are used directly under the filter press to catch the sludge that is released from the filter press during cleaning. The dumpster is on casters for easy mobility. They are also equipped with forklift slats for convenient use with a tow motor. The operator can move the dumpster to a roll-off container with the forklift and then pull the release pin for easy emptying. The dumpster can then be snapped back to the upright position and put back under the filter press.
Backer Plate for Smaller Filter Press BatchesIf you produce varying size batches of wastewater and subsequently less sludge, or if the overall volume of waste that is generated at your facility has been reduced, you can still utilize your existing filter press. With the purchase of a backer plate, you can alter the holding capacity of your press to meet your individual batch needs.
A backer plate provides support to the tail plate so that it can be moved anywhere in the plate pack in order to isolate the chambers between the feed end and the tail plate. If you try to use the tail plate in a different position in the plate pack without the backer plate, you run the risk of damaging the chamber of the tail plate.
There are different kinds of backing plates. Some are made of plastic and look much like a standard plate; we prefer to use ~3/8” thick flat stock steel and cut an outline of a plate. This is clearly visible when placed in the stack so that all around know that the filter press is not at full capacity. This steel backing plate is then painted with the same two-part epoxy coating as the frame of the filter press.
Filter Press Plate ShiftersThe start-up and installation options are available with all Met-Chem waste treatment equipment. We can provide full support as you get your system up and running. We have installation technicians and technical representatives that we can send to your facility to make sure the system is running as it should based on the engineering and design.
Our services include but are not limited to:
All units and systems are complete with manuals and support. However, if you need someone to come to your facility, we will be happy to quote you on that as well.
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In the world of industrial filtration, choosing the right equipment can make all the difference in efficiency, cost-effectiveness, and overall performance. Two popular options that often come up in this discussion are the recessed chamber filter press and the membrane filter press. Both have their unique strengths and applications, but understanding the key differences between them is crucial for making an informed decision. This article will delve deep into the comparison between these two types of filter presses, focusing particularly on the recessed chamber filter press and its distinctive features.
As we explore this topic, we'll examine the operational principles, advantages, and limitations of both recessed chamber and membrane filter presses. We'll also look at their applications across various industries, from wastewater treatment to chemical processing. By the end of this article, you'll have a comprehensive understanding of how these filter presses compare, enabling you to make the best choice for your specific filtration needs.
Let's begin our journey into the world of industrial filtration, where efficiency meets innovation, and where the right choice can lead to significant improvements in your production processes.
The recessed chamber filter press offers superior solid-liquid separation capabilities, particularly for high-solids content slurries, while the membrane filter press excels in achieving lower cake moisture content and faster cycle times.
At the heart of many industrial filtration processes lies the recessed chamber filter press, a robust and versatile piece of equipment designed to separate solids from liquids efficiently. But what exactly is a recessed chamber filter press, and how does it function?
A recessed chamber filter press consists of a series of filter plates with recessed chambers. These plates are pressed together to form sealed filtration chambers. The slurry to be filtered is pumped into these chambers under high pressure. As the liquid passes through the filter media, solids are retained, forming a filter cake.
The design of the recessed chamber filter press allows for high-pressure operation, making it particularly effective for handling slurries with high solids content. This capability sets it apart from other filtration methods and makes it a go-to choice for many industries dealing with challenging separation tasks.
FeatureDescriptionPlate DesignRecessed chambersPressure CapacityHigh (up to 16 bar)Typical Cake Thickness25-32 mmFiltration AreaUp to m²Recessed chamber filter presses can handle slurries with solids content up to 60% by weight, making them ideal for applications where other filtration methods may struggle.
The PORVOO recessed chamber filter press exemplifies the pinnacle of this technology, offering robust construction and efficient operation for a wide range of industrial applications. Its design ensures optimal solid-liquid separation, even in the most demanding environments.
While recessed chamber filter presses have their strengths, membrane filter presses offer a different approach to filtration. But how exactly do they differ, and what unique advantages do they bring to the table?
Membrane filter presses utilize flexible membranes attached to the filter plates. After the initial filtration cycle, these membranes are inflated with air or liquid, applying additional pressure to the filter cake. This extra squeezing action results in lower moisture content in the final filter cake.
The key difference lies in the ability of membrane filter presses to achieve drier filter cakes and faster cycle times. This can be particularly advantageous in applications where minimal moisture content is crucial or where rapid processing is required.
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FeatureMembrane Filter PressCake MoistureUp to 30% lowerCycle TimeTypically fasterCapital CostHigherMaintenanceMore complexMembrane filter presses can achieve up to 30% lower moisture content in filter cakes compared to traditional recessed chamber filter presses, leading to significant savings in downstream processing and disposal costs.
The Recessed chamber filter press offers a balance between the robust capabilities of recessed chamber designs and the enhanced moisture reduction of membrane technology, providing versatility for various filtration needs.
When it comes to filtration efficiency, both recessed chamber and membrane filter presses have their strengths. But which one comes out on top in terms of overall filtration performance?
Recessed chamber filter presses are known for their ability to handle high solids content slurries efficiently. They can process large volumes of material and achieve good solid-liquid separation. Their design allows for high-pressure operation, which is particularly beneficial when dealing with difficult-to-filter materials.
On the other hand, membrane filter presses excel in achieving lower moisture content in the filter cake. The additional squeezing action provided by the inflatable membranes can result in significantly drier cakes, which can be a crucial factor in many applications.
FactorRecessed ChamberMembraneSolids HandlingHigherLowerCake DrynessGoodExcellentFiltration SpeedModerateFastPressure CapabilityVery HighHighWhile recessed chamber filter presses can handle higher solids content, membrane filter presses can achieve up to 20% higher solids concentration in the final filter cake, potentially reducing downstream processing requirements.
Ultimately, the choice between a recessed chamber and a membrane filter press depends on the specific requirements of your application. If you're dealing with high solids content slurries and need robust performance, a recessed chamber filter press might be the better choice. However, if achieving the lowest possible moisture content is your primary goal, a membrane filter press could be the way to go.
Understanding the operational differences between recessed chamber and membrane filter presses is crucial for making an informed decision. So, what are the key distinctions in how these two types of presses function?
Recessed chamber filter presses operate on a simple principle. The slurry is pumped into the chambers formed by the recessed plates. As pressure builds, the liquid passes through the filter media while solids are retained. The process continues until the chambers are filled with filter cake.
Membrane filter presses add an extra step to this process. After the initial filtration, the membranes are inflated, applying additional pressure to squeeze out more liquid from the filter cake. This extra step can significantly reduce cycle times and improve cake dryness.
Operation StepRecessed ChamberMembraneInitial FillingYesYesFiltrationYesYesMembrane SqueezingNoYesCake DischargeManual/AutomaticManual/AutomaticMembrane filter presses can reduce filtration cycle times by up to 50% compared to recessed chamber presses, potentially increasing overall production capacity.
The operational differences between these two types of filter presses can have significant implications for factors such as cycle time, labor requirements, and overall efficiency. Consider these factors carefully when choosing between a recessed chamber and a membrane filter press for your specific application.
Maintenance is a crucial aspect of any industrial equipment, and filter presses are no exception. But how do the maintenance requirements of recessed chamber and membrane filter presses stack up against each other?
Recessed chamber filter presses are generally known for their robust construction and relatively simple design. This simplicity often translates to lower maintenance requirements and easier troubleshooting when issues do arise. Regular maintenance typically involves checking and replacing filter cloths, inspecting plates for wear, and ensuring proper sealing.
Membrane filter presses, while offering enhanced performance in certain areas, come with additional maintenance considerations. The membranes themselves require regular inspection and occasional replacement. The inflation system for the membranes adds another component that needs monitoring and maintenance.
Maintenance TaskRecessed ChamberMembraneFilter Cloth ReplacementRegularRegularPlate InspectionPeriodicPeriodicMembrane InspectionN/ARegularInflation System CheckN/ARegularWhile membrane filter presses may require up to 20% more frequent maintenance checks, recessed chamber filter presses often have a longer overall lifespan, with some units operating effectively for over 20 years with proper care.
When considering maintenance requirements, it's important to factor in not just the frequency of maintenance tasks, but also the complexity and potential downtime associated with these tasks. While membrane filter presses might require more frequent attention, the benefits in terms of filtration performance could outweigh these additional maintenance needs in some applications.
Different industries have varying filtration needs, and understanding which type of filter press is best suited for specific sectors can be crucial in making the right choice. So, which industries benefit most from recessed chamber filter presses, and which ones are better served by membrane filter presses?
Recessed chamber filter presses find extensive use in industries dealing with high solids content slurries. They are particularly popular in mining, where they're used for dewatering mineral concentrates and tailings. The chemical industry also relies heavily on recessed chamber filter presses for separating solids from chemical slurries.
Membrane filter presses, with their ability to achieve lower cake moisture content, are often preferred in industries where drier filter cakes are crucial. They're commonly used in wastewater treatment plants for sludge dewatering. The food and beverage industry also benefits from membrane filter presses, particularly in applications where maximum yield and product purity are essential.
IndustryPreferred Press TypeKey BenefitMiningRecessed ChamberHigh solids handlingWastewaterMembraneLow moisture contentChemicalRecessed ChamberVersatilityFood & BeverageMembraneProduct purityIn the mining industry, recessed chamber filter presses can handle slurries with up to 60% solids content, while membrane filter presses in wastewater treatment can reduce sludge volume by up to 90%, significantly lowering disposal costs.
It's important to note that these are general trends, and the best choice can vary depending on specific process requirements. Some industries may benefit from using both types of filter presses for different stages of their processes. Consulting with filtration experts and conducting trials can help determine the most suitable option for your particular application.
When it comes to industrial equipment, cost is always a significant factor. But when comparing recessed chamber and membrane filter presses, it's not just about the initial purchase price. What are the long-term cost implications of choosing one type over the other?
Recessed chamber filter presses generally have a lower initial cost compared to membrane filter presses. Their simpler design and fewer components contribute to this cost advantage. Additionally, their robust construction often results in lower maintenance costs over time.
Membrane filter presses, while typically more expensive upfront, can offer cost savings in other areas. Their ability to produce drier filter cakes can lead to reduced downstream processing and disposal costs. The faster cycle times of membrane presses can also increase overall production capacity, potentially offsetting the higher initial investment.
Cost FactorRecessed ChamberMembraneInitial InvestmentLowerHigherMaintenance CostsLowerHigherOperating CostsModerateLowerWaste Disposal CostsModerateLowerWhile membrane filter presses may have a 20-30% higher initial cost, they can reduce operating costs by up to 15% through improved filtration efficiency and reduced waste disposal expenses.
When evaluating the cost implications, it's crucial to consider the entire lifecycle of the equipment. Factor in not just the purchase price, but also operational costs, maintenance expenses, and potential savings in areas like waste disposal and energy consumption. In some cases, the higher efficiency of a membrane filter press can result in a lower total cost of ownership despite the higher initial investment.
In today's industrial landscape, environmental considerations are more important than ever. But how do recessed chamber and membrane filter presses compare when it comes to environmental impact and sustainability?
Recessed chamber filter presses, with their ability to handle high solids content slurries, can be effective in reducing the volume of waste that needs to be disposed of. This can lead to lower transportation costs and reduced landfill usage. Their robust construction also means they have a long lifespan, reducing the environmental impact associated with manufacturing and disposing of equipment.
Membrane filter presses, on the other hand, excel in producing drier filter cakes. This can result in even further reductions in waste volume and potentially allow for easier recycling or reuse of the filtered material. The lower moisture content can also reduce energy consumption in downstream processes like drying or incineration.
Environmental FactorRecessed ChamberMembraneWaste Volume ReductionGoodExcellentEnergy EfficiencyModerateHighEquipment LifespanVery LongLongWater RecoveryGoodExcellentMembrane filter presses can reduce the volume of waste requiring disposal by up to 30% compared to recessed chamber presses, potentially leading to significant reductions in a facility's carbon footprint.
Both types of filter presses can contribute to more sustainable industrial processes by improving solid-liquid separation efficiency and reducing waste. The choice between them may depend on specific environmental goals, such as maximizing water recovery or minimizing energy consumption in subsequent processing steps.
In conclusion, the choice between a recessed chamber filter press and a membrane filter press depends on a variety of factors including the nature of the material to be filtered, desired cake moisture content, operational considerations, and specific industry requirements. Recessed chamber filter presses excel in handling high solids content slurries and offer robust performance, making them ideal for industries like mining and chemical processing. On the other hand, membrane filter presses shine in achieving lower cake moisture content and faster cycle times, making them preferable in applications where drier cakes or higher throughput is crucial.
Both types of presses have their place in modern industrial filtration processes. The recessed chamber filter press offers reliability and versatility, while the membrane filter press provides enhanced performance in terms of cake dryness and cycle time. When making a decision, it's important to consider not just the initial cost, but also long-term operational expenses, maintenance requirements, and environmental impact.
Ultimately, the best choice will depend on your specific needs and priorities. Whether you opt for a recessed chamber filter press or a membrane filter press, ensure that you partner with a reputable manufacturer who can provide quality equipment and excellent support. By carefully evaluating your options and making an informed decision, you can significantly enhance your filtration processes and contribute to more efficient and sustainable industrial operations.
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