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Filtration Group application example – Chemical Industry Backflush filter R8-10 for the manufacture of plant protection products

Initial situation

Solution statement

Customer value

Challenge In the chemical industry the highest requirements for process quality, purity, safety, and environmental protection are in place, and therefore also for our clients who are committed to global food security with an emphasis on innovative cultural solutions, seeds, and crop protection. In the production of pesticides, methyl-phosphonic acid n-butyl ester (MPE) is produced during one step, which is a required precursor for the herbicide glufosinate-ammonium. The herbicide is used to fight weeds and root suckers. Process-specific provisions from clients require a high level of customization of the pressure housing. Consideratio of work standards, as well as build support and in-house approval of the fiter, guarantee Filtration Group‘s responsibility. Modification of the filter elements is the distinguishing feature of the 2-model system as compared to other products. The components of the filter element must be adjusted without changes to the basic dimensions.

� Fully automatic backflush filter with R8-10 flushing by using its own medium � Adjustment of the existing filter solutions to the specific circumstances of the client‘s processing � Modification of the filter elements with special fabric � Use of a tangential clamping element to reduce the radial distances within the filter elements � Use of a mechanical seal for the shaft opening � Through the use of the tangential clamping device, the particularities of the process can be addressed

while retaining the standard parts

� Reduction of the residual particulate load from the process � Significantly lessened damage to the pumps reduces the need for replacement � Process security by means of specifically customized filter elements � Use of tried and tested, robust backflush technology � High operational security from using a mechanical seal for the thermosiphon system

The backflush filter supplied by Filtration Group are used as pump protection fitlers. Pumps, which are used most of all for the transport of fluid media, must be protected from damages caused by solid particles. In this project particles result from the quenching of an organophosphorous liquid. The sump of the quench condensation column is sent through a canned motor pump into a cooler and subsequently fed to the quench once it is cooled. Coarse particles from the condensation column disrupt the subsequent processes and diminish the service life of the canned motor pump. Technical data � 2 x R8-10 backflush filter � DN 250 / size F09 � Material: Stainless steel 1.4571 � Specific process data is agreed to be confidential

Factory Equipment

Filtration Group GmbH Phone: +49 7941 / 6466 - 0 Schleifbachweg 45 Mail: [email protected] 74613 Öhringen www.fluid.filtrationgroup.com

Filtration Group application example – Chemical Industry Polymer binders with the automatic metal edge filter AF 75S

Initial situation

Solution statement

Customer value

Challenge Polymer binders (=dispersions) are required today in numerous industries and on all continents. These are used, among other things, to formulate low-odour and low-emission interior paints. Disperions are used in plasters, cements, for insulation materials, adhesives, technical textiles and carpets. Our customer is the global market leader in the production of polymer dispersions and dispersible polymer powders with sites in Europe and Asia. For a new production plant for dispersible polymer powders in South Korea with an annual capacity of 80,000 tons, Filtration Group was commissioned to supply an automatic metal edge filter (3x AF75S) for the filtration of the precursor VAE (vinyl acetate-ethylene copolymer).

� FG Automatic metal-edge filter AF 75 S with radial scraper cleaning � Compact inline filter system can be equipped with automatic cleaning � Filtration Group welded cartridge type AF 6076-XXX with high wear resistance to abrasive

media; sturdy trapezoidal profile for high-viscosity media; continuous welded design � Housing in multipart design for optimum operation

� Automatic filters enable automated operation of the system � Low Life-Cycle-Costs, because cleaning of screen basket filters and disposal of filter bags is

not necessary (replacement of so called knot catcher) � Process reliability through efficient filter cleaning � Precise separation quality (high product quality) � Optimized throughput time (increase of batch number by shortening the pumping time)

For the filtration of dispersions (batch operation), the compact inline filter does not consume any filter material. This eliminates the need for subsequent disposal. Solid particles or agglomerates are removed from the surface of the filter medium by scraper cleaning. The patented bearing of the filter elements (AKF-system) for the prevention of high axial forces (easy cleaning process) was further developed especially for the highly viscous dispersion formulations (up to 100,000 mPas). In addition, the housings have been selected for optimum operation in a multi-part design.

Factory Equipment


Info Already in 2017, automatic filters from Filtration Group were successfully used by our customer in Southern Germany as part of a capacity expansion for disperions.

Filtration Group application example – Factory Equipment Isocyanate with automatic metal-edge filter AF 73 S

Initial situation

Solution statement

Customer value

Challenge Our customer is a global chemical company and manufacturer of base and speciality chemicals as well as high-performance materials that are used in different everyday products. In the manufacture of highly viscous products in the chemical industry, such as adhesives, insulating components seals, underbody protection etc., Filtration Grup automatic metal-edge filters are often the only technology that provides economical filtration to protect downstream process steps against contamination. In the manufacturing process of MDI (methylene-diphenyl-isocyanate), a raw material for polyurethane, the main task is to retain and separate any possible agglomerates or deposits from the reactor. Isocyanate has almost no lubrication properties, which must be taken into account when designing the bearings. It reacts with substances that demostrate an OH group (e.g. water, also humidity etc.) vis-à-vis solid matter.

� Automatic metal-edge filter AF 73 S with optimised bearing points and a double action mechanical seal that is flushed with anhydrous white oil (vaseline)

� Filter supplied completely free of lubricants or preservatives� Shaft seal in compliance with Germany‘s „TA-Luft“ air quality regulations� No ingress of humidity into the process in order to avoid secondary reactions� The FG automatic metal-edge filter replaces existing basket strainer filters, thus minimising

employeess‘ contact with isocyanate

� Process safety through efficient filter cleaning and the associated improvement in safety andenvironmental protection

� Precision separation using the metal-edge filter principle� Cleaning performed without an interruption in filtration� Low life-cycle costs as no filter material is used

In this sepcial manufacturing process the products are processed in complex machines and systems, i.e. applied with fine nozzles. Foreign particles and agglomerates of products constituents would lead to malfunctions and product waste here, and in the worst case scenario, cause damage to the machines. In order to guarantee reliable operation for our customers, Filtration Group supplied an automatic metal-edge filter AF 738 with optimised bearing points and a double action mechanical seal that is flushed with white oil (vaseline).

Technical data

� Medium: methylene-diphenyl-isocyanate (MDI)� Operating pressure: 10 bar� Operating temperature: 25 – 40 °C� Filter fineness: 250 μm� Volume flow: 35 m³/h

Factory Equipment


Filtration Group application example – Chemical industry Conductive polymers with FG automatic backflush filter AF 173

Initial situation

Solution statement

Customer value

Challenge Electrically conductive materials play a key role for curved, 3D or foldable displays in the form of printed electronics. The materials used for this must have sufficient mechanical flexibility. Conductive polymers are long chains of molecules containing identical units that are linked together. In order to become electrically conductive,the polymer must imitate a characteristic of metals. In order for a current to be able to flow, there must be electrons which can move freely (as there are in metals), and which unlike in most materials are not fixed to atoms. Conductive polymers are used for antistatic equipment, as electrodes, and as functional layers in liquid crystal screens and OLED displays as well as in organic photovoltaic systems. Our customer, a technology group based in Hanau, provides an ideal solution for this in the form of conductive polymers which can be used in touch-sensitive touch panels. The polymer material is suitable for use as an electrode in touch screens and printed electronics.

� The AF 173 test filter that is used features pulsating external pressure segment cleaning in a continuous filtrate flow, and it provides automatic cleaning of the filter elements and back-flushing with demineralized Water

� The filter element rotates through an integrated wash station where through the application of externally supplied cleaning medium and pressure the filter fabric is backrinsed and washed into a collecting duct that leads to the outside

� The backflush nozzle and the backflush duct are sealed off from the filter chamber by press-fitted sliding sealing stripes.

� Low life cycle costs because no filter material is consumed � Less manual handling as there is no longer any need to change the module, bag and candle � Significantly reduced waste: the rinsed materials can be directly fed into the wastewater treatment

system � Less space required: previous filter solution requires considerably more operating space than the FG

test filter that is used

Our customer has a large portfoloio of materials and technologies for use in printed electronics. In the filtration of polymer solutions, the FG automatic backflush filter that is used provides reliable cleaning of the filter surface through temporary and / or partial flow reversal. The 3-stage cascade solution that was previously used was very time-consuming and expensive to operate. In order to achieve the required filtration quality, separation was carried out using a filter bag, a filter candle, and a modular filter.

Factory Equipment


Info Positive side effect: Previously, silicon and aluminium components were dissolved into the cascade from the filter modules, and this may affect the performance of the polymers. The use of FG’s technology enabled the concentration of aluminium and silicon to be reduced to 0.00 ppm.

Filtration Group application example – Chemical Industry Color filtration with the automatic filter AF 133

Initial situation

Solution statement

Customer value

Challenge The production process of paint manufacturing is subjected to strict regulations. The working conditions are comparable to the conditions of a chemical company, which means that there are different ATEX zones. These conditions have to be considered in the selection of machines and components. Due to the toxic gases the maintenance staff has to wear breathing masks when they change the mechanical filter bag. Because of the costly exchange of components, the customer was searching for a filter system which is automatically and self-cleaning without the expenditure of a filter aid and the loss of filter media.

After a comprehensive requirements analysis and a one-year test run, the customer opted for an AF 133 automatic filter with filter coil and segment cleaning system with external pressure on the recommendation of the Filtration Group employees. This made it possible to replace the previous bag filter system, which could only be maintained at great cost and effort. The modular design of the automatic filter made it possible to develop a tailor-made solution for the customer. In addition, the requirements of the various ATEX zones could be met without any problems, so that nothing stood in the way of use. For the future it is planned to use 8 additional automatic filters in the customer's factory.

� Lead time has increased four times in comparison to bag filters� Process reliability thanks to the efficient filter cleaning� Effective segmentally cleaning process of the filter with a high backflush pulse� Protection of the maintenance workers because of the elimination of toxic gases� No expensive process downtimes due to maintenance works� Protection of the environment, thanks to the avoidance of waste

The focus is on the removal of metal particles and gel plugs from solvent-based resin varnishes. The separation limit was set at <60μm - 80 μm . In addition, there were the following requirements:

� Reduction of paint losses and manpower � Use in ATEX zone 1 possible � Completely made of stainless steel (V4A) � Shortening of batch processing times � Use of filter aids

Product information

� semi-finished product � Highly filled with titanium dioxide � On nitrocellulose basis � Flow rate: ~5m³/h � Operating temperature: 50°C � Viscosity: approx. 335mPa/s at shear rate 10001/s

Factory Equipment


Filtration Group Application example - Chemical industry Dedusting unit for fibrous and light dusts in the production of polyethylene nonwovens

Initial situation

Solution approach

Challenge

In the production of nonwoven fabric made of polyethylene produced during production dusts and fibers that must be separated from the existing gas atmosphere. The occurring dusts are very light and fine and provided with a fiber content, which results in high filtration requirements. Since the gas present in combination with oxygen is extremely explosive, it must be ensured that no air is introduced into the system. For this reason, the filter elements can be cleaned only with nitrogen. The dedusting filter have to protect downstream components - such as heat exchangers - from contamination. Plant downtimes due to necessary cleaning work mean enormous costs for the customer due to the associated loss of production.

� A generously dimensioned round filter unit achieves a low filter surface load so that the very light dust can sediment after cleaning and fall off the filter elements.

� Conical filter elements with a reduced filter surface and thus greater pleat spacing, together with the rotating wing used, ensure a

satisfactory cleaning result even with these agglomerating fibers. � Special material selection for seals and other components to ensure resistance to the gas atmosphere. � Massive flanges and suitable gaskets ensure a nearly gas-tight design even at higher pressures.

� Reliable separation of particles and fibers by our filter material equipped with PTFE membrane, which significantly reduces the

contamination of downstream components. This reduces the number of plant downtimes due to the need for cleaning, which can increase production time and quantity

� Low-maintenance filter system ensures trouble-free continuous operation.

� By using our FG Quick-Lock system, we enable the customer to change filter elements quickly and without tools, which can shorten the duration of plant downtime for maintenance. Insertable gratings allow a more comfortable replacement of the filter elements.

The occuring dust must be reliably separated in order to protect the downstream components. At the same time, efficient cleaning of the dusts must ensure continuous operation without the need for maintenance work. Technical specifications

� Dedusting unit SFR-09 024 DN-240 S6. S1.. KA: Painted filter housing with a diameter of 2.4 meters, a height of approx. 5 meters and a total weight of 6.2 tons � 24 filter elements 852 032 Ti07 / 1 - 7.5: Conical Quick-Lock elements for tool-free element replacement with electrically conductive polyester fleece with PTFE membrane � Gentle and very efficient cleaning of the filter elements with compressed

air via conical rotating wings

factory equipment

Filtration Group GmbH Tel.: +49 7941 / 6466 - 0 Schleifbachweg 45 Mail: [email protected] 74613 Öhringen www.fluid.filtrationgroup.com

Customer value

filtration group application example chemical …filtration group application example – chemical...

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