optimization for existing tilting pan filters metalcraft
TRANSCRIPT
Optimization For Existing Tilting Pan Filters
Metalcraft
2
Metalcraft – Located in Tampa Florida
3
Metalcraft
Metalcraft Manufacturing
4
Metalcraft Services
Filter Pans
5
Metalcraft Car Frame
6
Metalcraft Bearing Pedestals
7
Level Track
8
Metalcraft Services
Installation of New Filter Components
9
Metalcraft Services
10
11
12
Optimization for Existing Tilting PanFilters
13
Reliability / Mission Time
• RELIABILITY speaks of intended function over time.
• MISSION TIME is critical to maximize acid production
14
Filter Mission Times
• Maintenance turnaround to turnaround
• Down day to down day (PM the filter)
• Scheduled wash cycle to wash cycle
• Scheduled cloth change out to cloth change out
15
Wash Cycle to Wash Cycle Mission Times
• Acid production is critical
• Interval times are critical
16
Cloth Change Mission Times
• Acid production is critical
• Intervals - Most Critical
17
Filter Performance Optimization
This is mechanical approach for existing tilting pan filters, offering increased mechanical reliability and increased recovery of P₂O₅. Results are, a reduction in maintenance costs and increased production dollars.
18
Objectives for Filter Optimization• Increase acid production
• Minimize dilution
• Increase P₂O₅ recovery
• Lower maintenance costs / Increase mission times
• Improve cloth cleaning efficiencies 19
Filter Optimization
Step 1• Initial operational and maintenance benchmarks
established.• A detailed study and mapping of the filter is
completed.
20
All aspects of the filter and its parts are measured21
Filter Optimization
Step 2• Measured data is integrated into the modeling
software.• Study of the filter in the “as found” condition
begins.
22
Filter Mapping Process23
Filter Optimization
Step 3• The filter is accurately modeled in its optimized
condition. • Demonstrates the recommended changes
24
Filter Optimization
Step 4• Client report submittal, steps planned in harmony
with client goals• Report includes optimized proposal package.
(How can Metalcraft best support changes the client would like to see?)
25
Filter Software Modeling – Design – Mapping Process
26
Components for Optimizing Existing Tilting Pan Filters
• Cloth spray headers
• Cam roller turnovers
• Enlargement of filtration area (pans)
• Filter valve timing
27
Cloth Spray Headers
28
Metalcraft Services
Nozzle Placement and Spray Patterns are Critical for Cloth Spray Header Efficiencies
29
Cloth Spray Header Optimization
• Nozzle Design and Efficiency
• Conflicting Sprays
• Delivered Flow and Pressure to Header
• Loop Design with Cleanout
30
Nozzle Design and Geometry
Vee Jet Flat Jet
31
sAddress cleaning for allareas of the pan - Corners
32
Typical Cloth Spray Header Installation
33
Metalcraft Services
Cam Turnover Sections
34
Cam Turnover
• Designed for accurate and simple field adjustment
• Assures proper operation
35
Metalcraft Services uses modeling software for both detailed design work and problem solving.
36
Cloth Spray Evaluation
3 D Modeling
37
38
39
40
41
42
43
44
45
46
47
48
49
50
Increased Filtration Area
51
Increased Filtration Area
• Considering new pans for an existing filter? • Build them with additional filtration area!
52
Filtration Area Increased to 13.92 s/m
Filtration Area Increased
.46 s/m Per Pan
53
Optimization for the Central Valve
• Is the valve timed correctly?
• Is dilution being addressed?
• Are wash and feed boxes located correctly to maximize filter efficiency
54
Central Valve
55
Optimization of Central Valve
• Adjustment / Repair of compartment baffles
• Replace Seal and Wear Plates
• Machining of Poly Ring and Timing Crown surfaces in place
56
Metalcraft Services
57
MCS 4/2010Metalcraft Services of TampaMetalcraft Services of Tampa MCS 4/22/2010
Filter Performance Optimization Results
58
Tilting Pan Filter Project Success – Example 1
Production and Down Time Cost Savings
• Savings of $0.9 Million per Year• Recovery of 3500 Tons of Phosphoric Acid Per
Year• Reduced Cloth Usage and Overtime Cloth Changes
59
Tilting PanFilter Project Success – Example 2
Production and Down Time Cost Savings
• Reduction of Filter Down Time Per Month• Increase P₂O₅ Recovery• Overall Filter Improvement Annual Savings - $2.2
Million Per Year
60
Other Filter Components for Optimization
Car Frames
Bearing Pedestals
Level Tracks
61
Car Frames
• Heavy Duty T316L Stainless Steel Design
• integrated Wear Track – Minimal wear to bottom flange of the frame
62
Improved Joint Design For Car Frames
63
Car Frame Bull Gears
Integral Bull Gear bolts directly to the frame
64
Filter Pans in Progress
65
Objectives for Filter Optimization• Increased acid production
• Minimize dilution
• Increase P₂O₅ recovery
• Lower maintenance costs / Increased Mission Times
• Improved cloth cleaning efficiencies 66
www.metalcraftservices.com
METALCRAFTLeading with Vision
67