Industrial filtration is essential in most industries. Filtration can ensure that the end product is of high quality, that machinery is safeguarded so that plant can run successfully and that running costs are minimized. With applications in water treatment, chemical production, foodstuffs, pharmaceuticals, power generation and many more, choosing the right filtration system can be vital to a process‘s efficiency. For high volumes of flow, one of the most suitable filtration systems is the high flow filter; although even such high flow filtering systems need choosing carefully by considering flow rates, types of contamination, operating environment and maintenance.

This guide addresses important criteria for choosing the right filtration system for your industrial application and shows how felt bags filters could fit into your overall filtration plan.

Understanding High Flow Filters

High flow filter: offers large volume process capability at low pressure drops, high solids removal efficiency. Most standard filter cartridges unable to provide the required flow rate; using high flow design can achieve 2 to 5 times the flow rate with fewer filter elements.

These filters are commonly used in:

Industrial water treatment

Oil and gas processing

Much of the oil obtained from the platform has to be converted into liquid form before it can be piped ashore. For this purpose, oil goes through a processing facility called the “Oil Treatment package,” where heavier, off-specification oils are “stabilised” through heating and separation. Gas is also processed in the “Gas Plant”.

Treatment of chemicals

Food and beverage manufacturing

Electronics manufacturing can be protected by the following:(except minimize the size and dimensions of devices)

Pharmaceutical processing

Generating plants

Electricity generation plants for public power supplies are generally Class I and Class II. Generation plants in the scope of this paper include utility and non-utility bulk power generating stations, Independent Power Producers, cogeneration, and all other CHP plants.

Their larger filtration surface area means they have an increased dirt-holding capacity, longer service life, and consequently less frequent maintenance.

Why Choosing the Right Filter Matters

Failure to choose the correct filtration system can result in a number of operational issues such as:

More downtime

Has higher maintenance costs

Decreased equipment life.

Product contamination:

Process inefficiencies

High power consumption

The right high flow filter improves productivity and operating costs as well as assuring high filtration efficiency.

Evaluate Your Flow Rate Requirements

The flow rate needed is one of the initial factors to consider when choosing a filtration system. For instance, some industrial processes require the filtration of large quantities of liquid.

Questions to consider include:

Fluid flow rate through system/min

Exist peak flow intempols?

Will future growth cause increased flow demands?

A high flow filter that is properly sized will operate efficiently without impeding flow or creating excessive pressure differential across the system.

When computing flow requirements it is best to consider present and future operational needs so as to not upgrade the system repeatedly.

Identify the Type of Contaminants

Having a good understanding of what contaminants are in your process stream is a must to select the proper filter media.

Common contaminants include:

Sediment and particulate matter

Rust and scale

Organic substances

Presence of undesirable chemical impurities;

Biologicalcontaminants

Process waste sediments.

The various filter media have been optimized to remove certain pollutants. For instance, one application may need the removal of fine particles whereas another may require removal of large suspended solids.

A full fluid analysis will allow the user to select filtration efficiencies and media accordingly.

Consider Micron Rating Requirements

The micron rating is a measurement of the size of particles that a filter will be able to filter out. This is an important factor in selecting a filter to achieve the filtration performance required.

Typical filtration levels include:

Coarse filtration of: 50 100 microns

Medium filtration: 10–50 Microns

Fine filtration: 1–10 micro m

Ultra-fine filtration: under 1 micron.

A high flow filter with the correct micron rating can both preserve downstream equipment and keep the process running smoothly.

Choosing an excessively fine micron rating (e.g. 1-micron) can significantly increase pressure drop and reduce the life of the filter, while an excessively coarse rating may not provide sufficient protection.

Assess Chemical Compatibility

Industrial environments can be exposed to aggressive chemicals, solvents, acids, and cleaning products.

When selecting a filter, evaluate:

Fluid composition

Operating p H range

Concentration of chemicals

Duration of exposure

The filter housing, seals, and media should be compatible with process fluid. Compatibility is important to avoid media degradation, which results in unreliable operation.

Ignoring the effect of chemical incompatibilities can cause premature filter failures and expensive downtime.

Analyze Operating Temperature and Pressure

Operating under Severe Conditions Industrial filters are often under severe operating conditions. Performance of the filter can be heavily influence by high temperature and elevated pressure.

Before choosing a high flow filter, review:

Maximum operating temperature

System pressure normal

Pressure variations

Cleaning procedures

Filters are manufactured to resist various operating conditions. Make sure the filter material is suitable for your application to optimize its use.

Compare Filtration Media Options

Filtration media.. The filtration media is the core of the filtration. There are many different media types that will give different levels of performance depending on the application.

Common media options include:

Polypropylene

Polypropylene media has good chemical resistance and can be used for many types of industrial applications.

Polyester

Polyester media has a high durability and performs very well at hightemperature applications.

Glass Fiber

Glass fiber media provides high quality particle retention, is used for fine filtration applications.

Felt Media

Suitable for a variety of applications, felt bag filters are used by many industrial plants as a cost effective pre-filtration or primary filtration process. The felt bags have an outstanding dirt-holding capacity and are suitable for high loading.

In applications with heavy particulate contamination, felt bag filters help protect downstream cartridge filtration systems by increasing the length of time between changing out the bags.

Evaluate Maintenance Requirements

There are large cost of ownership over the lifetime of filtration systems.

Consider factors such as:

Frequency of filter replacement

Installation comfort

Maintenance failures

Availability of replacement parts

A high quality high flow filter can mean less change outs as it generally has a larger area and more loading capacity.

Decreasing maintenance intervals can boost efficiency and reduce labor costs.

Consider System Scalability

Industrial operation is ever-changing. Filtration system used today might be not enough for next times.

When selecting a filtration solution, evaluate:

Future production goals

Expansion plans:

Rising flow requirements.

More Processing Lines

A scalable high flow filter system should be selected so that it can adapt as flow increases without large infrastructure upgrades.

Focus on Total Cost Rather Than Initial Price

Like purchase price, visibility is important, but a focus on one time costs can overlook the life cycle costs involved.

A comprehensive evaluation should include:

The life span of filter was another important factor. Filters were intended to be used for a period of time, over which they accumulated deposits and filtration capacity was gradually reduced. Any statement on depth filter life was given in terms of the filtration area per number of liters of filtrate.

Maintenance costs.

Energy use:

How often are they replaced?

Downtime costs.

In many instances a high flow filter offering high efficiency also offers better value by saving operating cost during the service life.

Equally, it is advisable to use felt bags filters, where feasible as this can improve overall system efficiencies and reduce filtration costs.

Industry-Specific Considerations

Various industries have different filtration needs.

Water Treatment

High throughput and reliable removal of contaminants are essential to safeguard water quality.

Food and Beverage

Hygiene and Product Quality Standards. Ventilation systems must be in accordance with rigid hygiene and product quality standards;

Chemical Processing

Chemical compatibility and resistance to aggressive fluids, is similarly important.

Pharmaceutical Manufacturing

A high level of filtration and contamination control will be required in order to conform with regulations.

Power Generation

Protecting critical equipment from particulate contamination preserves reliability.

High flow filter suited for your industry requirements can provide quality and budget saving regulatory approval.

Conclusion

Selecting the correct high flow filter for your industrial application involves a comprehensive assessment of flow demands, contamination types, micron ratings, operating conditions, and maintenance requirements. A detailed analysis of these factors can help one to enhance filter efficiency, minimize downtime and decrease expenditure.

For many applications, utilizing a carefully chosen high flow filter in conjunction with felt bags filters provides an excellent protocol for maximizing removal of contaminants and extending equipment life. Time spent optimizing your filtration system today can provide considerable benefits in the future.