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Continuous Pressure&
Steam Pressure Filtration
Hi-Bar Filtration
3 / 2
009
e
0
1
2
3
4
5
0 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 0,9 1
Sättigung S
Dru
ck p
[bar
]
mec
han.
Ent
feuc
htun
gsgr
enze
kapillarer Eintrittsdruck
Sr S3 bar SVakuum
Druckfiltration
t2: demoisturing time
30 s
pke
t2 = ∞ t2=0
Vakuumfiltration
120 s 60 s
25.06.2007
1
-1-
What are the advantages ?
Pressure Filtration
higher throughput rates
mS ~ ∆p, n
separating of fine particles
reduced moisture contents
(overcoming of the capillary forces)
S = f [ (∆p – pke), t2, ...]
improved filter cake washing
0
1
2
3
4
5
6
0 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 0,9 1
Saturation S
Cap
illary
Pre
ssur
e p C
[bar
]
t2: demoisturing time
t2=120s
t2=60st2=30s
pce
t2=∞
t2=0pressure filtration
capillary entry pressurevacuum filtration
mec
hani
cal d
emoi
stur
ing
limit
-2-
Theory of Filter Cake Formation
machineparameters
processparameters
productparameters
( ) 600,3A36060
npr
21AmM F01
cLsFss
.⋅⋅
α⋅⋅∆⋅κ⋅
η⋅ε−ρ=⋅= &
ms [kg/m²s] specific solids throughputηL [kg/ms] filtrate viscosityκ [-] solids concentration coefficientrC [1/m] cake resistanceε [-] porositiy
productparameters
n [1/min] filter speed∆p [N/m²] pressure difference in form zone
processparameters
α1 [°] cake forming angleΑ [m²] filter area
machineparameters
-3-
continuous filtration process with drum or disc filters
high filtration pressure difference of up to ∆p = 6 bar
cake discharge by air-blow-back
reliable sluice technology for sluicing the cake out of the vessel
Standard version of Hi-Bar Filtration:compressed air is used for filtration
Hi-Bar Steam Pressure Filtration:superheated steam is used for cake dewatering and cake washing
Hi-Bar Filtration Processes
Features of Both Versions
-4-
Hi-Bar Filtration Plant Design
With horizontal pressure vessel(large units) for:
filtering, washing and dewateringof bulk materials withhigh throughput rates
With vertical pressure vessel(small units) for :
sophisticated separation tasks likewashing and drying of valuable productsin the chemical industry, pharmaceuticalindustry, food industry, etc.
25.06.2007
2
-5-
Benefits of Hi-Bar® Filtration
Benefits of Hi-Bar Filtration
-6-
Hi-Bar Drum and Disc Filterin Horizontal Pressure Vessel
Hi-Bar Drum Filter Hi-Bar Disc Filter
-7-
Hi-Bar Filter in Horizontal Pressure Vessel Technical Data
Sizing of Drum Filters
56 - 1686 - 84[m²]Filtration Area
3.22.2[m]Disc Diameter
SXS[-]Filter Type
Sizing of Disc Filters
6.8 - 20
1.8
M
40 - 8116 - 40[m²]Filtration Area
3.22.4[m]Drum Diameter
XLL[-]Filter Type
-8-
Hi-Bar Steam Pressure Filtration Model of the "Condensate Front"
continuous moving of an even condensate fronthomogeneous heating of the whole filter cakeemptying of nearly all poresviscosity reduction of the residual liquidexcellent washing out (extraction)
25.06.2007
3
-9-
Hi-Bar Steam Pressure FiltrationProcess and Plant Principle
cake
filtrate, condensate
and air
compressedair
sluice
suspensionfeed
wash water
steam(Psteam)
∆pFiltration
=P1 – PATM ≤ 6 bar
Psteam = P1
P1 = pressure inside vesselP2 = pressure at cake discharge
P2 > P1
-10-
Hi-Bar Steam Pressure Disc Filter in a Horizontal Pressure Vessel
steam cabin
-11-
Filter area 6–24 m²
Oyster Disc Filter
Filter area 0.4–8.8 m²
Oyster Drum Filter
BOKELA Hi-Bar Oyster FilterDisc and Drum Filter
Filter
Pressure Vessel
Sluice
Main Parts steam
cabin
-12-
Hi-Bar Oyster Filter Plant
Oyster Drum Filter with steam cabin& exchangeable filter cells
filter area: 3.6 m²
25.06.2007
4
-13-
Oyster FilterExcellent Accessibility - Easy Maintenance
excellent accessibility for maintenance work by completely hinged pressure vessel
• no release of vessel inspection required
smooth design of all components
avoiding of unnecessary clearance volume
no unnecessary seals
CIP-equipment
-14-
Oyster Drum Filter with Exchangeable Filter Cells
• leading and tailing filtrate pipes• excellent cell emptying by filtrate
discharge at the leading and tailing edge of the cell
filtrate pipes
exchangeable cells
• optimal filtrate separation • no filtrate entrainment
Oyster Filter with steam cabin
-15-
Oyster FilterSluice System
Sluice with proven and well established swing valvesSingle or tandem sluice (depending on filter size)Avoiding of product sticking by heatingCIP
swing valve (solids sealing)
Upper swing valve (pressure sealing)
Lower swing valve
-16-
BOKELA Hi-Bar Oyster FilterSizing
* No single cell design
4
3
2
1
discs
3.5 x 3.5 m8.8 m²1.9 mM9*
2.8 x 2.8 m5.0 m²1.4 mS5
2.2 x 2.4 m2.0 m²0.9 mXS2
3.5 x 3.5 m6.0 m²2.2 mXS1
floor spacefiltration areadiametertype
24.0 m²
18.0 m²
12.0 m²
6.8 m²
3.6 m²
1.0 m²
filtration area
3.5 x 3.5 m2.2 mXS4
3.5 x 3.5 m2.2 mXS3
3.5 x 3.5 m2.2 mXS2
type
M7
S4
XS1
3.5 x 3.5 m1.9 m
2.8 x 2.8 m1.4 m
2.2 x 2.4 m0.9 m
floor spacediameter
Dru
m F
ilter
sD
isc
Filte
rs
25.06.2007
5
-17-
Application of Steam Pressure Filtration
Filter Drier+ Thermal drying
Filter Drierchem.
Reactor(+) + Chemical Material Conversion
or
Filter + +Thermal drying withdry product re-circulationor with additives
DrierProductRe-Circulation
Filter ....Filter+ + (+)
Multiple washingwith re-slurring, high wash water consumption, evaporation, ...
Re-slurrying
Alternative:Hi-Bar Steam Pressure Filtration
SteamPressure Filtration
-18-
Steam Pressure Filtration with the Oyster Filter Anorganic Compound
thermal efficiency: 1,010 MJ/t : 330 MJ/t = 305%
nextprocess
step
nextprocess
step
Hi-BarOysterFilter
filterstoragetank
storagetank
mc = (25-) 35 %pore liquid: 538 kg/t
energy consumption:1,010 MJ/t
- high energy costs- long cleaning periods incase of product change
- product loss product damage- investment and maintenance
mc = 15 – 20 %pore liquid: 250 kg/t
steam consumption: 110 kg/tenergy for steam production: 330 MJ/t
- no dryer required due toExtremely low moist. content
- quick product change- reduced energy costs- continuous operation
required: moisture content mc < 20 %(for product handling without sticking)
thermaldryer
mc < 20 %
-19-
Steam Pressure Filtration with the Oyster Filter Anorganic Compound
Oyster Drum Filter with steam cabin
filter area: 3.75 m²-20-
Steam Pressure Filtration with the Oyster Filter Precipitated Calcium Carbonate (PCC)
thermal efficiency: 1,140 MJ/t : 469 MJ/t = 243 %
Vacuum Drum Filter
low moisture contents* improve the product handling and * simplify the process design: - no product recirculation - no product mixing - careful product treatment without product damage - reduced energy costs
mc required < 25 %drying energy: 1140 MJ/tfor ∆mc (37% to < 25%)
Thermal Dryer
recirculated solids: 50 % StorageTank
cake moisture: 37 %pore liquid: 587 kg/t
driedCaCO3
StorageTank
cake moisture: 24 %pore liquid: 316 kg/t
steam consumption: 250kg/tenergy for steam: 469 MJ/t
Thermal Dryer
Hi-Bar Steam Pressure Filtration
25.06.2007
6
-21-
Hi-Bar Steam Pressure FiltrationWashing and Dewatering of FGD-Gypsum
0.80(t/h)steam consumption700600(m³/h)gas throughput
1212(t/h)solids throughput
3.311(%)cake moisture
1.23(m³/h)wash liquor
40 - 5050 - 100(mg/kg)Cl- content in the cake
0.3 – 1.01.5(wt-%)solids in the filtrate
3050(kW)energynonoflocculants
Results
Air blow backscrapermethod of cake discharge1.50.7(bar)pressure difference10.75(rpm)filter speed1617 - 20(mm)cake thickness22number of filters1018(m²)filter area
Hi-Bar Steam Pressure Filtration
Vacuum Drum Filter
Target:
reducing of
reducing ofreducing of
reducing of
-22-
Hi-Bar Steam Pressure FiltrationDewatering of Fine Coal
Comparison of Filter Performances
coal concentrate 1 coal concentrate 2technical data pressure Hi-Bar pressure Hi-Bar
disc filter SPF disc filter SPF
No. of Filters 1 1 1 1
filter area (m²) 120 146 120 85
solids throughput (t/h) 100 100 70 70
cake thickness (mm) 17.5 15 12.5 10
filter speed (1/min) 1.25 1 1 1.7
pressure difference (bar) 2.5 2.5 2 2.5moisture content (wt-%) 19.5 8.5 18 9.5water per 1t solids (kg/t) 242 93 196 105
gas throughput (m³/h) 4,500 1,600 3,500 2,100
power consumption (kW) 248 97 165 120
steam consumption (t/h) 0 9.2 0 7steam/kg water removal (kg/kg) - 0.62 - 0.67
-23-
Comparison of Filter Technologies
Hi-Bar Steam Pressure FiltrationDewatering of Hematite Iron Ore Concentrate
noyesthermal drying of cake
3880 - 100(kg/t solids)steam consumption
97248(kW)power
912.5(wt-%)moisture content
60.8(bar)pressure difference
2,500585(kg/m²h)specific solids throughput
15035(t/h)solids throughput
6060(m²)filter area
Hi-BarSteam Pressure
Filtration
Steamingon
Vacuum Filter
-24-
12.5585vacuum
9.02,0006.0C
limonite
11.0550 - 690vacuum
9.02,5003.0B
hematite/limonite
12.5480vacuum
6.98203.3A
hematite
MoistureContent
[mass %]
SpecificSolids Throughput
[kg/m²h]
PressureDifference
[bar]
Iron Ore
Pressure Filtration versus Vacuum Filtration
Hi-Bar Steam Pressure FiltrationDewatering of Hematite Iron Ore Concentrate
25.06.2007
7
-25-
Moisture Content Versus Time- Second Filtration / Continuous Operation -
15
17
19
21
23
25
27
29
31
33
35
250 300 350 400 450 500 550
No. of Test Trial
Moi
stur
e C
onte
nt [%
]
67 % A / 33 % C, No. 254 - 268, 13.11 - 15.11
75 % A / 75 % C, No. 269 - 292, 13.11 - 15.11
100 % A, No. 293 - 354, 15.11 - 1.12
75 % A / 25 % B, No. 355 - 453, 3.12 - 8.12
75 % C / 25 % D, No. 454 - 518, 10.12 - 15.12
100 % A, No. 519 - 536, 17./18.12
Target: mc = 23 %
extremely low moisture content
Hi-Bar Steam Pressure Filtration Dewatering of Red Mud
-26-
Soda Content Versus Wash Ratio- Second Filtration, Continuous Operation -
0
0,3
0,6
0,9
1,2
1,5
0 1 2 3 4 5 6Wash Ratio [kg wash water / kg solids]
Soda
Con
tent
[%
]
all measurements
upper trend line
lower trend line
tendency from first filtration
Hi-Bar Steam Pressure Filtration Dewatering of Red Mud
extremely low soluble soda content
-27-
mc = 35 % mc = 23 %
Vacuum Filtration Hi-Bar Filtration
Hi-Bar Steam Pressure Filtration Dewatering of Red Mud
Comparison of Filter Technologies
-28-
Results and Economy of Hi-Bar Steam Pressure Filtration
PRODUCT: Anorganic Product CaCO3 Fine Coal Gypsum
steam consumption per ton dry solids mSteam 110 kg 250 kg 70 kg 80 kg
CALCULATION OF PORE LIQUID (mSolid = 1t) moisture content pressure filtration mc 35 % 37 % 20 % 11 %
calculated mass of pore liquid in filter cake mL 538 kg/h 587 kg/h 250 kg/h 124 kg/h
moisture content steam pressure filtration mc 20 % 24 % 10 % 3 %
calculated mass of pore liquid in filter cake mL 250 kg/h 316 kg/h 111 kg/h 31 kg/h
reduction of pore liquid using steam ∆mFI 288 kg/t 272 kg/t 139 kg/t 93 kg/t
CALCULATION OF ENERGETIC EFFICIENCY steam consumption mSteam 110 kg/t 250 kg/t 70 kg/t 80 kg/tenergy comsumption of thermal dryer(boiler efficiency = 75 %) qSteam 330 MJ/t 469 MJ/t 131 MJ/t 150 MJ/t
energy consumption thermal dryer(0.1l oil per kg steam) q(∆mFI) 1010 MJ/t 1140 MJ/t 583 MJ/t 389 MJ/t
thermal efficiency = ∆mL / mSteam η 306,1 % 243,1 % 445 % 259,3 %
SPF
PF
25.06.2007
8
-29-
Hi-Bar Filtration Pilot Plant
mobile plant for on site operation
Hi-Bar Pressure and Steam Pressure Filtration
pressure up to ∆p < 6 bar
disc or drum filter
automatic filter control
all necessary peripheral equipment ensuring a quick start up of pilot operation
View of the Pilot Plant
-30-
Hi-Bar Filtration Pilot Plant
Pilot Drum Filterwith steam cabin and
exchangeable filter cellsfilter area: 0.6 m²
Pilot Disc Filterfilter area: 3.75 m²
-31- -32-
www.bokela.com
Hi-Bar Filter
Drum Filter
Disc Filter
DYNO Filter (MF)
BackflushFiltration
VacuumFiltration
PressureFiltration
Hi-Bar Pressure &Steam Pressure
Filtration
Filter Revamping
FILTRATEST
ServicesFilter RevampingTrouble Shooting
ConsultingDevelopment
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Pan Filter Backflush Filter
DYNO Filter (sieve)
Hi-Bar Oyster Filter
BOKELA do Brasil LtdaRua Sampaio Viana 277
2° andar04004.000 São Paulo – SP
Brazilphone: +55 11 3052 0444
fax: +55 11 3052 [email protected]
BOKELA Australia PtyBuilding 5 Spring Lake Commercial
1 Springfield Lakes BlvdSpringfield Lakes, QLD 4300
Australia phone : +61 7 3288 1400
fax: +61 7 3288 [email protected]
BOKELA GmbH
76131 KarlsruheDeutschland
Tel.: +49 721 96456-0Fax: +49 721 96456-10