Two recent and successful projects, on vastly differing materials, but following our well proven method serve to show how we work with potential clients to find the process solution. 1 – In the development of an advanced nano porous material with a process stage that involves removing salt from the filter cake. 2 - Converting what had been an effluent sent to landfill into recyclable and saleable products. Again with the requirement of removing salt from the filter cake. The start of the process is really quiet simple and very low cost: As explained in PROCESS, to determine the suitability of handling the client's product on the Polyfilter, we carry out a laboratory test using a representative sample of the slurry and our specially designed Buchner filter. From as little as typically 5 litres of slurry, we can determine if the product is suitable for filtering on a production scale on the “Polyfilter”. The other benefit of these tests is that once the filtration rate has been established, we can quickly and easily provide a budget (ballpark)cost for the complete filter package. With non hazardous materials these tests are carried out free of cost at our works.
Using our specially designed Buchner filter the potential client's slurry is poured into the Buchner and allowed to settle under gravity for a few seconds. This allows the heavier solids to form on the filter cloth and in effect become the filter medium.The vacuum is then applied and a filter cake is formed, noting the time taken.
Once a filter cake is formed the cake is washed, in this instance with tap water, to reach the specified saline level. By knowing the filter area of the Buchner and the time taken for each stage we can calculate the product throughput in litres or kg/m2/h. After the filter cake has been dried, the throughput in dry solids (DS) can also be determined.
The nanosphere project was being funded by an EU grant so it is somewhat of an understatement to simply state that funds were tight! The initial Polyfilter proposal to the client was too expensive for the available budget. However, the great thing about the Polyfilter is its modular construction. At a future date this allows additional sections to be easily inserted into the filter length and increase the filter area and in turn the throughput. After further consultation, the initial plant throughput was reduced which in turn reduced the size and first cost of the filter package.
Once the filter arrived on site the client was eager to get into production! As the picture shows, the filter still on the shipping pallet was elevated using stacks of pallets. Whilst the connections were being made, the production staff made a trial batch and within 4 hours of arrival, material was being produced. Not obvious in this photograph is the fact this filter package is supplied with 3 vessels. These are to separate the mother and wash liquors and allow a single stage counter current cake wash to minimise the volume of cake wash water used. Over the next few months the filter reliably produced material for appraisal and as the marketing team had predicted acceptance of the product exceeded the client's expectations.
Phase 2 As finance became available this was a return to site and, with some client assistance, an extra section was inserted into the filter.Thanks to progressive plant improvements and process developments by the client, the filter capacity increased by more than the expected 50%.
Phase 3 - Thanks to the success of the initial EU funded project, the material has gained international accreditation and business has increased. The Client has since raised capital and ordered a 10 x scale filter for the production facility.This replicated the pilot filter and also has counter current cake washing . It has become the Master Pilot Plant
As interest and sales of the product continues to grow, it is anticipated that additional plants to be installed at strategic locations worldwide. Polyfilters will continue to support this business and supply filters for each of these new facilities.
