Customer application case: Solid-liquid separation project of a chemical enterprise in South Asia
A medium-sized chemical manufacturing enterprise in South Asia mainly focuses on the synthesis of industrial-grade surfactants and intermediates. With the expansion of production capacity, its original filtration equipment, due to insufficient processing capacity and poor corrosion resistance, led to an excessive solid content in the filtrate, affecting the stability of the downstream processes. At the same time, the high salinity and weak acidity of the slurry produced during the production process severely corroded the ordinary carbon steel equipment, requiring a batch of filter plates to be replaced every three months, resulting in high maintenance costs. After extensive comparisons, the customer finally selected our BAY6/450 type all-stainless steel plate frame filter press as the core equipment for the slurry dehydration process.
The customer's production line generates approximately 8 to 10 tons of mixed slurry with a solid content of 15% to 20% every day, with a temperature ranging from 50 to 60 degrees Celsius and a pH value between 4.5 and 6.0. The slurry has a certain corrosive property. The original equipment used carbon steel filter plates, and the surface coating began to peel off after continuous operation for several months, causing secondary pollution of the filtrate and frequent blockage of the counter-current pipelines. Each shift required a shutdown for cleaning, seriously reducing the output efficiency. The customer urgently needed a corrosion-resistant, highly sealed, and easily compatible with the existing SS304 pipeline filtration system, and required the installation and commissioning to be completed within two weeks after arrival.
Our company, based on the customer's provided slurry composition and flow data, equipped them with the BAY6/450 complete machine solution. This equipment uses a carbon steel frame with an outer layer of SS304 stainless steel. All filter plates, filter frames, and the flanges and screws of the counter-current holes, as well as the screws, are made of SS304 material, fully compatible with the customer's existing stainless steel pipelines, without the need for additional adapters. The 120-ton hydraulic cylinder provides stable compressing force, combined with the 3927 type filter cloth, can achieve a filter cake moisture content of less than 30%. Before shipment, our engineers conducted video guidance for the customer to complete the hydraulic system debugging and filter cloth installation rehearsal, ensuring that the equipment could be quickly installed and put into operation upon arrival at the site.
The equipment was delivered to the Karachi port within the agreed delivery period. After the customer completed the pipeline connection and circuit connection, the equipment was successfully tested in one go.
After the equipment was put into continuous production operation for six months, our company conducted a remote follow-up visit. The customer's feedback was as follows:
-
Filter efficiency significantly improved: The single batch filtration cycle was shortened from the original 90 minutes to 55 minutes or less, and the daily processing capacity increased by approximately 25%, fully meeting the production rhythm after expansion.
-
Corrosion problem completely eradicated: All SS304 components in contact with the slurry had no obvious rust or pitting marks on the surface, and the flange interfaces had no leakage. The equipment has not replaced any filter plate accessories since its operation and the maintenance cost has decreased by nearly 70% compared to before.
-
Operating environment significantly improved: The single counter-current structure combined with precise sealing has no splashing or dripping phenomenon on the site, the workshop floor remains dry and clean, the safety of workers' operation has improved, and there is no need to frequently clean accumulated liquid.
-
Filter liquid quality meets the customer's process requirements: The clarity of the filtrate reaches the customer's process requirements, the frequency of pipeline blockage in the subsequent neutralization and concentration processes has significantly decreased, and the overall operation rate of the production line has increased from the original 78% to over 93%.
The customer's production supervisor stated during the follow-up visit that the corrosion resistance performance of this filter press exceeded expectations, and the pressure of the hydraulic system remained stable after long-term operation, requiring no frequent pressure supplementation.
This case fully demonstrates that the BAY6/450 type all-stainless steel plate frame filter press has excellent material tolerance and operational reliability when facing corrosive industrial slurry. Its all SS304 over-flow components design, convenient pipeline connection method, and stable hydraulic system can effectively help overseas customers solve the actual pain points of equipment fragility, impure filtrate, and frequent maintenance, especially suitable for solid-liquid separation needs in the chemical, food processing, and mining industries in South Asia, Southeast Asia, and the Middle East.