Customer Case: Application of 6-bag Carbon Steel Multi-bag Filter in Industrial Cooling Water System
The cooling water circulation system of a medium-sized petrochemical plant in the Middle East frequently experiences blockages. The original filtration equipment was unable to effectively handle the high suspended matter content in the raw water, resulting in decreased efficiency of the heat exchangers, increased maintenance downtime, and more frequent shutdowns. The plant requires a robust, high-flow, continuous operation solution under medium pressure, with minimal human intervention.
The cooling water system of this client operates at a flow rate of approximately 280 gallons per minute, with the working pressure fluctuating between 80 and 95 PSI. The average water temperature is around 85 degrees Celsius, which is close to the working limit of ordinary rubber seals. The original filter used an upper-inlet and upper-outlet design, and the process of replacing the filter bags was messy and time-consuming. Moreover, the old filter housing suffered corrosion due to insufficient surface protection, and rust particles entered the downstream process, further exacerbating the equipment wear.
After evaluating the system requirements, we recommended the JYMF-6P/CS model of 6-bag carbon steel multi-bag filter, with a bottom-in-bottom-out flow configuration. The filter housing is made of heavy-duty carbon steel and is coated with gray anti-corrosion paint, matching the color standard of the customer's existing pipelines. Each filter is equipped with six 100-micron PE filter bags, which are welded seamlessly with plastic mouths using the full heat fusion process, eliminating any bypass leakage. The design pressure is 150 PSI, and the maximum working pressure is limited to 100 PSI, which perfectly matches their system specifications.
We installed double NPT internal thread pressure gauge interfaces on the inlet and outlet pipes for real-time monitoring of pressure differences. A vent valve was added at the top and a drain valve at the bottom, both with NPT internal thread interfaces, facilitating the start of exhaust and maintenance drainage. The sealing material is nitrile rubber, which can withstand temperatures below 100 degrees Celsius, ensuring long-term reliable operation under its working conditions. All flanges comply with the ANSI B16.5 150# standard and seamlessly connect with the existing pipeline network.
After continuous operation for three months, the customer provided the following feedback on the improvements:
The filtration efficiency reached 99%, and the pressure difference remained below 15 PSI throughout the filter bag's service life. The filter bag replacement interval was extended from the original 10 days to over 21 days, reducing the filter bag consumption by more than half, and the annual consumable cost decreased by approximately 40%.
The anti-corrosion paint coating showed no signs of peeling or rusting, even in the humid climate of the Middle East and under environmental temperatures often exceeding 45 degrees Celsius, it remained intact. The nitrile rubber seals maintained good elasticity, and there was no obvious deformation or leakage at the flange connection. The heat exchanger efficiency returned to the design level, and unplanned shutdowns due to scaling were almost completely eliminated.
The maintenance team particularly appreciated the design of the top vent valve and bottom discharge valve. The system effectively avoided air blockage issues upon startup, and the shell could be completely emptied before filter bag replacement. They pointed out that the heavy-duty 6-bag configuration could handle flow fluctuations without generating pressure spikes, providing stable and reliable filtration performance, which exceeded their expectations.
This case demonstrates that our 6-bag carbon steel multi-bag filter is a reliable solution for industrial cooling water applications, suitable for scenarios that require high flow rates, corrosion resistance, and low maintenance frequency. The combination of 100-micron PE seamless filter bags, ANSI standard flanges, and features such as vent valves and discharge valves for maintenance makes it an ideal choice for conditions with strict requirements for equipment uptime and operational efficiency.