Customer Case: JYCF-2-316L Candle-Type Filter Helps Southeast Asian Chemical Enterprises Solve the Problem of Filtering High-Viscosity Resin Solutions
The first issue is that the filter bags get clogged extremely quickly. During the processing of approximately eight tons of resin solution in each batch, the filter bags usually reach the pressure limit after operating for three to four hours and need to be stopped for replacement. For a single batch, it often requires replacing two to three filter bags, resulting in the production cycle of a single reactor being artificially prolonged by nearly twice.
The second issue is the unsatisfactory filtration effect. Due to the uneven distribution of the filter bag pore size, some small cross-linked particles penetrate through the filter layer and enter the downstream storage tank, resulting in sedimentation substances in the final product during storage. As a result, the customer complaint rate remains high, and high-end customer orders have thus been lost.
The third issue is the high cost of consumables. The filter bags are disposable items, and their monthly consumption is huge. Moreover, the discarded filter bags contain resin residues, which are expensive to dispose of, and this does not align with the green production policy that the enterprise is promoting.
The filtration accuracy has reached the standard level. After testing, the turbidity of the filtrate has decreased from the original average of 12 NTU to below 1.5 NTU. No sediment was found in the downstream storage tanks, and the complaint rate of the end customers has been zeroed out. As a result, the enterprise's high-end product line has been able to be restarted.
The single batch filtration duration has been reduced from approximately ten hours to within five hours, resulting in a doubling of production efficiency. The turnover rate of the synthesis vessels has significantly increased, and the monthly output has risen by approximately 40% without adding any synthesis equipment.
The filter element is in good condition. The recovery rate of flow after each backwashing exceeds 90%. Up to now, no titanium rod filter element has been replaced in the equipment. This has completely eliminated the previous passive situation where a large number of filter bags were consumed every month.
The operational convenience was recognized by the front-line workers. The fully enclosed system prevented the resin odor from spreading in the workshop, improving the working environment. At the same time, it reduced the loss of material volatilization, and the product yield increased by approximately 3%.
The project leader stated that the JYCF-2-316L candle-type filter has solved the long-standing filtration problems they have been facing. Especially the combined solution of pre-coated with titanium rods filter elements has not only ensured the filtration accuracy but also enabled the filter elements to be reused repeatedly for a long time. The operating cost is much lower than expected. Currently, this enterprise has included the second set of the same model JYCF-2-316L candle-type filter in the procurement plan to be used in another newly-built production line.