Customer Case: Successful Application of Stainless Steel Basket Filters in Coastal Chemical Plants Project Background
When a large coastal chemical enterprise was expanding its organic solvent distillation production line, it encountered problems such as frequent blockages and difficult maintenance of the original filtration system. The production medium was a high-temperature organic solvent containing trace solid catalysts, with characteristics of strong corrosiveness, high temperature (150°C), and continuous operation. The original carbon steel filter had already suffered severe corrosion and mesh basket deformation within three months, resulting in increased system pressure difference, increased energy consumption, and the need for weekly shutdown for cleaning, which seriously affected production efficiency and costs.
- High corrosion resistance: Capable of withstanding environments containing chloride ions in organic solvents.
- High-temperature and high-pressure resistant: Working temperature 150°C, design pressure not less than 1.6 MPa.
- Maintainability: Reduces downtime and facilitates quick cleaning.
- Long lifespan: Reduces the frequency of spare parts replacement and the overall operation and maintenance costs.
- Customized adaptation: Compatible with the existing DN80 pipeline system. The flange standards must comply with the existing local regulations on site.
Based on the analysis of the customer's working conditions, we have provided the following customized improvement plans:
Material Upgrade
Body and cover: The material has been upgraded from standard 304 to 316L stainless steel, significantly enhancing its resistance to organic solvents and chloride ions.
Filter basket: Made of 316L stainless steel with a double-layer reinforced structure. The basket has a precision of 18 mesh and undergoes heat treatment to enhance its structural strength at high temperatures and prevent deformation.
Sealing components: Standardly equipped with PTFE sealing rings to ensure sealing reliability under high temperatures.
Structural Reinforcement
Increase the design pressure to 2.0 MPa to provide a greater safety margin.
Add a guiding locking device to the quick-opening cover structure to ensure the alignment and sealing performance during frequent opening and closing.
Operation and Maintenance Optimization
Provide a set of backup baskets to enable quick replacement during downtime. Move the cleaning operations to the offline stage, and reduce the system downtime from the original 4 hours to 30 minutes.
At the sewage outlet, an air-operated ball valve interface was selected for the customer, facilitating the future integration with the automatic sewage discharge system.
Implementation and Results
Installation and Commissioning: The product was delivered in October 2023. We provided remote installation guidance. The product perfectly matched the on-site pipelines and was installed successfully in one attempt.
Performance: As of July 2024, this filter has been operating stably without interruption for more than 9 months.
- Pressure difference stability: The pressure difference between the inlet and outlet remains within the initially set range and does not show any significant increase.
- Zero-fault operation: No corrosion leakage or basket deformation occurred.
- Facility maintenance: Customers have reported that the quick-opening structure is easy to operate, and the backup net basket strategy has significantly enhanced the flexibility of the production line.
Quantitative Benefits:
"We are extremely satisfied with the performance of this custom filter. It not only solved our difficult corrosion and clogging problems, but also its quick-opening design and backup basket solution greatly simplified the maintenance work. The supplier has a deep understanding of the working conditions, responds quickly to customization requests, delivers products on time, and is a reliable partner. We are considering promoting this solution on several other production lines with similar working conditions."
For specific harsh operating conditions (such as coastal areas, high temperatures, and corrosive media), standard industrial products often fail to achieve the optimal service life and economic benefits. Through professional condition analysis and in-depth customized services, optimizations are made in key materials, structural design, and maintenance strategies, providing customers with a one-time solution that truly achieves cost reduction and efficiency improvement. This highlights our core capability in providing technical value-added services in the complex industrial fluid filtration field.