Customer Case: Upgrading the Liquid Raw Material Filtration System of a Large Chemical Enterprise

Background and Challenges

A medium-sized chemical production enterprise in South China, mainly producing industrial coatings and resin additives. The liquid raw materials (such as solvents, additives, resin liquids) need to be filtered before being stored and transported to remove mechanical impurities (rust, dust, fibers, etc.) that may have been mixed in during transportation and storage. Previously, this enterprise used single-bag filters operating in parallel, but as its production capacity expanded, the original solution exposed three major drawbacks:

• High maintenance frequency

  The single-bag filter has limited processing capacity and requires each set to be shut down for filter bag replacement 2-3 times per day, significantly affecting the continuous feeding rhythm.

• Complex piping, increased leakage points

  Multiple single-bag filters operating in parallel result in a crisscrossed piping system, and each cleaning or bag replacement process takes a long time to empty the system, and there is a risk of leakage at the flange connection points.

• Unstable filtration accuracy

  Frequent opening and closing of the filter leads to accelerated wear of the sealing ring, and occasionally, bypass phenomena occur, causing the nozzles of the downstream grinding machines and sand mills to get clogged. This results in an increase in equipment maintenance costs every month.

The technical department of the enterprise clearly stated the requirements: to increase the processing capacity of each unit, reduce maintenance frequency, simplify the piping layout, while maintaining a filtration accuracy of 100 microns and a medium temperature range of 60-80°C, with a working pressure of approximately 80 PSI.

Solution Implementation

After on-site condition assessment and flow calculation, we recommended and installed the JYMF-4P/304 stainless steel multi-bag filter for this customer. We also customized three adaptations for its medium characteristics:

• Sealing upgrade

  Although the standard nitrile rubber can meet the temperature requirements, considering that the medium contains a small amount of aromatic solvents, we recommended replacing it with a fluorine rubber sealing ring to ensure long-term resistance to swelling.

• Optimization of bypass structure

  Installing exhaust valves and drain valves on the bottom-in-bottom-out piping system makes it convenient to drain air during the initial start-up and avoids uneven pressure on the filter bags.

• Filter bag selection

  Directly using the 100-micron PE filter bags from the customer's original brand ensures a zero-acclimation period for replacement.

The installation process only requires two flange interfaces (4" ANSI) on the original main pipeline, removing all 4 single-bag filters and their parallel piping, replacing them with a 4-bag filter, reducing the area to one-third of the original.

Operation Results and Effects

After the equipment was put into use, after continuous 3-month production tracking, the results were remarkable:

• Extended maintenance intervals

  The total filtration area of the 4-bag filter is 4 times that of the single-bag filter, significantly increasing the filtration capacity. Under the same impurity load of the feed, the bag replacement cycle was extended from 2-3 times per day to once every 3-4 days, significantly reducing manual intervention and filter bag consumption.

• Improved production continuity

  Due to the reduction in maintenance frequency, the feeding process was no longer frequently interrupted, and the daily output increased by approximately 12%, and the workload of night shift personnel decreased significantly.

• Improved equipment reliability

  The bottom-in-bottom-out design ensures that the filter inside is always filled with liquid, eliminating the air hammer phenomenon when starting the pump. After simplifying the piping, the number of flange connection points was reduced from 12 to 4, with zero leakage records within three months.

• Significant improvement in downstream equipment protection

  The solid content of the filtered raw materials remained within the required range, and the replacement frequency of the grinding machine nozzles decreased from 2 times per month to 1 time per quarter. This alone saved approximately 20,000 yuan in spare parts and labor costs annually.

• Improved operational experience

  The sanding surface is less prone to contamination, and cleaning is convenient with on-site wiping and cleaning; filter bag replacement only requires opening the top cover ring, no climbing or lifting equipment is needed, and an ordinary operator can complete it within 10 minutes.

Summary of Experience

This case demonstrates that for general chemical liquid filtration scenarios with medium to high pressure, large flow, and non-extreme corrosivity, the JYMF-4P/304 multi-bag filter can replace the multi-single-bag parallel solution with a lower comprehensive operating cost. The core value of it lies not in technological breakthroughs, but in the improvement of operational efficiency brought about by structural optimization. When making a selection, it is recommended to pay particular attention to medium compatibility (sealing material) and actual pressure difference monitoring. Combined with regular blowdown, the service life of the filter bags can be maximized.