Membrane Squeeze Filter Presses and Filter Plates

How They Work and When Best to Utilize

There are three basic types of filter plates used in conjunction with filter presses. They include recessed chamber, plate and frame and membrane squeeze plates.

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Membrane squeeze, or diaphragm squeeze, filter plates offer a number of benefits, from time savings to improving the lifespan of the membrane. M.W. Watermark&#; offers membrane squeeze filter press/plate solutions to a range of industries. Discover how membrane (diaphragm) squeeze plates work and what advantages they bring to the table.

How Membrane Squeeze Filter Presses Work

Membrane squeeze presses operate similarly to recessed chamber and plate and frame filter presses that utilize polypropylene filter plates. However, the chambers in the filter plates have membranes to squeeze out the excess water from the slurry. As a result, this type of filter press may be able to remove a significant amount of fluid. And therefore, they can also reduce cycle time as long as the filter cake is compressible.

Membrane squeeze presses and plates are also considered when the slurry has higher than average solids and/or has variable volume, and when the time saved by the squeezing process can be justified by higher equipment costs. (Time is money).

In a typical filter press application, approximately 80% of the solids are pumped into the press in the first half of the cycle, with the remaining half considered the consolidation stage. With membrane squeeze, the cycle is shortened and the cake moisture content is reduced (see chart).

Membrane Squeeze Equipment Requirements

The result is increased throughput and better liquid recovery. Adding membrane squeeze to a filter press requires a specialized plate stack, a squeeze water manifold, and a filter plate pressurization system. Typically, membrane plates are alternated with standard chamber plates in a &#;mixed pack&#; as shown in the photo below.

The Membrane Squeeze Filtration Process

The filtration process of a membrane squeeze filter press typically includes six steps. Here&#;s how membrane squeeze filtration works:

1. First, the follower presses the membrane filter plates together via the hydraulic cylinder, effectively sealing their surfaces.
2. Once the press has reached the specified pressure, the pressurization stops and the press maintains the pressure.
3. Next, the feeding process begins. During this process, the slurry is pumped into each chamber via the thrust plate&#;s feeding port. Under the specified pressure, the slurry begins to form a filter cake on the filter cloth while any liquids are forced out of the chamber.
4. After the feeding process has concluded, the filter cake may be washed if required by the application. (The option for cake wash must be included in the manifold configuration). In some instances, air blowing may be used to further dry out the filter cake.
5. Then, the membrane squeezing begins. Using high-pressure water or air, the filter plate membranes squeeze the filter cake in order to reduce its liquid content.
6. Now that the filter cake is mostly free of moisture, the squeeze manifold pressure drops and the membrane on each plate returns to its starting position. The press is opened and the filter cake is discharged.

Benefits of Using a Membrane Squeeze Filter Presses and Filter Plates

Now that we&#;ve discussed how membrane squeeze filter presses work, let&#;s summarize the benefits of adding a membrane filter press to your operation.

Because diaphragm filter presses utilize membrane technology, they greatly influence the dryness of the filter cake. When put head-to-head against standard filtration processes, membrane filtering achieves the lowest residual moisture values in the solid. This is vital in filtering applications where the degree of dewatering is of the utmost importance, especially in applications where the separated solid or liquid is the actual product.

In addition to achieving a high degree of dewatering, membrane squeeze filter presses and plates also help reduce the filtration cycle time. With a faster cycle time comes faster turnaround times, which consequently can lead to an increase in productivity.

Benefits of Replaceable vs. Welded Diaphragms

Another advantage of using membrane plates can be found in the option for replaceable vs. welded diaphragms. If the membrane component happens to break, the diaphragm itself can be removed and replaced, versus requiring the replacement of the entire filter plate. This provides for a significant cost savings and a quicker fix over waiting several weeks for replacement welded membrane plates to arrive.

Also, if chemical compatibility is a concern, replaceable diaphragms are offered in various materials of construction, including EPDM, NBR, Viton, and more.

Membrane Squeeze Presses and Plates from M.W. Watermark

From chemical plants to gold mining and everything in between, membrane filter presses and plates have been used successfully in a number of applications. Find out if utilizing a membrane/diaphragm squeeze filter press is right for your particular application by reaching out to M.W. Watermark. Contact us to learn more or request a quote today.

About M.W. Watermark

M.W. WATERMARK wants to make a difference. We are passionate about the world&#;s water. We are innovative, focused on customer service and always try to exceed expectations. We are an environmentally conscious company with people who are energized, encouraged and inspired to make a difference on our planet by helping to keep our shared, finite water supply clean and usable for generations to come. We build amazing, custom water and wastewater treatment equipment. Together, we can make a difference.

© M.W. Watermark, L.L.C.

M.W. Watermark, LLC. M.W. Watermark® is a federally registered and protected trademark owned by M.W. Watermark, L.L.C. All rights reserved

Any third party trademarks referenced on this site are the trademarks of their respective owners, and M.W. Watermark makes no claim to such marks and is not affiliated with such companies.

The affordability of a filter press depends on several factors, including the initial investment, operating costs, and long-term returns. While the initial purchase cost of a filter press may be high, they are often considered a cost-effective option given their many benefits in the production process.

Factors affecting the affordability of filter presses

Initial investment in filter presses

The initial cost of purchasing a filter press is one of the most important factors companies consider. Several factors, including model, specification, brand, production capacity, and additional features usually determine the initial cost of a filter press. In the market, the prices of different models and specifications of filter presses vary greatly, so companies need to make careful comparisons and evaluations.

Initial investment in filter presses

First, different models and specifications of filter presses may have different production capacities and processing capabilities. Filter presses with higher capacity are usually more expensive, but can process larger quantities of material more quickly, thus increasing productivity.

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Second, additional features and special designs of filter presses can also affect their price. For example, some filter presses come with automated control systems, advanced filtration media, and customized operator interfaces, and these add-ons can increase the cost of the equipment.

Finally, brand and manufacturer are also one of the important factors that affect the price of a filter press. Well-known brands are usually known for their quality reliability and technical support, and their products may be priced higher. However, some emerging brands or low-cost manufacturers may offer more competitive prices but require more attention when purchasing.

Therefore, when purchasing a filter press, companies should carefully consider their needs, budgetary constraints, and long-term operational plans, compare with multiple manufacturers, and select the most cost-effective model and specification. It is also important to ensure that the equipment purchased can meet production requirements and is backed by reliable quality and good after-sales service.

Operating Costs of Filter Presses

Ongoing costs associated with the operation of the filter press include two main areas: maintenance costs and energy consumption.

Maintenance costs:

• Regular maintenance: Filter presses require regular maintenance, including cleaning the filter plates and cloth, checking the hydraulic system, and replacing consumables (e.g., seals, and filter cloth). These maintenance tasks help keep the equipment functioning properly and reduce the risk of breakdowns.
• Parts replacement: As the usage time increases, the filter press may need to replace some key parts such as oil seals, valves, pumps, etc. The replacement cost of these parts can increase operating costs.
• Labor maintenance: If a company does not have an in-house maintenance team, it may need to hire external maintenance technicians for maintenance and repairs, which will add additional labor costs.

Energy consumption:

• Electricity consumption: Filter presses are usually driven by electric motors or hydraulic systems, so their energy consumption is mainly from electricity. Filter presses with long operating hours and high production volumes will consume more electricity.
• Heating energy: Some filter presses may require a heating process to suit specific processing requirements. The energy consumption of heating equipment (such as heaters or steam boilers) is also part of the operating costs.

Operating Costs of Filter Presses

To calculate the return on investment (ROI) of a filter press implementation, it is first necessary to estimate the operational cost savings and productivity increases resulting from the filter press. The value of these cost savings and increases can be calculated in the following way:

Operating cost savings:

• This is done by comparing the difference in operating costs, including maintenance, energy consumption, and consumable costs, between a filter press and an alternative filtration method, such as a centrifuge or vacuum filter.
• These differences are multiplied by the expected service life to obtain the total operating cost savings from the filter press.

Increased productivity:

• The increase in productivity due to filter presses is estimated by comparing the processing speed and efficiency of filter presses with alternative filtration methods. This can be achieved by reducing production downtime, increasing filtration efficiency, etc.
• The value of the productivity increase is multiplied by the expected service life to obtain the total productivity increase due to the filter press.

Finally, the net benefits of the filter press implementation are obtained by adding the values of total operating cost savings and total productivity increase and subtracting the initial investment cost of the filter press. Divide the net benefit by the initial investment cost and multiply by 100% to get the ROI of the filter press.

Factors to consider for the affordability of filter presses

Scale of operation

The effect of production volume on the affordability of filter press prices is significant. Generally, the price of filter presses becomes relatively more affordable as the production volume increases. This is because the fixed costs of a filter press can be spread over more products as production volume increases, thereby reducing the cost per unit of product. Additionally, larger filter presses are typically more economical than smaller ones because they can handle more material and increase productivity.

The scalability and flexibility of a filter press solution are critical to responding to changes in production volumes. Scalability refers to the ability of a filter press to be expanded or adapted for different production scales. This includes increasing the number of filter plates or cloths, replacing filter presses with larger capacities, and so on. Flexibility refers to the ability of the filter press to adapt to different types and characteristics of materials, as well as different filtration requirements. Filter press solutions with good scalability and flexibility can remain cost-effective as production volumes change and provide optimal filtration results when processing different materials and products.

Maintenance requirements

Evaluating the maintenance needs and associated costs of filter presses is critical to effectively managing the operation and maintenance of the equipment. Filter presses typically require regular maintenance to ensure stable and reliable operation and to extend their useful life. Maintenance needs are multi-faceted and include the following:

• Cleaning and maintenance: Filter presses require regular cleaning and maintenance, including cleaning the filter plates, replacing the filter cloth, checking the hydraulic system, and cleaning the filter media. These tasks help keep the equipment running properly and reduce the occurrence of breakdowns.
• Parts replacement: With increased use, the filter press may need to replace some key parts, such as oil seals, valves, pumps, and so on. Timely replacement of these parts helps prevent equipment failure and damage.
• Overhaul and repair: When the equipment malfunctions or needs to be repaired, appropriate overhaul and repair work is required. This may include troubleshooting, replacing damaged parts, etc.

Preventive maintenance is critical to maximizing the life of your filter press. Regular preventive maintenance allows you to check that all parts of your equipment are functioning properly, identify and resolve potential problems promptly, reduce unplanned downtime, and extend the life of your equipment. Preventive maintenance also reduces repair costs and avoids production delays and losses due to equipment failure.

Factors to consider for the affordability of filter presses

Quality and durability

To ensure long-term affordability, it is critical to invest in high-quality filter presses. High-quality filter presses typically offer more reliable performance and a longer service life, which reduces repair and replacement costs and lowers the total cost of ownership of the equipment. In addition, high-quality filter presses are typically more efficient and stable in operation, resulting in increased productivity and lower production costs.

Manufacturer-provided warranties, support, and after-sales service are also important considerations when investing in a high-quality filter press. Quality manufacturers usually offer a long warranty period and promise to provide free repair and maintenance services during the warranty period. In addition, they provide timely technical support and training to help customers resolve problems with equipment operation and ensure optimal performance.

Of the different types of filter presses, which is more economical?

• Manual filter press: This type is simple to operate, relatively low cost, and suitable for small-scale laboratory or research purposes. However, due to the need for manual operation, the productivity is relatively low and not suitable for large-scale production.

manual filter press product 02 manual filter press product 01

• Automatic filter presses: Automatic filter presses usually have higher productivity and automation and are capable of handling large quantities of suspended solids. Although their initial investment is high, they are more cost-effective in long-term operations by increasing productivity and reducing labor costs.

automatic filter press product 02 automatic filter press product 01

• Membrane filter presses: Membrane filter presses utilize special membrane filtration technology to achieve higher filtration precision and cleaner products. Although their initial investment is higher, membrane filter presses are often more economical where high-quality filtration and fine separation are required.

membrane filter press product 02 membrane filter press product 01

Therefore, determining which type of filter press is more economical requires taking into account factors such as production size, filtration requirements, budgetary constraints, and long-term operating costs, and selecting the most suitable solution

Summary

Filter presses perform solid-liquid separation tasks efficiently, reducing the time and labor costs associated with handling liquid or solid wastes. Filter presses are cost-effective and provide long-term benefits in industrial applications. High-quality filter presses can reduce maintenance costs and increase productivity for a wide range of industries, including chemical, pharmaceutical, and food, to meet different operational needs. By investing in quality filter presses and properly evaluating the return on investment, companies can realize long-term affordability and improve production management efficiency.

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