A large manufacturing enterprise in East China, mainly engaged in the production of fine chemical products, has long faced the problem of pipeline impurity blockages during the production process. The enterprise mainly produces high-purity resins and coating additives, and uses a large number of pumps, valves, heat exchangers and measuring instruments on the production line. Due to the occasional presence of particulate impurities in the raw materials and the crystallization of by-products generated during the reaction, the downstream equipment is frequently blocked. On average, it needs to be shut down for cleaning twice a month, which seriously affects the production continuity and product quality.
Challenges and Pain Points
Before the project began, the customer’s original filtration system had the following issues:
The filtration accuracy is insufficient. With only a single layer of simple filter net, it is impossible to effectively intercept fine particles.
The filter needs frequent cleaning. Each cleaning process requires disassembling the pipeline, which takes approximately 3 to 4 hours.
After the filter screen was damaged, there were no spare parts available, so urgent procurement was needed, which affected the production plan.
The original filter had a high pressure drop, which increased the operating load of the pump and resulted in relatively high energy consumption.
The customer urgently needs a filtration solution with high efficiency, easy maintenance, and the ability to handle various media. At the same time, the equipment must be corrosion-resistant, temperature-resistant, and capable of meeting the demand for future capacity expansion.
Solution
Based on the customer’s operating conditions and the on-site layout, we have provided a customized stainless steel basket filter solution:
Material selection: The main body and filter basket are both made of 316L stainless steel, which is resistant to acid and alkali corrosion and suitable for resin solvents and high-temperature media.
Filtering accuracy: The structure is equipped with a double-layer filter basket. The outer layer is a coarse filter screen, and the inner layer is a precision filter screen, achieving staged filtration and extending the cleaning cycle.
Structural design: A quick-opening top cover is adopted. The filter basket can be removed for cleaning without disassembling the pipeline. The operation time has been shortened from the original 3 to 4 hours to within 30 minutes.
Size customization: Based on the customer’s pipe center distance and space constraints, the height of the cylinder body and the positions of the inlet and outlet flanges were customized to achieve seamless replacement.
Backup filter basket: A set of backup filter baskets is provided with the equipment. They can be quickly replaced to ensure that production does not stop during maintenance.
Implementation effect
After the equipment was installed and debugged, it was put into operation for 6 months and achieved remarkable results.
In terms of the number of equipment shutdowns due to blockages, it has decreased from 2 to 3 times per month before the renovation to only 1 time every 2 months, significantly reducing unplanned shutdowns. The single maintenance time has been shortened from the original 3 to 4 hours to within 30 minutes, effectively improving maintenance efficiency. The failure rate of downstream equipment has significantly decreased, and the energy consumption of pumps has reduced by approximately 8%, while the product qualification rate has increased from 96.5% to 98.2%.
Customer feedback: The new basket filter not only resolves the long-standing problem of blockage, but also significantly reduces the workload of maintenance personnel. The quick-opening structure and the design of the backup filter basket make daily maintenance simple and efficient. The corrosion resistance of the equipment also performs exceptionally well in actual operation, with no leakage or corrosion phenomena.
Customer Review
“This stainless steel basket filter is one of the most ‘stress-free’ equipment on our production line. After installation, it requires almost no special attention. Each time the filter basket is cleaned, the impurities that have been intercepted can be clearly seen, and the effect is very intuitive. Now our production line can operate continuously for a longer period of time, and the product quality has also become more stable.”
— The head of the production equipment department of this enterprise
Summary
Through the implementation of this customized filtration solution, the chemical enterprise successfully optimized the filtration process of its production line, reduced maintenance costs and energy consumption, and improved the product qualification rate. The stainless steel basket filter, with its high filtration efficiency, easy maintenance and customizable features, has become a reliable choice for fluid purification in industries such as fine chemicals, coatings, and resins.
Post time: Mar-30-2026