I. Customer Challenges: Recovery of High-Value Catalysts and Process Bottlenecks
In the production process of its flagship catalyst products, XX Chemical has a crucial step: after the reaction is completed, the liquid product needs to be separated from the expensive and highly efficient solid catalyst powder. The challenge they face is:
- High-flow processing: The volume of the reaction liquid to be processed in each batch is large (more than 50 cubic meters), and the filtration system’s flow rate must reach 100 m³/h; otherwise, it will affect the overall production cycle.
- High-precision interception: The particle size of solid catalysts is mainly between 10 and 25 micrometers. They must be completely intercepted and recovered; any loss would mean a huge cost loss.
- Harsh operating conditions: The reaction solution is somewhat corrosive, and the process temperature is maintained at 70-75°C. The equipment material must be corrosion-resistant and able to withstand high temperatures.
- Production pressure: The original filtration equipment had a limited capacity to handle contaminants and was frequently replaced, resulting in significant fluctuations in system pressure. It was unable to operate continuously at a stable 1.0 MPa, thereby affecting product consistency.
The client urgently needs a high-capacity filtering solution that is efficient, stable, and customizable to address their specific problems.
II. Our Customized Solution
After thoroughly understanding the technical details and pain points of the client, our technical team proposed a customized 7-bag filter solution:
Tailor-made core equipment:
- Model: 7-layer filter, with a large filtration area design, capable of easily handling a flow rate of 100 m³/h.
- Shell material: SS304 stainless steel, ensuring excellent corrosion resistance to the reaction solution.
- Key structure: Side-in bottom-out flow direction, combined with a special internal guide plate design, ensures that the fluid flows uniformly through all filter bags, avoiding deviation, and maximizes the utilization of the filtration area.
- Mechanical strength: The shell thickness is 5.0mm, manufactured according to a design pressure of 1.6 MPa, ensuring long-term stable operation under a working pressure of 1.0 MPa and eliminating any safety risks.
- Surface treatment: The inner and outer walls are treated with sandblasting, which enhances corrosion resistance and makes cleaning and maintenance easier.
Precise matching of filtration accuracy:
We recommend and provide high-precision polyester (PES) needle-punched filter bags with a 15-micron accuracy. This material has excellent temperature resistance and chemical stability, can precisely intercept all catalyst particles, and ensures extremely high filtration efficiency and filtration capacity.
Convenient integration and maintenance design:
The import and export are configured according to the customer’s on-site pipeline, customized to the DN250 (ISO) flange standard, achieving seamless connection.
With the hydraulic quick-opening cover design, a single worker can complete the rapid replacement of 7 filter bags within 10 minutes, significantly reducing the downtime.
III. Application Results and Customer Value
Since the implementation of this customized filter, remarkable results have been achieved:
- Significant improvement in efficiency: The filtration speed fully meets the flow requirement of 100 m³/h, and the processing time for a single batch has been reduced by 40%, significantly enhancing the production capacity.
- Significant cost reduction: The catalyst recovery rate exceeds 99.8%, and it helps customers save tens of thousands of yuan in losses each year. At the same time, due to its large dirt-carrying capacity, the filter bag’s replacement cycle has been extended by three times, thereby reducing the cost of consumables.
- Stable and reliable operation: The equipment operates smoothly under the working conditions of 1.0 MPa and 75°C, with minimal pressure fluctuations, ensuring the stability of product quality and the safety of production.
- Maintenance is simple: The quick-opening lid design and the side-in, bottom-out structure make the maintenance process quick and easy, significantly reducing the labor intensity of workers.
Customer review:
“At first, we were just looking for a standard filter. But their technical team demonstrated true professionalism. They thoroughly understood our process challenges and provided a completely customized solution for us. This 7-bag filter not only met the parameters, but also completely resolved our production bottlenecks and cost issues. This was a very successful collaboration!”
Post time: Nov-07-2025