Challenging Conditions: Severe Corrosion and High Risk of Blockage
In a large chemical industrial park in East China, the raw material refining plant’s acid recovery section’s pre-filter before the conveying pump frequently failed. The medium was dilute hydrochloric acid containing a small amount of rust particles and by-product salt crystals. The working conditions were characterized by severe corrosion and easy crystallization. The inner wall of the original ordinary carbon steel filter was severely corroded, and the filter screen was frequently clogged with salt crystals. It required a shutdown for replacement every two weeks, resulting in high maintenance costs and affecting continuous production.
Precision customization: Dual strengthening of materials and structure
For this highly corrosive environment, instead of simply switching to all-stainless steel (which would be too costly), we customized a solution for the client, which involves a carbon steel main body with a special inner lining for corrosion protection.
Special lining anti-corrosion: On the inner wall of the carbon steel filter and the surface of the filter basket, the sintered spraying PTFE (polytetrafluoroethylene) process was adopted. This coating can completely prevent corrosive media from coming into contact with the carbon steel substrate, is resistant to hydrochloric acid corrosion, and at the same time has a smooth surface, which greatly reduces the adhesion and scaling of salt crystals.
Structural reinforcement design: To address the issue of blockage, we have designed the filter basket with a large conical bottom and a large volume structure, and have also expanded the flow area and extended the effective filtration cycle.
Economic balance: While ensuring corrosion resistance, the solution of using a carbon steel substrate with PTFE coating results in a cost reduction of approximately 40% compared to using a complete 316L stainless steel. This provides customers with an extremely cost-effective option.
Application results: From consumables to stable components
- Significant lifespan extension: The filter replacement cycle has been extended from 2 weeks to over 6 months, and the cost of spare parts and management has been significantly reduced.
- Maintenance costs have been reduced: unplanned shutdowns due to corrosion leakage and pipeline maintenance have been completely eliminated.
- Production continuity guarantee: The operational stability of this section has been fundamentally improved, making it a standardized solution for customers in filtering corrosive media.
Customer feedback: “The cost of using carbon steel is comparable to the corrosion resistance of stainless steel. This customized solution precisely addresses our pain points and demonstrates the power of professional selection and design.”
Post time: Jan-28-2026