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since 1997
"INTECH GmbH"
We are interested in cooperation with the manufacturers of filter separator, who are looking for an official and reliable distributor to deal with supply & delivery of their equipment to the industrial plants in Russia.
The company’s top management and sales team are well acquainted with the Russian market, its mentality and laws; they also understand industrial specifics of the financial and economic activities of the Russian customers. All our sales managers have a large customer database, extensive experience of successful sales and well-established connections with the potential buyers of your filter separator. This allows our managers to promptly set out the most promising directions for promotion and to ensure a rapid entry of the products into the promising Russian market. Our employees, who are fluent in English and German, are focused on working at the international market with the supplies of foreign equipment.
Our team of experienced engineers, who can handle the most serious technical problems, constantly keeps in touch with the Russian customers, holds meetings and delivers presentations regarding the latest achievements of our manufacturing partners. They point out the engineering challenges and actively communicate with all the departments at Russian plants. That is why the specifics of doing a business in the Russian Federation are well-known to us, and we also know the equipment of the local industrial plants and their up-to-date modernization needs.
Once we become your authorized representative in Russia, our marketing staff will carry out a market research in order to check the demand for filter separator, will submit a market overview for filter separator that you offer and evaluate the needs for this type of equipment at local plants. Our specialists will also estimate the potential and capacity of this market at local industrial plants. Our IT-team will start developing a website for your products in Russian. Our experts will assess the conformity between your filter separator and customer needs as well as analyze the common reaction to the new goods in general. We will look into the categories of potential customers, and pick out the largest and the most promising plants.
Upon becoming your authorized agent on the territory of Russia, ‘Intech GmbH’ LLC (ООО «Интех ГмбХ»), will obtain certificates, if required, for a batch of the goods, for various types of filter separator in compliance with Russian standards. We can also arrange the inspection in order to obtain TR TS 010 and TR TS 012 Certificates. These certificates provides permission to operate your equipment at all industrial plants of the EAEU countries (Russia, Kazakhstan, Belarus, Armenia, Kyrgyzstan), including the hazardous industrial facilities. Our company is eager to assist in issuing Technical Passports for filter separator as per Russian and other EAEU countries’ requirements.
Our engineering company ‘Intech GmbH’ LLC (ООО «Интех ГмбХ»), collaborates with several Russian design institutes in various industrial segments, which allows us to conduct preliminary design as well as subsequent design works according to the standards, construction rules and regulations that are applicable in Russia and other CIS countries. It also enables us to include your filter separator into the future projects.
The Company has its own logistics department that can provide packing service, handling as well as the most efficient and cost effective mode of transportation of the goods (incl. over dimensional and overweight goods). The goods can be delivered on DAP or DDP-customer’s warehouse basis in full compliance with all the relevant regulations and requirements that are applicable on the Russian market.
Our company has its own certified specialists who will carry out installation supervision and commissioning of the delivered equipment, as well as further guarantee and post-guarantee maintenance of filter separator. They will also provide necessary training and guidance for the customer’s personnel.
Filtration is a process, during which suspensions and gaseous suspensions are separated by a porous membrane.
A simple filter separator is a cylindrical vessel which is mounted vertically. Inside it is divided into two parts by a horizontal membrane. Fluid enters the top of the vessel and is filtered through the membrane, residue is retained, and filtrate moves further into the lower portion of the vessel.
The advantage of filtration, in comparison with settling, lies in the fact that solid particles are removed completely from suspension.
A separator for fluid is a technical device separating suspension (emulsion), fully or partially, to a solid and a liquid phase (respectively referred to as "residue" and "filtrate"). Separation is carried out by passing the suspension through a porous filter membrane. In addition to the filtration process, the device performs additional cleaning from the traces of dispersion medium by residue washing method, as well as its pressing and drying.
Different types of separators differ from each other by purpose (universal or for a particular type of suspension), material structure (made of carbon fiber or stainless steel, rubber, plastic, etc.), degree of tightness, method of residue removal, degree of automation, geometric position of the axis (horizontal, vertical), etc.
Regardless of the type, filter separator has a closed housing, equipped with inlet and outlet pipes (mainline, fittings). Filter medium within the housing representing filter membrane with residue particles collected on its surface is the main part of any separator.
Filter membrane lets external phase (liquid or gas) pass through and retains dispersion one (solids). As a result, two streams are formed: residue, which is a layer of particles deposited on the membrane, and filtrate, which is a clarified liquid which has passed through the membrane. Filtrate and residue or only one of the obtained products may be of value in production.
The filter membrane of a separator must:
In most separators, membranes represent a metal or fabric mesh. Membranes for the chemical industry are made of polyamide (polycaproamide), polyester fibers (Dacron), polyolefin fibers (polyethylene, polypropylene), and chlorine-containing (chlorine), acrylonitrile (nitron) and glass fibers. Disposable filter membranes in the form of paper strips are widely used. Very occasionally filter elements are made of natural materials (wool, cotton, silk). Incompressible membranes are made of ceramic. Such filter elements are made in the form of a cartridge for compactness. The ability to filter high-temperature environments is their main advantage.
To protect pores against rapid clogging (especially during filtration of low-concentration suspensions with fine particles) filter membranes are covered with a preventative precoat layer. It can be of a powder (diatomite, pearlite, asbestos) or of a fibrous pulp. The precoat layer is applied to filter membranes during manufacture or is preliminary added to the filtered slurry to a certain concentration (depending on the size of solid particles in suspension, their amount and so forth). At that, the precoat layer is also removed during the process of residue removing, but it may further be subjected to regeneration.
Separators are divided into five types depending on the technological purpose:
Separators are divided into three types according to the type of discharge:
Liquid centrifugal separators are used for separation of liquids using centrifugal forces. Rotor is the main mechanism in them. It is a working body of a separator, and its design provides a coned disc stack that separates the flow of liquid into layers having a thickness of 0.4-1.5 mm.
Separation consists in the fact that dispersed particles moving in stream should have time to be deposited onto discs until they flow away from the disc stack along with the flow. The disc stack is required to reduce particle deposition path, and thus the centrifugation time. Laminar regime of liquid displacement takes place over the rotor by flow separating into thin layers. This contributes to an intensification of centrifugation.
Liquid components in liquid centrifugal separators are usually discharged after clarification by discharge discs, mounted stationary relative to the rotating rotor.
If we consider the dynamic parameters of separators, they can be attributed to high-speed centrifuges, i.e. to machines, operated at speed above the critical.
A rotor of a liquid centrifugal separator consists of such parts as base, disc support, disc stack and also a cover.
In dividing separators, a product subject to treatment comes from a disc support to channels that are formed by holes in coned discs. When the product rises, it spreads between the discs. Liquid light component moves in the gaps between the discs towards the axis of rotor rotation. It rises up the outer vertical channels and is discharged from the rotor.
Heavy liquid component together with solid particles moves to the rotor periphery, i.e. to the slurry space. Heavy liquid components move to the passage between the separating disc and rotor cover, as a result of which they are discharged from the separator. Solid particles are deposited on the rotor base. Their discharge is performed depending on the type of separator.
In cleaning separators, a product subject to treatment comes into the slurry space through the channels of disc support. The largest particles of the solid component are separated in this area. Liquid with remaining solid particles moves in gaps between discs, where the solid components are separated definitively, and is directed towards the axis, and is discharged from the rotor through the outer channels of disc support.
Physico-chemical properties of emulsions, such as particle size, density and viscosity, influence the separator performance.
Operating principle of disc stack centrifuge separator
Disc stack centrifuge separators are widely used. The principle of operation is that emulsion is fed into the lower part of rotor, equipped with discs (conical septa), through the central pipe. Such discs have openings and separate the mixture into multiple layers. Heavy liquid is thrown to the periphery of the rotating drum, and more light liquid moves to the center. Separated liquids cannot mix again, as they do not come into contact with each other anymore.
Separators may be equipped with discs with holes and without holes. Discs without holes separate solid residue, which settles on the walls of the drum. This residue is discharged manually. The clarified liquid moves towards the center and upwards, and then goes out.
A high level of productivity and quality of operation are considered to be the advantages of disc stack centrifuge separators, and the complexity of the design is their downside.
Fluid separators are used to separate emulsions and to clarify liquids. Drums of such devices have a larger diameter (up to 300 mm), drum speed varies from 5500 to 10 000 rpm. Disc stack centrifuge separators are widespread. In such machines substance stream is divided into thin layers without speed increasing.
Band separator has the simplest design; an endless rubber band with corrugated surface and slots is the main component of the device. The band is covered with a filter fabric and is stretched on two drums. One of them is the drive drum and it provides the band movement. Another drum, together with the guide rollers, provides the band tension required.
During the band movement at the upper portion its edges are moving on two guide bars. The chamber of round or rectangular cross section is installed between these bars over their entire length. Upper flanges of the chamber are adjacent to the bottom surface of the band. At the bottom, the chamber is connected by means of fittings with the channel for filtrate and washing liquid, connected with a vacuum line. The inner space of the chamber and manifold is divided by transverse membranes. Sections formed by the membranes serve for filtrate and washing liquid discharging.
Suspension is fed at the beginning of the band upper line. The band edges are folded over their entire length and represent capped edges. The band itself resembles a trough. This design makes it easy to remove the residue slipping off the filter material under its own weight, with a roller or by flushing with water jets. Before cleaning the residue is pre-loosened by means of compressed air.
A band with a width of up to 3 m and a length of up to 9 m is installed at the separators. The speed of the band depends on its length and properties of the treated suspension. Residue thickness is 1 to 25 mm.
An advantage of a band separator is that there is no distributor in its design.
Transverse ribs divide the band surface into a number of sections, having elongated slots in the middle. There are high capped edges, as well as chutes for rubber cord on both sides of the band. This cord provides snug fit of filter cloth to the band. Filter cloth is put onto the band in the form of an endless blanket, into the edges of which rubber cords, stacked into the chute, are sewn.
Suspension subject to filtration is supplied by a chute, behind which the flow divertor is located, adjusting the liquid level on the band. That is, the excess suspension flows over the flow divertor, and then it flows into a drain funnel. The residue resulting from the suspension filtering is washed on the band by means of washing liquid coming from the nozzles.
Filtration and washing areas are separated by a barrier deflector, preventing suspension from flowing into zone where the residue is washed. Filtrate is removed through the manifold.
At the end of the table the cloth is separated from the rubber band and bends around a special roller. Due to this the residue is cleared therefrom. Quite often divided beam is used to supply compressed air or steam to purge the fabric.
Prior installation of the drum filter separator it is necessary to calculate the required operating parameters of the device, which include:
Also coefficients of specific resistance of residue and filter membranes, and moisture content in residue after filtration, optimal value of the residue layer thickness, drying time, specific consumption of washing liquid are determined experimentally.
Based on the obtained data the overall required filtration area is determined, based on which the selection of the separator is carried out.
The design of filter separator generally includes the following devices:
Working drum of the separator is divided into four conditional areas, excluding area contacting with the tank where suspension is filtered. This area takes 30-40% of the surface of the drum and ensures capture of suspension to be treated. This tank is equipped with a stirrer of continuous or discontinuous action, by which a uniform consistency of suspension is provided.
The first area of the drum with the vacuum equipment provides active filtration and primary drying of residue. Due to pressure drop, the separated moisture is supplied through the filter layer into the drum cells and is discharged outside from there. In the second area the residue is initially watered, and then dewatered by the same vacuum. In the third area, the residue is loosened by compressed air and is cut by blade. In the fourth area filter surface is regenerated (cleaned) by air under high pressure. Thereafter, the drum surface is dipped into the tank with suspension and the cycle is repeated.
Impurities are removed from the water and are deposited on the bed grains under the effect of adhesion force. The residue of deposited impurities accumulated in the bed, has a very fragile structure. With the destruction of this structure, some adhering particles become detached from the bed grains and are transferred to the next layer of bed, where they become deposited again in the pore channels.
Water clarification in granular bed is the total result of adhesion and suffusion processes (the process reverse to adhesion and consisting in particles removing with fluid flow). Water is clarified in each bed layer as long as the intensity of particles depositing is higher than the separation intensity. Particles break away harder, as the residue accumulates.
Separators having granular bed are widely used to remove suspended solids after biological treatment. Microbiological processes do not develop in them, the content of nitrogen and phosphorus and does not change in them. The separator is essentially a tank containing granular material. Water passes downwards or vice versa through this material. Distribution of water before filtration and collecting of the purified water should occur uniformly.
Quartz sand is used as a granular bed. When contaminants are accumulated in the separator housing, water supply to the filtration stops and the water-air washing is conducted.
Currently, there are separators with a variety of bed options (two-layer bed, multilayer bed, moving bed, etc.). Performance efficiency of filters is virtually indistinguishable from each other.
Settling process is used for suspensions thickening, as well as for their classification by fractions. Thickeners and classifiers do not differ from each other by design, but when thickener calculating it is necessary to take into account the deposition rate of the smallest particles, and during classifiers calculating, it is necessary to take into account the deposition rate of the particles, which must be separated at this stage.
Settlers-thickeners
Thickeners represent a sort of settling tank for suspensions thickening. Classifiers represent a sort of settling tank for the classification of solid particles by fractions. As per the operating principle, there are three types of settling tanks:
Wet separator with a housing for a continuous flow of up to 75 gallons per minute.
Magnetic ceramic drum Æ150 mm x 609 mm with a housing of mild steel with top-mounted stainless steel scraper. The drive motor power is 0.12 kW. Housing is about 250 mm high x 711 mm wide x 381 mm of the overall length.
A through feed of slurry through the separator is recommended. Thus, metal particles will remain on the drum.
In the chemical industry, fine particle mixtures of gas and solids occur during materials processing. Smoke and dust should be marked among such materials that appear during solids grinding, melting, substances burning and materials sieving. In addition, the liquid and gas mixtures in the form of mist are formed by condensation.
The term "aerosol" is used to indicate the gases, which contain fine particles of solids or liquids. There are many operations which result in contaminated gases or gas mixtures containing a certain amount of foreign gas.
Separation of gas mixtures as well as purification of gases from impurities is a major technological task, for example, to protect the environment.
Superfine impurities, that is, solid, liquid or gaseous are removed during gas cleaning process. At that gas mixture is separated into separate gas components.
Purification of gases from mixtures solves such important tasks as:
In some cases, the recuperation process does not give any economic benefit, and produces only the environment cleaning up. However, if cyclic cleaning of used material is used, gases purification can be fully repaid.
In the production process, it is often necessary to carry out gases purification from solid and liquid particles suspended therein. Cleaning methods can be grouped as follows:
The easiest way to remove suspended particles from gas is carried out by gravity separators (under the influence of gravity), and by the cyclone separators (under the influence of centrifugal force).
Settling chambers are used for preliminary rough scrubbing. In such chambers separation of solid particles is carried out by gravitational settling under the influence of gravity forces.
A solid particle makes the following movement in the gravity separator: it moves along the device with the velocity w and moves down at a rate of deposition of w0. Indicator of absolute velocity of solid particle movement is defined as the diagonal of a parallelogram with w and w0 sides. Gravity separator must have such a length l, so that solid particles had time to gravitate to the bottom moving at absolute velocity.
The equation of the theoretical performance of the settling device is as follows:
Vsec = fω, m³/sec
Baffle collectors are the simplest devices for cleaning gases from dust. Baffle collectors are equipped with vertical baffles, which prolong the path of gas and reduce its speed for better dust deposition. This procedure provides the best dust collection.
Dust precipitation chambers are intended for rough cleaning of hot kiln gases from dust. In such separators gas stream is divided into a series of flat horizontal jets by horizontal metal baffles.
Gas subject to cleaning is fed into the channel by means of the adjusting gate and fills the chamber, in which the baffle-plates are located (distance between the plates varies from 40 to 100 mm). As the gas moving along the chamber the solids are deposited on the plate’s surface.
Superfine droplets of liquid are formed during gases circulation within the separator. Droplets are produced in case of gas contacting with the walls or built-in design elements, and these droplets moisten the place of contact and flow in the form of liquid film. Formation of droplets
Aerosols (superfine mists) are formed under conditions of supersaturated gas condensation in cold pipes. Aerosols must be removed from the gas stream, since they are deposited on the walls of pipelines and can cause water hammer.
Separation of liquid mist is of particular importance when working with toxic fluids, as residues of such substances may cause an ecological disaster.
The droplet size of liquid mists varies from 1 to 100 microns. Indicator of droplets density exceeds the density of the gas in which they are dispersed. As a consequence, droplets are more susceptible to the rotational forces and the inertia.
In an aerosol separator, a gas stream moves directly and collides with an obstacle, and then turns in the opposite direction. Droplets having a higher specific gravity indicator pass this way longer than the light particles. Therefore, colliding with an obstacle, heavy particles flow in a form of a liquid film.
Aerosol separators include:
Deflector plates act as simple barriers for multiple rotation. Large droplets are settled in the process of aerosol flow bypassing of such obstacles.
In terms of design, plate packing is a plurality of thin corrugated plates, stacked on each other. The plate pack turns the aerosol stream. When colliding with the plates, droplets are converted into liquid film and are drained through openings in the plates.
Braided packing is made of fine sieve cloth (wire braid). Aerosol stream makes many turns in its path and becomes gradually settled. Braided packing is often embedded in the evaporators.
Cyclone mist eliminators (cyclones separators) are used for the deposition of dispersed mist. In such devices aerosol stream moves in a circle in a result of centrifugal force influence. The droplets are thrown onto the separator walls down which they flow in a form of liquid film. The purified gas exits through immersion pipe. These devices are often connected to the evaporators.
The above methods of gas suspensions separating by means of a gravitational field and centrifugal force practically don’t work with finely dispersed compositions, since too fine particles with dimensions not exceeding 10 microns have an extremely low settling rate under these conditions. However, separation of these suspensions can be easily done in an electrical field.
Two electrodes with different surface when connected to the poles of the current source set up an inhomogeneous electrical field. At the same time, field of an electrode with smaller surface area has a higher voltage. For example, if we take fine wire and plate as electrodes, then the field voltage starts to increase from plate to wire. "Critical" potential difference in gaseous space will cause an electric discharge between the electrodes, which will be accompanied by a bluish glow (the so-called corona) near the wire. This discharge is called the corona discharge, and the wire is called the corona electrode.
Gaseous ions charged positively and negatively are formed in the place where the corona glows. Under the conditions of high voltage field their speed is sufficient to ionize neutral particles that collide with them. In their turn, newly formed ions are involved in the ionization of the remaining particles. Thus, this ionization process occurs exponentially.
If the wire has a negative charge and the plate has a positive charge, the wire will attract positively charged ions, and the plate will attract negatively charged ions. When the voltage of the electric field is sufficient (about 4-6 kV/cm), a constant flow of ions is established between the electrodes. If one passes the cleaned gas between the electrodes, solid particles contained in it will receive charge from ions and will follow them. Negative ions are more mobile and they pass a longer distance from corona to the plate than positive ions. This means that they stand a better chance to collide with solid particles. Therefore, the particles of gas suspension mainly become negatively charged and are directed to the plate, and then deposited therein. For this reason, the plate is called the collecting electrode. A small portion of solid particles is positively charged and is deposited on a wire. To remove the settled particles from the plate, it is periodically shaken. Due to low electrical resistivity, droplets transmit their charge to the plate, moisten it and are drained.
This process requires only DC. If an alternating current is connected, the charged particles will receive frequent pulses in different directions. As a result, they will be discharged with the gas flow before they have time to reach the collecting electrode.
Under the same conditions, the degree of gas purification increases at a decrease in conductivity of solid particles. Good conductivity causes quick charging of particles from the plate. Thus they are subjected to the Coulomb repulsive force, whereby they are carried away from the electric field together with the gas stream.
Electrostatic precipitator separators are applied for separation of gas suspensions using an electrical field. Such devices are available in two types: pipe and plate-type.
The design of a separator includes a stack of vertical metal pipes which are collecting electrodes having a diameter of 150-300 mm and a length of 3-4 m. Wires are strung at the axes of these pipes, which are the corona electrodes with a diameter of 1.5-2.0 mm.
Pipes connect two chambers with their ends. Distribution of original gas suspension and removal of deposited solid particles occurs in the lower chamber. Discharging of purified gas occurs in the upper chamber. The wires for the vertical position fixing are suspended by the lower ends to the frame, which is based on the insulators. Dust deposited on the electrodes is removed by shaking. To achieve it, several connected hammers produce continuous blows onto the upper frame, and in such a way wires are shaken. Also dust is periodically removed from the pipe. For this hammers system connected to a common drive is installed between the rows of pipes. The pipe system is installed entirely in a protective enclosure.
Plate-type electrostatic precipitators differ from pipe electrostatic precipitators by the fact that plates are used instead of pipes as the collecting electrodes. The plates are mounted vertically, and wires suspended to the frame are located in the space between them.
Plate-type electrostatic precipitators are distinguished by less metal content, they are more space effective, easy to install. Due to their design they allow to remove deposited dust more easily. Pipe electrostatic precipitators have a higher specific productivity because they can operate at higher field intensity.
When cleaning the gas from very small particles, first, it is necessary to increase their electrical conductivity, since the charge received by solid particle is inversely proportional to its squared diameter. Particles having a low conductivity, being deposited on the electrodes cannot quickly give the charge. Because of this they push back other particles, which are close to the pipes or plates. Thus, deposition of solid particles with a small size is impossible in electrostatic precipitators. To solve this problem you can moisture the original gas suspension, thus increasing electrical conductivity of solid particles.
A housing or group of bodies, between which there is an internal interaction along with isolation from influence of the environment, can be called a system. Systems, consisting of parts having different properties and boundary surfaces, are called heterogeneous. There are no boundary surfaces in homogeneous systems.
A phase is a homogeneous part of the system, having specific physical properties and a homogeneous composition. Phases and systems may consist of one or more components, each of which can independently exist after separation.
Any heterogeneous system consists of two or more phases. One phase is the internal (dispersed) phase, the other one is external (dispersing). The dispersing phase surrounds individual particles of the dispersed phase. The main distinction of homogeneous system from heterogeneous system consists in particle size of the dispersed phase (in homogeneous systems these particles do not exceed the size of molecule).
Heterogeneous systems can be gas, liquid and solid by the state of aggregation of the dispersed phase. Gas heterogeneous systems consist of a gaseous dispersing medium, in which solid or liquid particles are suspended. Gas systems are represented by two main types: mechanical and condensed. The basic difference between these types of gas systems consists in the particle size.
Mechanical gas systems are formed by the process of:
Dimensions of particles of mechanical gas systems are in the range of 5 to 50 μ.
Condensed gas systems are generated by the process of:
The particle size of condensed gas systems are in the range of 0.3 to 0.001 μ.
The particle size of the condensed and mechanical gas systems can vary. For example, particles of condensed systems can unite to form particles exceeding the size of the particles of mechanical suspensions. In their turn, solid particles of mechanical suspensions can approach the condensed particles by size. The particles, size of which does not exceed 0.1 μ, are in Brownian motion. Particles, having size less than 0.1 μ, are not settled by gravity forces and are suspended for indefinite time.
There are many sources of inhomogeneous gas systems formation. Dusts are obtained by:
Smokes and mists are the result of processes that are accompanied by vapor condensation:
Filters
Upon becoming the official distributer of fabric filters, our company ‘Intech GmbH’ LLC (ООО «Интех ГмбХ»), carries out the following: finds the buyers of your products on the market, conducts technical and commercial negotiations with the customers regarding the supplies of your equipment, concludes contracts. Should a bidding take place, we will collect and prepare all the documents required for the participation, conclude all the necessary contracts for the supply of your equipment, as well as register the goods (fabric filters) and conduct customs clearance procedures. We will also register a certificate of transaction (Passport of Deal) required for all foreign trade contracts in the foreign currency control department of the authorized Russian bank so that currency transaction could be effected. If required, our company will implement an equipment spacing project in order to integrate your equipment into the existing or newly built production plant.
We are convinced that our company ‘Intech GmbH’ LLC (ООО «Интех ГмбХ»), will become your reliable, qualified and efficient partner & distributor in Russia.
We are always open for cooperation, so let’s move forward together!
