Many industries use media filtration. This application can be in the form of ion exchange for water softening / demineralization, sand filtration, activated carbon, or other medium bed fluid treatment processes.
However, whether it is applied in waterworks, power companies, pulp and paper, steel, or any other industry, the problems tend to be similar.
In the process of media filtration, the same complaints appear again and again: resin or media leakage, excessive pressure drop, screen blockage, and high requirements for backwash/rejuvenation. These problems can be solved by using properly designed and specified equipment and internal components of the equipment, which can be said to be the most important investment in media bed filtration.
In order to ensure proper design results, design engineers need to understand the system pressure. Is it designed to avoid clogging? In case of hydraulic failure, is it able to withstand the possible strain and retain the medium? Is it possible to retain the particle size in normal use? Will it go through the required traffic? Is it designed to provide differential pressure to ensure uniform flow? Has corrosion been considered? Are suitable alloys available and developed? Can the flushing be repeated successfully without clogging?
For filtration products, the manufacturer may require a set of “Lateral Assemblies” to form the distribution system of activated carbon tower or desalting tank. Requirements for horizontal distribution/collection systems can be provided to manufacturers. Given flow data and vessel details, this data can be used to generate a set of header side tubes.
In fact, it is possible to produce a variety of header side pipes that meet these specifications. The question is: which design is best for the illustrator? Although the term “lateral header” is commonly used, other configurations (such as “hub lateral” system, “leg drop nozzle” configuration, and others) may serve the process better and more economically.
Ideally, manufacturers’ application engineers would ask their customers a series of questions designed to elicit more specific information about their customers’ overall needs.
For example, they may discuss the media filtration process to ensure that they have an understanding of the process and fully consider key areas. A preliminary understanding of the details of such processes is essential to reduce overall maintenance and costs and to obtain the best product.
Advantages and application of wedge wire screen
Wedge wires are generally recommended because of their high strength and ease of cleaning.
It can be supplied in a variety of forms for distribution/collection systems, most commonly in the nozzle and lateral configurations. The side can be provided with a variety of end configurations to fit the design.
Usually, a wedge wire is applied to the drill pipe. This design provides better support and allows the design of Engineering jigs to ensure optimal distribution and collection and to maximize bed utilization.
All of the above are based on the accurate determination of media retention requirements. The notch size of wedge wire products is critical to ensure that all analysis, design, and manufacturing methods are achieved.
Considering the tolerance, many wedge steel wire products on the market are still based on the original drilling use. They are usually manufactured with a dimensional tolerance of + / – 0.002 inches or more. When trying to retain 0.010 inches of ion exchange medium, the result is obvious.
Structural materials
Structural materials also need to be addressed. The typical liquid that the filtration system “sees” is water. It can be wastewater or boiler feed water, river water, brackish water, seawater, or ultrapure water.
In the process industry, filtration may also involve a variety of chemicals. Fortunately, most of these fluids can be handled by components made of suitable stainless steel, nickel alloy, or duplex alloy.
The customer shall ensure that the materials supplied by the supplier are compatible with the specific system fluids used. The filter system is also provided with a PVC side pipe slot to fix the medium.
PVC has good corrosion resistance, but poor structural stability. Pressure changes often lead to plastic bending, which changes the size and shape of the notch. PVC will also wear and change the retention force.
Wire mesh screening is often used in filtration applications, but the effect is not good, and it is not as reliable as wedge wire.
Because the cross-section of the wire is round, there is always a tendency of particle deposition and blocking. The wedge-shaped steel wire is made of triangular steel wire continuously wrapped on the longitudinal support steel wire.
Wires are welded at each intersection. Triangular cross-section wedge wires with flat fixed surfaces are easier to clean and backwash more effectively.
In addition, water pressure, system stress, and careless handling may cause chafing or tearing of the wire cloth. For these reasons, many engineers prefer the strength, anti-clogging, easy backwashing, and dimensional stability of wedge wire.
Many systems also use downstream protection in the form of basket filters or resin traps. Wedge-shaped steel wire is also an ideal filter medium for this application.
It is strong and strong and retains the reserved process conditions.
The nature of the wedge wire construction allows it to be scrubbed, cleaned, and washed without damage. The basket can be designed to meet the requirements of pipeline size, pressure drop, variable configuration, and process conditions.
As a result, the wedge wire provides engineers with an excellent retention medium for long-term design and manufacture of vessel internal parts, resin traps, and other filtration products, resulting in long-term cost savings and improved efficiency.