I. Overview:
1. Product Features:
The series of box and plate and frame filter presses are a kind of slurry which can be composed of two phases of solid and liquid. Under the action of hydrostatic pressure, the liquid is oozing out through the filter element, the filter medium (filter plate, filter cloth), and the resistance is retained. A device in which particulate matter forms a filter cake to effect solid-liquid separation. Through the configuration of integrated superposition hydraulic system, gas diaphragm press, variable frequency speed control, PLC programmable control and other technologies, the automatic closed circuit of the filter press is realized. The box filter press consists of a plurality of vane filter plates arranged to form a filter chamber. When the solid in the slurry forms a cake, the filter plate material is: reinforced polypropylene molded, imported TPE elastomer. Features: acid, alkali, salt erosion, non-toxic, odorless, light weight, high strength (high temperature 0-80 ° C,), easy to operate. Salt-tolerant solution and polar solvent, good toughness, stable chemical properties, filter plate adopts point-like conical boss design, compression molding, fast filtration speed, high dewatering rate of filter cake, uniform washing and thorough, fine sealing surface sealing performance intact.
2. Main use and scope of application This model has the characteristics of strong adaptability to the environment of suspension medium. It is widely used in solid-liquid separation in coal, chemical, metallurgy, electric power, paper, non-ferrous mines and food, medicine, sewage treatment (ceramic mud) and other industries.
3. Safety (1) It is strictly forbidden to use the filter press in the absence of filter plates and filter cloths! ! ! Otherwise, it will affect the stability of the whole machine, causing damage to the whole machine and affecting production.
(2) During the working process, it is strictly forbidden to repair or adjust the components to avoid damage and accidents.
(3) The filter press operator should be familiar with the structure, performance and operating procedures of the machine. It is strictly forbidden for other personnel to start the machine without authorization.
(4) The equipment is not allowed to work above normal working pressure.
Second, the main body structure principle This model filter press is mainly composed of the frame part, the filter plate part, the pull plate transmission part, the feeding part, the hydraulic pump station part and the electric control cabinet part.
1. The frame part consists of: main beam, thrust plate main bearing, main beam bearing main bearing, compression plate bearing, hydraulic cylinder bearing and nameplate. The thrust plate main bearing, the main beam support main bearing, the compression plate main bearing, the hydraulic cylinder main bearing and the main beam are assembled to form a rectangular frame. The rear end of the frame is bolted to the thrust plate support by a thrust plate, and the thrust plate support is coupled to the foundation by a ground bolt to form a position of the filter press. The head end of the frame is placed on the cylinder support by the two legs of the hydraulic cylinder bracket. When the filter press is pressed, the hydraulic cylinder and the hydraulic cylinder support have a sliding movement of about 5 mm to release the elastic elongation when the main beam is pressed. Deformation. The hydraulic cylinder support is fixed by the anchor bolt and the foundation foundation.
2. The hydraulic cylinder part is composed of hydraulic cylinder block, piston, piston rod, sealing ring, guide sleeve, support ring, front and rear end cover, front and rear cavity interface, electric contact pressure gauge and bleed valve. The hydraulic cylinder is coupled to the compression plate by a piston rod and a spherical horn. The electric contact pressure gauge displays the working pressure of the cylinder, and simultaneously collects and feeds back the pressure signal of the cylinder to the PLC control cabinet to realize the automatic pressure holding of the cylinder. The bleed valve is used to remove the gas inside the cylinder to ensure smooth running of the piston rod.
3, the filter plate part is also called filter element, consisting of filter plate set, filter cloth, handle, and other components. It is placed between the thrust plate and the compression plate in the rectangular frame, and is supported on the two main beam rails by the handles on both sides of the filter plate. Depending on the application and the environment in which it is used, all filter plates are compacted to form a number of sealed filter chambers. The filter cloth is sandwiched between the filter plates, the periphery functions as a gasket, and the middle portion is used as a filter material; the feed holes of each filter plate form a feed channel, and are arranged on the pressure plate (before feeding) and the thrust plate The feed holes are connected; when the slurry with a certain pressure enters the filter chamber through the feed hole, the particulate matter is intercepted by the filter cloth in the filter chamber, and the filtrate water is percolated through the capillary pores of the filter cloth and passed through the filter plate. The flow channel and the filtrate hole flow out; for the filter press equipped with the dark flow filter plate, the four holes on the corner of the filter plate form a filtrate water return passage, which communicates with the return hole on the corner of the thrust plate, and is This discharges the filtrate water; for a filter press equipped with a diaphragm filter plate, the small filter press generally occupies a hole in the corner of the dark flow filter plate as a press air passage, and communicates with the air inlet hole on the thrust plate.
4. The pressing plate is also called the head plate. Its main functions are: (1) Pressing the filter plate together with the thrust plate to form a seal for each filter chamber of the filter plate. (2) When loosening, the distance from the filter plate is about 1000-1500mm (the distance signal is collected by the proximity switch), which is used as the space for the filter press to open the frame. (3) A filter press that requires a feed at the tip end, and a feed port is provided on the pressure plate. The pressing plate portion is placed between the rails of the two main beams through the rollers on both sides thereof, the plane faces the plane of the thrust plate, and the other surface is connected with the piston rod of the cylinder. The piston rod drives it to reciprocate on the main beam to achieve the closing, pressing and loosening of the filter plate.
5. The thrust plate, also known as the tail plate, forms a filter press frame together with the main beam and the cylinder portion. Its main function: (1) Press the filter plate together with the pressure plate to form the filter plate into each sealed filter chamber. (2) Set the feeding and blowing interface. For the filter press that needs to set the dark flow, press, and reverse blow function, the return pipe and the air pipe interface are also set on the thrust plate.
Third, the working principle of pressure filtration (1) Close the compression filter plate: under the push of the piston rod of the cylinder, the compression plate is closed in the direction of the thrust plate and the filter plate is pressed. When the pressing pressure reaches the upper limit of the set pressure of the electric contact pressure gauge, the oil pump stops supplying oil; when the pressing pressure falls back to the lower limit of the set pressure of the electric contact pressure gauge, the oil pump is re-supply; at this time, the filter press is under pressure status.
(2) Feeding: The feed valve is opened, and the slurry enters each filter chamber through the inlet system of the pipeline system and the filter plate, and the solid particles remain in the filter chamber, and the filtrate passes through the filter cloth and is discharged from the filtrate hole on the filter plate. As time goes on, the solid particles in the filter chamber accumulate more and more. After the formation of the filter cake, the feed is stopped (Note: the cake cake is limited by the feed concentration, and the cake is generally judged by the return of the filtrate tube), and the feeding process ends.
(3) Loosen the filter plate: the cylinder is unloaded and the piston rod is retracted. The piston rod drags the head plate and moves backwards to a distance of <1500mm as the space for the frame pull plate.
(4) Pulling plate discharge:
a. After the filter plate is manually pulled, each filter plate is pulled apart in turn, and the unloading material is dropped by its own weight into the tray to the next.
b. After the filter plates are all pulled apart, the filter plates are returned to the starting position and the unloading is completed.
Fourth, installation and commissioning
(1) Basic requirements for installation:
1. The foundation of the filter press is designed and constructed for fixing and equipment load. The design of the foundation and supporting pipelines shall comply with the relevant national standards.
2. The base of the cylinder support base and the tail support should be on the same center line with a deviation of ≤ 3mm. The anchor bolts must be subjected to secondary grouting.
3. The foundation should be leveled, and the horizontal error of each installation reference plane is ≤ 2mm.
4. The stress on the process line should not be applied to the body of the filter press.
5, there should be enough space around the filter press, the minimum distance for barrier-free is not less than 1m, and there should be a clear space of not less than 2.5m above.
6. Equipment installation should be carried out under the guidance of the manufacturer.
(2) Installation and adjustment:
1. Installation of cylinder support and thrust plate support:
(1) Leveling the four upper planes of the push plate support and the cylinder support with the level, and leveling the height with a transparent hose. The height of the upper plane at four points (calculated height) is less than or equal to 2 mm;
(2) Pull or suspend the line with the powder line, and the center of the positive cylinder support and the thrust plate support should be on the same center line with a deviation of ≤ 2mm;
(3) After satisfying the above requirements, hang the anchor bolts for secondary grouting. After the secondary grouting reaches the civil design strength, re-adjust the requirements of (1) and (2), tighten the bolts (the bolts are pre-buried, and tighten the bolts);
(4) The hydraulic cylinder support has a needle roller, clean the oil groove, put the needle roller and add the grease in the needle roller groove, and add the grease to the groove depth 1/2.
2, electric control cabinet installation:
After the electric control cabinet is hoisted in place, the control lines and power lines are connected.
3. Filter plate installation:
(1) For the friction plate movement handle, before installing the filter plate, first apply a layer of (lithium-based) grease on the upper surface of the main beam rail;
(2) When installing the filter plate, the positioning handle and the driven handle should be respectively installed on both sides of the main beam;
(3) The filter plate is equipped with a filter cloth, a pressure ring (the sleeve filter cloth does not need a pressure ring) and a side buckle, which is hoisted onto the main beam rail, and then the filtrate tube is installed;
5. Operation and use:
1. Before each shift, check the shift record and master the working condition of the filter press. It is strictly forbidden to operate the equipment with faults.
2. The filter press should work under normal compression pressure and feed pressure. The compression pressure is low, and the high feed pressure will cause the filter press to spray.
3. It is forbidden to start the operation under the condition that the number of filter plates is less than specified, so as to avoid accidents.
4, filter cloth installation should be flat, not allowed to fold, no foreign matter, so as not to cause spray. When the filtrate is found to be turbid, it is proved that the filter cloth has been damaged, and the new filter cloth without damage should be replaced in time.
5. When the manual auxiliary unloading is applied, the hand-held button box set by the near machine is used to control the filter plate to be opened, and the manual auxiliary unloading in the automatic state is prohibited. The artificial auxiliary discharge is mainly used to remove the mud cake on the sealing surface of the filter plate, especially the sealing surface at the lower edge of the filter plate. The hazard of the mud cake on the sealing surface is not removed in time: the sealing surface of the plastic filter plate is crushed, and the spray material is severely damaged, which may cause the tail plate or the filter plate to tilt, resulting in instability of the whole machine.
6. Under the normal feeding conditions, when the moisture content of the filter cake is increased, or the filter cloth is stained with the filter cake, the unloading is not clean, indicating that the filtering effect of the filter cloth is deteriorated, and the filter cloth should be stopped immediately. The direct consequence of not cleaning the filter cloth in time is to deteriorate the working state of the filter press and damage the filter plate, filter cloth and filter cloth pressure ring. Under normal circumstances, it is necessary to arrange a high-pressure water cleaning work for the filter cloth every shift.
7. It is recommended to develop a filter cloth cleaning system and clean the filter cloth once per shift. The cleaning method is as follows: using the hand-held button to control the operation of the box, sequentially pulling the filter plate, and simultaneously starting the filter cloth to clean the water pump, and manually holding the high-pressure spray gun to clean the surface of the filter cloth.
8. The filtrate is found to be mixed, indicating that the filter cloth or the filter cloth is damaged, and must be replaced before the next cycle. At the same time, high-pressure water is used to rinse the filter tank between the star-point bosses on the filter plate to restore the normal water filter function of the filter plate. Otherwise, the filter plate will be damaged by the bias of the web.
9. The web of the filter plate is broken, which is generally caused by the bias. Under normal circumstances, the filter cake on both sides of the web of the filter plate is as thick, and the force on the web is balanced. However, when one side of the web is damaged due to breakage of the filter cloth or poor sealing of the pressure ring, the filter is not normal (the slurry runs directly to the back of the filter cloth without filtering, and the water tank between the star points of the filter plate is clogged). This balance is broken. One side is filtered into a cake, while the other side is not filtered. The filter cake on one side of the filter is continuously filtered under the action of pumping pressure, and the cake is continuously formed. When the thickness of the filter cake exceeds the design thickness, the filter cake extrusion web is deformed to the unfiltered side (the web is subjected to a bias). When the filtration is finished and the filter plate is unpacked, this deformation disappears. When re-feeding, this deformation reappears. Therefore, the filter plate web will continue to withstand the effects of alternating stress without solving the filter chamber sealing problem. Eventually, fatigue cracks will occur due to the action of alternating stress, and the crack will expand until it breaks.
10. If the filter cake is found to be thin, the feeding time should be extended appropriately. If it is found that the discharge is difficult, the feeding time should also be extended appropriately.
Sixth, maintenance and maintenance:
Good maintenance and maintenance ensure that the filter press works properly and extends its service life. To do this, you should do the following work.
1. The operator must be familiar with the contents of the instruction manual and operate, adjust, use and repair according to the requirements of the manual.
2. Always check whether the whole machine is zero, whether the components are safe and reliable, whether the fasteners are tight, whether the hydraulic system works normally, whether the oil leaks, and whether the transmission components are flexible and reliable.
3. Check the quality of the hydraulic oil frequently. Whether the oil level in the fuel tank meets the requirements, whether the hydraulic oil is pure, and the surrounding of the hydraulic system should be kept clean, waterproof, dustproof and electricity-proof.
4. The oil temperature in the fuel tank is not higher than 60 °C; the water tank is strictly prohibited from entering water and dust, and the oil filter on the hydraulic station is often cleaned.
5. When working, the filtration pressure, compression pressure, and liquid temperature must not exceed the specified value. In the absence of the filter plate or the maximum displacement of the compression plate is greater than the piston stroke, it is forbidden to open the machine.
6. When starting the oil pump in winter, it should be put into use when the hydraulic oil temperature rises above 15 °C as needed. Apply low-condensation point hydraulic oil to alpine areas.
7. When the new fuel pipe is replaced for the first time, the personnel must not be close to the high pressure oil pipe.
8. Clean the filter cloth and maintenance equipment after work every day, keep the water permeability of the filter cloth, and keep the equipment clean. The filter press should be stopped when the filter plate is closed, but it must not be pressed.
Seven, common faults and troubleshooting methods:
(1) Hydraulic system failure:
1. Reasons and treatment methods for severe noise or pressure instability in hydraulic system:
(1) The oil pump is sucked up or the suction line is blocked. Treatment method: Refueling the fuel tank to solve the leakage of the oil suction pipeline and clean the oil suction pipeline.
(2) Hydraulic oil is low for the year. Treatment: Replace the hydraulic oil.
(3) There is air flow in the hydraulic oil circuit. Treatment: Discharge air.
(4) Grinding after the oil pump is damaged. Treatment: Replace or repair.
(5) The relief valve is unstable. Treatment: Replace or repair.
2. Reasons and treatment methods for insufficient or no pressure in the hydraulic system:
(1) The oil pump is damaged. Treatment: Replace or repair.
(2) The pressure adjustment is incorrect. Treatment method: readjust and correct.
(3) The viscosity of the oil is too low. Treatment: Replace qualified hydraulic fluid.
(4) There is a leakage oil in the oil pump system. Treatment: Symptomatic replacement or repair after inspection.
3. Reasons for the shortage of cylinder pressure during compression and treatment methods:
(1) The high pressure relief valve is damaged or stuck. Treatment: Symptomatic replacement or repair after inspection.
(2) The reversing valve is damaged. Treatment: Symptomatic replacement or repair after inspection.
(3) The piston seal is damaged. Treatment method: Replace.
(4) The piston rod seal is damaged. Treatment method: Replace.
(5) The O-ring in the cylinder is damaged. Treatment method: Replace.
(6) There is a bias in the pressure adjustment. Processing method: readjust.
(7) The oil pump is damaged. Treatment: Replace or repair.
4. Reasons and treatment methods for insufficient cylinder pressure when returning:
(1) The low pressure relief valve is damaged or stuck. Treatment: Symptomatic replacement or repair after inspection.
(2) The piston seal is damaged. Treatment method: Replace.
(3) The piston rod seal is damaged. Treatment method: Replace.
5. Reasons for serious leakage between filter plates and treatment methods:
(1) The filter board frame is deformed. Treatment: Symptomatic replacement or repair after inspection.
(2) There are debris on the sealing surface. Treatment method: clean up.
(3) The filter cloth has wrinkles and overlaps. Treatment method: Replace.
(4) Insufficient pressing force. Treatment method: Appropriately increase the pressing force.
6. Reasons for the breakage or deformation of the filter plate frame and treatment methods:
(1) The filtration pressure is too high. Treatment method: Reduce the filtration pressure.
(2) The temperature of the feed liquid is not enough. Treatment method: Reduce the temperature appropriately.
(3) The pressing force is too high. Treatment method: The pressing force is adjusted properly.
(4) The filtering speed is too fast. Treatment method: Reduce the filtration speed.
(5) The feed hole is blocked. Treatment: Clean the feed hole.
7. Causes and treatment methods of shotcrete:
(1) The sealing surface of the filter cloth is damaged or folded. Replace the damaged filter cloth or unfold the filter cloth.
(2) There is a residual filter cake on the sealing frame of the filter plate. Remove the residual filter cake.
(3) The cylinder pressure is insufficient. Adjust the compression pressure or overhaul the hydraulic system.
(4) The feed concentration is too low. Appropriately increase the feed concentration.
8, the reasons for not forming a cake and how to deal with it:
(1) The filter cloth is damaged. Replace the filter cloth.
(2) The filter cloth pressure ring is not well sealed. Press or replace the pressure ring.
(3) The feed size is too large. The upper process controls the particle size of the slurry.
(4) The feed size is too small and the filtration performance is poor. Increase the feeding time and increase the feed pressure.
(5) The concentration is too low. Increase the feed concentration and extend the feed time.
9. Reasons for the difficulty of unloading cakes and treatment methods (1) The filter cake is too thin. Increase slurry concentration and extend feed time.
(2) The water permeability of the filter cloth is lowered, and the water content of the filter cake is high or not. Clean the filter cloth, extend the feeding time, and appropriately increase the feed pressure.
(3) The filter cloth is not damaged. Replace the damaged filter cloth or pressure ring.