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Distributor / authorized representative that deals with supply & delivery of vacuum filters to industrial enterprises of Russia

Engineering company ‘Intech GmbH’ LLC (ООО «Интех ГмбХ»), Russia, has been successfully working with a number of Russian industrial enterprises at the local market for more than 20 years. Since the company’s founding, it has acquired immense engineering experience, market reputation, and has realized more than a hundred large-scale projects at the industrial plants in Russia. Our company is continuously in search of new business partners, who consider Russian market investment-attractive and want to boost their sales in the region, as well as expand their field of activities and enter a new international level. 

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We are interested in cooperation with the manufacturers of vacuum filters, 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 vacuum filters. 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 vacuum filters, will submit a market overview for vacuum filters 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 vacuum filters 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 vacuum filters 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 vacuum filters 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 vacuum filters 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 vacuum filters. They will also provide necessary training and guidance for the customer’s personnel.

Vacuum filters. A brief overwiew.

Drawing of the band vacuum filter

Vacuum filters

This is a continuous vacuum-operated filter. Filtrate movement and the direction of gravity force in the vacuum filter coincide.

A perforated rubber band is moved by the driving and tensioning drum around the closed circuit. The cloth used as a filter membrane is pressed to the band by rollers. The suspension is fed from the trough onto the filter cloth. The filtrate exposed to differential pressure moves into the vacuum chambers located below the band, and then it is discharged from the filter. The cake forming on the filter cloth is washed with liquid which is fed from nozzles. Wash fluid is sucked into other vacuum chambers and then it is also discharged from the filter.

The cake is dried using vacuum. Then, it is separated from the cloth when the band passes the roller, and is discharged into the tank. The filter cloth is regenerated when passing the rollers on its way back. Regeneration means cleaning by mechanical brushes, washing and steam curing.

Advantages of band vacuum filters include: simple design, no distribution head, possibility for cake dewatering and favorable washing conditions. With easy cake removal and cloth regeneration, band filters are suitable for difficult-to-filter suspensions.

General description of the vacuum disk filter

Filtering is performed using a porous membrane. During this process, a layer of solid particles (cake) is accumulated on one side of the membrane, and filtered liquid (filtrate) which passed through the membrane is accumulated on the other side. For filtration, it is necessary to have the suspension pressure higher than the pressure on the other side of the membrane. Such conditions are created by injecting the suspension via pumps, due to gas pressure, vacuum on the other side of the membrane.

Vacuum filters

Arrangement of the vacuum filter is shown in the drawing above. The sectored disks (usually made of aluminum) are arranged on the hollow shaft and covered with filter cloth. The shaft with the disks rotates with max. speed of 3 rpm in the tank whereto the suspension is fed for filtration. When a vacuum pump connected to the filter (like in the vacuum drum filter) creates vacuum, the liquid passes through the cloth to get inside the disks.

Residue which remains on the filtering surface of each disk sticks to it as a cake. Thickness of such cake depends primarily on the properties of the residue.

Change of operation cycles in the vacuum disk filter is the same as in the drum filter.

The vacuum disk filter is filtering equipment with rotating disks (or drums) whose main task is to separate suspensions with solid phase particles of approximately similar size with moderate settling rate.

Vacuum disk filters are used mainly when the cake of at least 8 millimeters is formed during a short period of time (no more than 3 minutes). Here, the largest solid phase particles should make at least 20 per cent of the total solid phase volume and should have the settling rate of 18 mm/s or higher.

The suspension to be separated in the vacuum disk filter should be absolutely safe, and its liquid phase should not crystallize under vacuum conditions. Highly volatile, fire- and explosion-hazardous suspensions as well as poison-containing suspensions are not allowed to vacuum filtration. The cake formed on the filtering equipment is not washed. Only minor cake cracking is allowed during drying.

Vacuum disk filters are now mainly used in coal industry, ore production, and metallurgical industry.

Design of the vacuum disk filter

The vacuum disk filter consists of a trough, a distribution head and multiple disks mounted on a rotary compartment shaft. Each disk has a certain number (12 to 18) of individual hollow sectors covered with filter cloth or a mesh. The sectors are made of metal or polypropylene. The hollow shaft is installed horizontally in supporting bearings and has two walls (external and internal) with 12 to 18 channels (compartments) between them. Channels and cavities between sectors are interconnected. The compartments face the surface of the hollow shaft with a tightly pressed distribution head which consists of four chambers. Vacuum pipelines are connected to these chambers.

Drawing of the vacuum disk filter

Vacuum filters

Operation principle of the disk vacuum filter

When the shaft starts rotating, all sectors communicate in series with the distribution head chambers. In the filtration zone, vacuumed filtrate is supplied to the sector cavity through the filter membrane. Then, the filtrate is discharged from the filter through the compartments of the shaft and the chamber connected to the vacuum line. Meanwhile, solid phase is collected on the surface of the filter membrane to form a rather thick cake just in a few minutes.

Free liquid is sucked from the cake in other two zones (dewatering and drying). Then, it is discharged from the filter through special chambers.

Compressed air is supplied through another chamber in this section to separate the cake from the membrane. The final cake is removed with a knife. Pulsating compressed air is supplied by the blowing valve. In the regeneration zone, air or steam are supplied through another chamber to regenerate the filter cloth.

It should be noted that the regeneration zone is used only if the filter membrane got clogged with the cake. Carbon steel filters have a cast compartment shaft which consists of several individual parts. Stainless steel filters are equipped with a welded shaft which consists of individual solid sections.

Normally, the vacuum disk filter has a welded trough with an overflow gutter to enable a constant level of suspension. A rotating agitator has its own drive. A distribution head of the disk vacuum filter is fully cast and has fittings to discharge filtrate from the filtration zone, as well as fittings of the drying zone which are used to supply compressed air for the cake blowing and regeneration of the filter cloth.

Equipment with a filtering surface of up to 51 sqm is equipped with a single distribution head, while all other filters with a larger filtering surface have two distribution heads.

General description of the vacuum drum filter

While calculating the strength of these devices, the following main components should be minded: paired coupling of pivots (a drum with pivots in calculations is considered as a simple beam); end wall of the drum (design wall diagram looks like a round plate with radially located rigidity ribs; a pivot transfers the resultant moment in the middle of the plate, and the external contour of the wall face is calculated as a fixed-ended beam); the drum rim has cylindrical shape, it is subject to hydrostatic pressure of suspension; the force of the cake collection mechanism and bending moment caused by the gravity force of the drum.

The drum vacuum filter is a rotating cylindrical perforated drum covered with a metal mesh and filter cloth.

In the chemical industry, the vacuum drum filter with an external filtering surface is the most popular. These filters are characterized by easy operation, good speed of filtration, and suitability for different suspensions.

Calculation of filters for suspensions is performed in two stages. First, it is necessary to determine the total filtering surface and to select the number and the design of filters correspondingly. The next step is to specify the efficiency of the selected filtrate and the number of filters.

Drawing of the drum vacuum filter with an external filtering surface

Vacuum filters

Zone I is designed for filtration and cake drying. In this zone, the compartments are connected to the vacuum line. Due to the pressure drop, filtrate passes through the filter cloth, drum perforation and mesh into the middle of the compartment. Then, the filtrate is discharged from the filter through the pipe. Here, the cake is formed on the outer surface of the cloth. When the compartments come out from the suspension, the cake is partially dried.

Zone II is intended for cake washing and drying. In this zone, the compartments are connected to the vacuum line. The device supplies the wash liquid which passes through the cake and is discharged via pipes. The cake is dried in the places where liquid is not supplied.

Zone III is the cake removal zone. In this zone, compartments are connected with the compressed air line to loosen the cake and facilitate its removal. Then the cake is removed from the cloth surface with a knife.

Zone IV is intended for filter membrane regeneration by compressed air blowing in order to remove solid matters remaining on the membrane after previous stages.

The cycle is repeated after all stages are completed. All filter sections are operating in sequence, but the sections work independently from each other. Thus, the filtering process runs continuously. During drum rotation, compartments pass dead spots where they are disconnected from the vacuum and compressed gas sources.

Settling of solid matters due to gravity force occurs in the suspension trough. This process occurs in the direction opposite to filtrate movement. Thus, the suspension is to be stirred by an agitator.

The necessary filtrate performance, mass concentration of solid matters in the suspension, and pressure drop during washing and filtering are used as the initial filter calculation data. In addition, such filtering constants as filtered cake moisture, specific resistance of the cake and filter membrane, duration of the cake drying process and the cake layer thickness should be experimentally determined. These studies are conducted in a laboratory compartment.

Calculation of drum vacuum filters

Prior to calculations based on the filter breakdown into technical zone, it is necessary to set sector angles of preliminary cake drying, dead spots, cake removal zones, as well as regeneration of the filter membrane.

Duration of a single filter cycle is inversely proportional to the drum rotation frequency:

τcycle = 1/n

The following formula is used to calculate the total filtering zone:

During drum rotation, the compartments pass dead spots where they are disconnected from the vacuum and compressed gas.

Fv = (Q·τc)/(υfsp·Kcor)

where Fv is set performance for the filtrate (in m³/s),

Kcor is the correction factor where the necessity of the filtering surface increasing due to increased resistance of membranes caused by multiple use (for Kcor= 0.8), is considered, Ѵfsp is the filtrate specific volume, which is calculated by the formula:

υfsp = hcake/x0

where hcake is the filter cake layer thickness, m;
x0  is the ratio of the filter cake volume to the formed filtrate volume.

After Fv is found, filter design version is selected from the catalog, and the number of filters to provide necessary performance is determined.

Then, it is necessary to check suitability of the selected filter. For this purpose, the correspondence between rotation frequency of the drum and the range of frequencies specified in the catalog should be determined. In addition, designed and standard filtering sector angles are compared. If frequency value exceeds that specified in the frequency range, or filtering angle is higher than standard, the calculations should be repeated with a different height of sediment layer.

After that, a new calculation of the filter is performed. Distribution of technical zones is determined from the catalog. Drum rotation frequency is selected to be the smallest of those calculated according to the formulas:

n1 = φf / (360·τf)

n2 = (φwashd2) / (360·(τwashd2))

where φf, φwash, φd2 is the filtration, washing and drying sector angles;
τf, τwash, τd2 is the duration of filtration, washing and drying.

Vacuum filter operation cycle includes seven actions:

  1. immersion into the suspension with cake formation and filtrate discharge;
  2. air suction through the cake and removal of the filtrate cake;
  3. cake washing;
  4. air suction through the cake and removal of the remaining wash liquid;
  5. cake removal and loosening;
  6. cake cleaning;
  7. regeneration of filter cloth.

Compartments are connected to the vacuum line on the first four stages, and connected to the compressed air line on the last three stages.

During blowing, a thin spiral wire pushes the filter cloth to the drum surface to prevent its possible extension. In some cases, cracks may appear in the cake. This may lead to layer cracking and vacuum breaking if air comes through the cracks. In such cases, cracks are covered with a covering band which moves over the cake surface.

Various ways are used to remove cake depending on its structure and thickness:

  • layer thickness 8-10 mm – the cake is removed with a slice which is mounted along the drum generating line at some distance from the surface;
  • layer thickness 2-4 mm is removed using infinitely thin cords located in parallel at a distance of 6-25 mm which move along a closed path and envelope tensioning and guide rollers; cords are separated from the filter cloth with the cake;
  • layer about 2 mm thick is removed using a rubber roller rotating in the direction opposite to the drum rotation direction; layer on the roller is removed with a knife;
  • layer about 1 mm thick - belt cloth method is used for cake removal where the filter cloth runs along the same way as the endless cords: from the drum surface it is supplied to the discharge roller to remove the cake using a knife, then it passes the washing roller and is returned to the drum.

When separating fine suspensions, pores of the filter material get clogged quickly. For this reason, а grainy membrane with thickness 50-75 mm is used instead of the filter cloth. Diatomaceous earth is often used as the production material. The filtration process looks as follows: the suspension of the grainy material is supplied to the trough, a detachable unit is turned on and the filter is operated for 30-60 minutes. The cake of the desired thickness is formed. Then, the suspension is supplied into the trough for filtration. During separation of the suspension, the alluvial layer with the settled cake is gradually cut with a knife. The knife moves very slowly and it covers about 0.01-0.05 mm during a single rotation of the drum. The alluvial layer regenerates with its thinning.

The working zone of compartment drum vacuum filters is up to 50 m². The drum diameter is 1-4 m, the length is 0.2-5 m. The drum rotates with angular velocity of 0.1-3 rmp. A 0.1-4.5 kW motor is used to drive the drum. Filter materials are selected according to suspension.

Filters

Upon becoming the official distributer of vacuum 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 (vacuum 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!

Intech GmbH SARLIntech GmbH SARL