PRODUCT BULLETIN
Essa® Certified Pressure Filters
Introducing a new range of Essa®
Certified Pressure Filters
FLSmidth® is releasing a new line of plant and laboratory
pressure filters. The Essa® Certified Pressure Filters will
be typically used on mine sites in gold rooms, assay
laboratories and other metallurgical test facilities.
The CPF015 and CPF035 Certified Pressure Filters are
the result of a collaborative project involving FLSmidth
metallurgical process specialists and product engineers
working with a firm of independent engineers conversant
with pressure vessel verification. An independent design
verifier was engaged, and the pressure filters have
been registered with WorkSafe Western Australia and
incorporate world’s best practice design features.
SAMPLING,
PREPARATION
AND ANALYSIS
 1
Reason for the redesign
Pressure filters are identified as
pressure vessels
A Mines Safety Bulletin No. 125 (attached with this
bulletin) issued by the Government of Western Australia
– Department of Mines and Petroleum (DMP) on 24
September, 2015, identified pressure filters as pressure
vessels, stating: “Since filter presses work with the filtrate
drain always open, some duty holders are operating
under the misconception that this type of equipment
is not categorised as a pressure vessel (i.e. classified
plant). However, to slowly force liquid out, the filter
barrel necessarily stores pressure above the filter cake
for prolonged periods. In addition, pressure will build if
the filtrate outlet becomes blocked and the drain valve is
inadvertently left closed.” (p.2)
The safety bulletin also stated that recent mine site
inspections had identified some issues and potential
problems with this type of equipment, and listed factors
that might contribute to an increased risk of harm. The
Western Australian Department of Mines and Petroleum
instructed that mines within their jurisdiction operate
compliant units. FLSmidth believes that other authorities
and regulatory bodies will require the same standard in
the future.
FLSmidth was alerted about the issue prior to the safety
bulletin being released. Even though the whole industry
generally accepted that pressure filters weren’t classified
as pressure vessels, we took the proactive step to conduct
an independent review to ascertain whether our units
complied with AS 1210: Pressure Vessels.
While FLSmidth was confident that its existing design of
pressure filters did not pose any safety risks beyond those
expected with the operation of this type of equipment,
it acknowledged that the equipment being identified
as a pressure vessel made it necessary to comply with
AS 1210 as soon as possible. Additionally, we made the
strategic decision to ensure the new design range would
also comply with the international ASME VIII: Rules for
Construction of Pressure Vessels (Division 1). This allows
it to be officially used in operating territories other than
Australia.
We and our design partners created the new design to
achieve compliance so that we could confidently offer
it to customers. The former design was immediately
withdrawn from the market globally and we asked
any customers with outstanding orders for their
understanding during the delay while redesign and
manufacture were taking place.
Redesign process
The design brief
The research and development team’s brief for the new
range of pressure filters was to design and manufacture
a range of laboratory pressure filters that conforms to a
recognised pressure vessel standard which is safe, easier
to use and conforms to regulatory requirements.
The redesign project also allowed the opportunity to
improve the design from an ergonomic and safety
perspective, meeting current occupational health and
safety expectations, as well as productivity expectations.
Customer consultation
During the period of redesign, the team were effectively
given a blank canvas to create something that is world’s
best practice in pressure filter design, while fulfilling the
compliance issues.
FLSmidth sought consultation from internal personnel
with extensive metallurgical and operational experience,
as well as customers, about an improved design to meet
all the needs of plants and operators. This took into
account ergonomics, safety, ease of use, durability and
reduction of contamination.
 2
Recommended solution
and implementation
Rigorous redesign phase
The team undertook a comprehensive research, design
and development phase which included the following
stages:
1. Rigorous design phase and concept development.
2. Conceptual designs evaluated by end users.
3. Prototypes manufactured.
4. Prototypes industrially tested under normal working
conditions in commercial laboratories.
5. Design improvements in the areas of ergonomics and
functionality made as a result of the user testing.
6. Independent design verifier engaged.
7. Final design of the product.
8. Design registration, production of manufacturing
drawings and associated documentation.
9. Manufacture in accordance with AS 1210 and ASME
VIII Division 1.
Results
The current design, which FLSmidth believes will be
a market leader, is now compliant with AS 1210 and
ASME VIII Division 1. It has been thoroughly reviewed by
WorkSafe Western Australia and is registered with the
regulatory body (please refer to the attached Letters of
Registration from WorkSafe for evidence of compliance
with both AS 1210 – 2010 Class 3 and ASME VIII
Division 1).
The Essa CPF015 Certified Pressure Filter handles a
capacity of 15 litres and is designed for general laboratory
and plant applications. The larger diameter Essa CPF035
Certified Pressure Filter handles a capacity of 35 litres.
It is used for specialised large volume metallurgical test
work and similar batch processing. The pressure filters are
both floor-mounted and are fabricated almost exclusively
using stainless steel materials and fittings, providing both
durability and contamination-free operation.
FLSmidth is confident that the new design of Essa
Certified Pressure Filters is one of the safest and easiest
to use pressure filters on the market. FLSmidth looks
forward to supplying our customers with this high quality
pressure filter in 2017.
The highlights of the new design are as follows:
• Designed and constructed in accordance with AS
1210, which allows it to be used as a pressure
vessel (classified plant) in Australia and, in particular,
Western Australian mine sites. The ASME VIII Division
1 registration also allows the pressure filters to be
used in other global territories.
• Robust and long lasting: fabricated almost exclusively
using stainless steel materials and fittings.
• Rated to operate under design conditions of 1380
kPa (200 psi) at 50°C: makes filtering fine samples
quicker, reducing sample preparation time and
increasing productivity.
• Ease of use: the swing-out barrel is positioned at a
suitable height for easy loading and unloading of
sample material.
• All control levers are within easy reach for operator
comfort during long shifts.
• Operator safety: lid clamping wheel is fitted with an
interlock mechanism which prevents the wheel from
being turned to release the lid while the barrel is still
pressurised.
• Rotating base for loading and unloading: reduces
the risk of contamination of the filter cake or loss of
sample.
• Protective spray shield: the base of the barrel
incorporates a stainless steel shield that protects the
operator from any liquid spray should the bottom seal
be broken.
• Quick access to the filter cake: there is no need to
tediously unscrew the base plate as the barrel easily
lifts off the filter cake via a simple lever arrangement.

 3
Mines Safety Bulletin No. 125

Subject: Compliance requirements for batch-type pneumatic filter presses used

in laboratories
Date: 24 September 2015
Background
Batch-type pneumatic filter presses are pressure vessels (i.e. classified plant) commonly found on
mine sites in gold rooms, assay laboratories and other metallurgical test facilities. They are typically
used to remove the liquid fraction from small batches of mineral slurries to produce a damp filter
cake, which is further dried before analysis.
Although designs vary, most units typically consist of a cylindrical barrel supported in a free-standing
frame. The top closure is commonly clamped in place using a bridge bar and manually operated
power screw (or pneumatic actuator). The bottom closure supports the filter cloth or metal mesh
and includes collector channels directed to a filtrate drain nozzle.
Liquid is pressed out of the filter cake using regulated compressed air (typically < 700 kPag), which
is fed into the cylinder barrel above the liquid level. The filtrate nozzle is left open to allow the liquid
to drain out.

Typical free standing batch type pneumatic filter press for laboratory use.
This example has a manually operated top closure.

Summary of hazard
Numerous hazards can arise with this type of equipment, including:
uncontrolled release of pressure, liquid and material (from the seals) while the filter is
pressurised

Postal address: Mineral House, 100 Plain Street, East Perth WA 6004
Telephone: (08) 9358 8002 Facsimile: (08) 9358 8000 ResourcesSafety@dmp.wa.gov.au
www.dmp.wa.gov.au
wa.gov.au
 premature seal failure, with the potential for uncontrolled pressure release and loss of
containment if
seals are not checked for chemical compatibility with the liquid materials being filtered,
particularly when tasks change in the laboratory
there is an uncontrolled substitution of sealing materials with alternatives not approved by
the original equipment manufacturer (OEM)
the common hazards associated with the use of compressed air (e.g. air blast, pressure
injection), including the generation of noise as compressed air vents through the drain nozzle
when liquid is pressed out of the filter cake
uncontrolled release of pressure if incorrectly rated hose or fittings are substituted (e.g. water
hose instead of air hose) when the compressed air supply connection is not permanently fixed
unsecured free-standing filter presses being knocked or pulled over
hazardous manual tasks associated with repeated disassembly, assembly and clamping down
of the top and bottom closures (e.g. charging with mineral slurry, removal of filter cake, cleaning
and maintenance).

Contributory factors
Since filter presses work with the filtrate drain always open, some duty holders are operating under
the misconception that this type of equipment is not categorised as a pressure vessel (i.e. classified
plant). However, to slowly force liquid out, the filter barrel necessarily stores pressure above the
filter cake for prolonged periods. In addition, pressure will build if the filtrate outlet becomes blocked
and the drain valve is inadvertently left closed.
Recent mine site inspections have identified many issues and potential problems with this type of
equipment. Factors that may contribute to an increased risk of harm include:
failure to
install and maintain an appropriate safety relief device to protect the vessel in situations
where the filter press can be inadvertently over-pressurised
proactively inspect and maintain the equipment, instead of “running to failure”
secure air hose connections with locking pins, clips or whip checks
adequately secure the filter to the floor or bench
provide adequate warning and instruction signs for equipment
undertaking ad hoc modifications, such as
substitution of seals
using incorrectly rated air hoses and fittings
replacing corroded barrels with pipe sections of different material or wall thickness
fitting additional leverage on the closure capstan and excessive tightening of the top closure,
which can increase the risk of failure and uncontrolled pressure release by overstressing the
barrel of the filter or bridge piece, or damaging the seals
lack of operator awareness of
the design pressure or maximum allowable working pressure (MAWP) of equipment (e.g.
connecting filter presses to 7, 8 or 10 bar compressed air supplies without checking that
the filter press is adequately protected from over-pressure)
the corrosion allowance or need to monitor wall thickness when inspecting and maintaining
equipment.

Mines Safety Bulletin No. 125 Page 2 of 3

 Actions required
Regulatory requirements
Duty holders are reminded of the following requirements of the Mines Safety and Inspection
Regulations 1995:
keep certain records, particularly for registered classified plant [r. 6.25]
inspect, operate and maintain pressure equipment in accordance with AS/NZS 3788 [r. 6.26]
design, construct and test pressure vessels in accordance with AS 1210 [r. 6.33]
register pressure equipment, other than piping, that has a hazard level of A, B, C or D according
to AS 4343 with the State Mining Engineer before it is used on a mine site — unless it is already
design registered with another statutory authority in Australia [rr. 6.34(1) and 6.34(5); General
Exemption dated June 2013]
inspect registered classified plant
using a competent person appointed under section 44 of the Mines Safety and Inspection
Act 1994
keeping records of such inspections in a classified plant record book
for general pressure vessels, inspecting at intervals no greater than three years [r. 6.40;
General Exemption dated December 2003].
Safe systems of work
Duty holders who operate this type of plant need to confirm the plant is included on the site’s
classified plant register so it can be managed accordingly.
Undertake a task-based risk assessment for each laboratory task, and generate appropriate
safe working instructions for each application where this type of equipment is utilised.
Review the risk assessment whenever there is a change of use.
Training and assessment
Train and assess operators and maintainers in the safe use and maintenance of this type of
equipment, and provide suitable information and instruction.

Further information
Visit www.dmp.wa.gov.au/ResourcesSafety for information on general exemptions.
www.standards.org.au
AS/NZS 3788 Pressure equipment – In-service inspection
AS1210 Pressure vessels
AS 4343 Pressure equipment – Hazard levels

This Mines Safety Bulletin was approved for release by the State Mining Engineer on 24 September 2015

Mines Safety Bulletin No. 125 Page 3 of 3