er ) PMT INDUSTRIES SDN. BHD. ex257- VERTICAL PRESSURE LEAF FILTER OPERATING MANUALINTRODUCTION1, Introduction ‘ty 1.1 Whatis a Pressure Leaf Filter? The pressure leaf filter has long been a proven system of pressure filtration used extensively in the vegetable oil industry. These filters consist of a filter vessel mounted horizontally or vertically, into which are fitted filter leaves with selected wire mesh on both sides for the separation duty involved. In the vertical tank filter, the filter leaves are located on a centralized manifold outlet. The vessel, which is of vertical construction with removable head and cone bottom, is usually mounted on the support platform steelwork, from suitable supports welded into the vessel sides. The filter cover is mounted from a hydraulically operated davit and lifting device allowing the cover to be swung aside for intemal acoess to the vessel. As only periodic inspection is required, the cover is sealed by either swing bolts and nuts or by segment C clamps. For filter cake removal, an air operated vibrator and cake discharge door or butterfly valve are fitted, allowing the semi-dry cake to be automatically discharged. This type of unit offers large filtration areas in a small floor space, concentrated cake discharge, a totally enclosed operation and ease of automation, The filtration process begins within minutes of the start of the filtration cycle. Solid particles form a filtering layer on the fine outer wire cloth of the filter leaves. This process, known as bridging, enables all solids that can be filtered to be extracted from the slurry. Correct selection of the outer filter cloth allows spontaneous bridging without the need to use filter aid. ‘As the leaves filter on both sides, a large filtration area can be obtained in a relatively small vessel. Each leaf consists of five layers of stainless steel wire cloth, with the outer layers of fine mesh acting as the filtration media, and the center layer facilitating drainage of the filtrate. The remaining layers act as support for the filter media. The layers are stretched and riveted or bolted in a rugged tubular frame. Due to this unique construction, there is no deposit of particles or impurities inside the filter leaf as there is a constant internal flow acting within the coarse mesh and tie tubular frame. This special design also ensures a rapid and equal cake deposit ail over the leaf. This allows a minimum pressure drop inside the leaf even at high filtration rates. This differential pressure makes it quite impossible for the cake to slip or fall. In some instances, pre-coating is necessary in the filtration process. Sometimes, the concentration of solid parts to be filtered tends to be too low or the solid parts are too small, Slurry then passes through the filter screen without any filtration taking place. This is due to the concentration of the particle size present being too small to allow individual particles to collect and bridge across the openings of the filter meshes. Pre-coating will enable the filter screens to be covered with a layer of finely divided material. This will C then act as the actual filter medium, Page 1 of 3LI tis a Pressure Leaf Filte The end of the filtration cycle depends on two conditions: 1) The reach of maximum permissible cake-thickness. The maximum permissible cake thickness is mostly based on leaves spacing (Please refer to 1.2 Technical Specification). There should be no overfilling of the allowable cake space. The filter leaves can be damaged and bent when the cake formation from adjacent leaves touches, making them useless. 2) The reach of maximum permissible filter pressure which is 4.5 bar. ‘The disposal of the dry cake begins by blowing the cake dry with compressed air, inert gas or steam, before the cake is being discharged automatically by the pneumatic vibrator and the butterfly valve cake door. The vibrator assembly, which acts as both cake discharge mechanism and a leaf spacer is mounted from outside the filter vessel. The vibrator shaft passes through a rubber membrane and utilizes an ‘O’-ring seal to ensure that all the vibration energy is utilized in the filter cake release. Generally, pressure leaf filter has a limitation. When the concentration of solids in the slurry exceeds 30-35 % in volume, this filtration process cannot be conveniently handled. The filtration cycle will be shorter and the amount of time spent cleaning the leaves increases. This is due to the available cake space being less than half of the total volume of the filter tank. Thus, when the percentage of solid by volume in the slurry approaches the percentage of cake space by volume allowed in the filter tank, the amount of oil filtered in each cycle is reduced tremendously. Cake Building 5 Ply Leaf ConstructionLI What is a Pressure Leaf Filter? Vertical Pressure Leaf Filter — Features Top Cover with Davit Arm Vibrator Assembiy Filter Leaves a = Outlet Manifold 4 a Feed Inlet Oi Butterfly Valve & Cake Door Page 3 of 3|. Introduction C 1.2.1 Technical Specification Pressure Leaf Filter Model PLF 8 -780/920-9 A) General + Filtration Area Bm + Floor Space 2314 x 2070 mm + Cake Holding Capacity 184 dm? + Height 2379 mm + Noof Filter Leaves 9 pos + Nett Weight 908 kg + Leaf Spacing 70 mm B) Vertical Vessel Cc Filter Vesse! comes with four support lugs for floor mounting. Of welded construction with all structural parts in steel unless specified Vessel Diameter 760 mm + Hydrostatic Test 7.8 bar + Vessel Volume 0.9m + Design Temperature 150°C + Design Pressure 6 ber + Working Temperature 130°C. + Working Pressure Sber ‘© Material of Construction ‘= Vessel Finish Interior + Vessel Finish Exterior © Cover Closure Cc © Cover Lift Nozzles :- + Ft Feed inlet + F2_ Filtrate Outlet + F3 Cake Discharge + F4 Vibrator Connection + F5 — Menometer Connection Carbon Stee! SA 283 or equivalent. Sandblasted to SA 2.5, then treated with one coat of vegetable oil Sendblasted to SA 2.5, then painted with one coat of zinc compound primer and one epoxy paint finish. ‘Swing bolts and handwheels. Davit complete with hydraulic hand pump. DN 50 PN 16, + FB Vent inlet DN 50 PNIG N80 PN16 + FZ Air To Vibrator 38" NPT DN 350 PN 10 + FB Pressure Transmitter 11NPT DN65(Special} + “FO High Level +°NPT DN 50 PNIG + F10 LowLevel NPT Page 1 of 2C Cc 1.2 Technical Specification pees ©) Conical Bottom / Cake Discharge Valve ‘The fiter vessel is equipped with conical bottom terminating in an AMRI Isoria 10 PN10 Type 4: ST.6K3G.K pneumatically operated butterfly valve for ease of cake discharge. The butterfly valve comes complete with ‘Actair 50 @ double acting pneumatic actuator ( conto! air pressure of 80 psi on iubricated fluid ). * Herion’ solenoid valve 24V DC & "HKC" APL 210N limit switch (1/0-1/0), Material Code Body (37) Shaft (6K) Disc (3G) Liner (K) Size Duele ron 13% Chromium Stainless Steel Ductile ron High Content in Nitrile DN350 ‘A 600 mm diameter counter flange complete with bolts & nuts for flange mounting is include D) Filter Leaves 4 set of 9 filter leaves providing a filter area of 8 m?. All leaves are of 5-ply construction as follows ‘ply Drainage mesh 4x4 mesh, Wire diameter 1.6 mm. Material Aisi 304 2ply Support mesh 8x8 mesh, Wire diameter 0.7 mm. Material Aisi 304 2ply Filter mesh 60x60 Mesh Wire diameter 0.18 mm Material 316. Leaf Binding ‘All meshes are enclosed in a heavy duty capping channel of Accessories a) 1pc b) 1 set ©) 2pes ¢) tunit e) 2sets f) 2pes g) tpc h) 2pes i) 2pes 4.6mm thickness. Leaf comers have 160mm raaii with 3mm rivets ‘on 40 min intervals. Outlet flow through 34.8 mm diameter nozzle at the bottom of the leaf with a vibrator fork at the top side. All materials are in Aisi 316 L 100 mm Compound Pressure Gauge -1 to 9 Bers. Seal & Gasket for Vibrating Assembly. Emergency Spacer Ring Drainage Manifold © Rings for Fiter Leaves Top Cover Gasket Non- asbestos Outlet Gasket Emergency Plug Hook SpannerASSEMBLY & MAINTENANCE2, Assembly and Maintenance 2.1 Piping It is important to follow the general rules for good process piping when installing your filter. © Use adequately sized lines and fittings to minimize pressure losses. Locate all valves and all other controls to be within easy reach of the operator. © Eliminate all places where solids may collect, especially on the discharge side of the filter. Failing to do so will cause the filtrate to be contaminated. © It is important to have a flooded filter pump suction, oversized suction lines and fittings, tight fittings and packing. This will eliminate the possibility of enstrained air in the feed, which can cause cake disturbance and bleeding. Liquid level in the filter will also be lowered and affect filtrate clarity. It is important not to allow the filtrate to flow back into the pipeline after the installation of the filter system. If the discharge pipe work is routed above the filter tank, a non-return valve must be mounted near the filtrate outlet manifold. ‘© Whenever there is a tendency for solids to settle freely in the filter tank, pump in a volume of unfiltered slurry greater than that being filtered, and re-circulate the excess from the vent of the filter back to either the pre-filter storage tank or to the suction side of the pump. * If the discharge pipe work is too long, pressure losses will occur and this could reduce the working cycle time of the filter unit. * In addition, it is highly recommended to install the following controls and instruments: 1. Non-retum valve at the filtrate outlet. 2. Pressure gauge in pre-filtrate inlet line and filtrate outlet line. 3. Sight glass in pre-filtrate inlet line, filtrate outlet line and vent line. 4 . Flow-meter in the filtrate outlet line. Page 1 of 82, Assembly and Maintenance 2.2 Pump Capacity Feed pump must have a flow rate that is regular and continuous. We would recommend the single stage open impeller centrifugal pump to our customers. The size of the feed pump needed should be based on the desired flow rate at the maximum operating pressure of your filter tank, A margin for increased flow or increase turbulence should always be given, when taking in account the free settling solids. ‘We recommend that the feed pump must have the following characteristics: Cc «Flow rate that is 15% to 20% of the filter tank’s volume, enabling the tank to be filled up in a maximum of 6 minutes. © A capacity that is 15% greater than the desired flow rate when operating at 4.5 bar. In instances where centrifugal pumps are unavailable in the required size or material of construction, positive displacement pumps can also be used. These conditions are only applicable if the filter pump and the filter tank are situated on the same level. If the pump is placed lower than the filter tank, the pump pressure must be adjusted accordingly till the above condition is met. Page 2 of &2. Assembly and Maintenance 2.3 Pre-start up After the installation of the filter, there are a few major points that need to be checked before commissioning, 1. Check each filter leaf, be sure that every nozzle has an o-ring and it is in good condition. If not, please replace it immediately. 2. Prior to placing the filter leaves in the filter tank, wet the o-rings in filtered oil. This will make mounting easier and lessens the chance of damaging the o-ring when putting the nozzles into the manifold. 3. Carefully insert the filter leaves in the correct sequence into the manifold, and ensure that each leaf is fully seated. Extreme care should be taken when carrying out this procedure. The leaves are arranged in such a way that they are numbered 1 from one end of the manifold, and with increasing order till the other end. The center leaf has the largest area of all. Symmetry is observed about the conter leaf. The leaves at both ends have the smallest area, with the leaf area in increasing order till the center leaf, followed by a decrease in leaf area again. 4. Check cover gasket. Make sure it is in good condition. Make sure it is properly seated and lapped in the gasket groove of the tank rim. 5. Make sure that the cover lift mechanism is in good working condition. The lifting and sinking of the cover should occur smoothly. 6. Make sure that the vibrator lubricator is clean and filled with the correct grade and quantity of oil. 7, Donot exceed the maximum allowable air pressure for operating the vibrator (6 bar) and the butterfly valve. Test the vibrator and recheck the tightness. 8. After connecting the air lines, ensure that the butterfly valve is able to open and close smoothly without problem. Make sure that the butterfly valve is closed at all times, except during the cake discharge process. The indicator on the eG instrumentation box will indicate the position of the valve. Page 3 of 82.3 Pre-start up —_—a A 9. Make sure that the feed pump, electric motors, air compressors and any other Gevices are ail operating in the correct voltage. 10. Tightened the hand wheels by hand every time after closing the filter cover. Never use a crow bar or any other device. Tighten 2 or 3 times till a good metal contact is established. Page 4 of 82. Assembly and Maintenance 2.4 Maintenance Our filter tank is a standard, well-constructed and well-designed pressure vessel. It should receive the maintenance regularly to keep it in tip-top condition. Below are a few major points that should be observed when conducting checks on your pressure vessel. 1. During the replacement of the cover gasket, it should be replaced with a lipseal rubber gasket of size 12.5 x 20 millimeters. The ends should be cut at an angle and as much material as possible should be crowded into the gasket ring. 2. The frequency of replacing the o-ring of the filter leaves depends on the frequency of usage. However, once the leaf is removed from the manifold, it is advisable to replace the o-ring, 3. The filter leaves should be periodically inspected to observe if plugging/blinding has taken place by looking through the leaves at an angle of 45 degrees. Bare or thin spots in the filter cake also indicate plugging/blinding. Residual solids adhering to the screen can be removed by steam blowing. 4, The usable cake space can be reduced and the filter cycle will be shortened when the filter leaves are bent out of shape. Frequent straightening of the bent leaves will cause the binding to loosen and ultimately, leakage will occur. Bent leaves are usually caused by either overfilling the filter with solids beyond the point where the adjacent filter cakes touches or by unequal forces resulting from partial plugging of the filter screens. 5. Do not overfill the cake space. Good cake drying, washing and cleaning can only be carried out when the adjacent filter cakes do not touch. Overfilling of the cake will cause considerable damage and distortion to the filter leaves. 6. Never backwash or allow backflow of liquid through the pressure leaf filter. This will damage the filter screen. The filter screen will bulge out and tear away from the frame, Page 5 of 82.4 Maintenance 7. Do not brush or scrape 2 leaf when cleaning it, This will result in solids or impurities sticking onto the wire mesh and plugging it. The wire mesh may also be damaged. Do not dislodge the cakes with a pick or crowbar. 8. Check that the lubricator in the FRL unit is clean and filled with the correct grade and quantity of oil. 9. Make sure that the vibrator nuts are checked weekly for tightness. If slackness occurs, the bad vibration effect will result in quick wear of the vibrator forks on the leaves and the spacer rings. 10. It is important never to interrupt the flow through the filter cake during the filter cycle to ensure consistent filtrate clarity and also to obtain well blown filter cake. Do not completely close the valve on the pipeline from the filter manifold. This is very important in phases 3 and 4 of the filtration cycle. Page 6 of 82, Assembly and Maintenance 2.5 Mechanical Cleaning Method 1) High-Pressure Water Jet Clogged filter leaves can be cleaned well with a high-pressure water jet, which operates between 60-80 bar pressure. This blowing through with the high-pressure water jet has to be against the outside of the filter leaves, in the same direction as the filtration is effected. The filter leaves have to be placed with the nozzle downwards, so that the water is able to flow away easily. 2) Steam ‘Steam can also serve as an alternative or in combination to the using of high-pressure water-jet. Steam, at a pressure of 3-5 bar with a temperature between 135 degree Celsius and 150 degree Celsius can be used. 3) Alkalic Cleaning ‘The filter leaves can also be cleaned by placing them in a pit or tank filled with 10% concentration of Sodium Hydroxide (caustic soda). The temperature at which this cleaning process takes place is between 70 degree Celsius and 90 degree Celsius. The exposure time needed is between 12~24 hours. After the exposure time is over, check the filter leaves to observe if plugging has taken place. This can be done by looking through the leaves at an angle of 45 degrees. Residual solids adhering to the screen can be removed by steam blowing. Note: Under no circumstances should hydrochloric acid or cleaners containing free chlorine be used. Alkalic cleaning is not required in crude oil filtration. Page 7 of 82, Assembly and Maintenance 2.6 Trouble Shooting 1) High Pressure and Short Cycles Plugged screens generally cause high starting pressure. This problem can also arise if the initial pumping rate of fine bleaching clay is too high. If the screens are not plugged, but the high pressure and short cycle still persists, add some filter aid to the bleaching clay. The amount of filter aid to be added is about 25% of the weight of the bleaching clay. 2) Cloudy filtrate Poor filtrate clarity is generally caused by a few different factors: a. Bleaching clay is too coarse. b. Holes in the screens. c. Loose bindings. The gap between the filter screens and the frame might be more than the allowed 0.1 millimeters. This will cause leakage 4. Improper or worn out leaf o-ring. e. Fluctuating filter pressure. £ Entrained air in the pre-filtered slurry. g. Trapped solids in the filtrate outlet lines, which may be carried over during the re-circulating operation. h. Plugged sections of the screens becoming unplugged during the filter cycle. i, Wom out manifold. 3) Uneven Cake Build Up (Thicker At The Bottom Than At The Top) This problem will generally produce pear-shaped cakes. This problem is undesirable and is usually caused by the settling of solids within the filter tank. The usable cake space in the filter is reduced and the classification of solids which accompanies this problem, caused low flow rate. This problem can be eliminated by re-circulation of excess liquid through the vent of the filter. Page 8 of 8FILTRATION CYCLE3. Filtration Cycle 3. Filtration Cycle The following instructions and diagrams will only serve es a guide. Please adjust accordingly to achieve your own filtration needs. The filtration is performed by a vertical pressure filter. Filtration of crude palm kernel oil can be carried out without the addition of filter aid. In some instances, it might be necessary to add filter aid during the first run to condition the leaves. The filtration oycle consists of 8 steps. Please refer to flow chart C22-07-04P Phase 1~8 for reference. The sequences of filtration are as follow: 1) Filling the filter tank 6 minutes 2) Circulation until a clear oil is obtained minutes 3) Filtration (dependent on foots content) 0.5-1.5 hours 4) Emptying the filter tank 6 minutes 5) Air blowing the filter cake 30 minutes 6) Opening the butterfly Valve 1 minute 7) Cake Discharge 1-2 minute 8) Closing the butterfly valve 1 minute Initial situati : Storage tank is filled with unfiltered crude palm kernel oil. Filter tank is clean. Phase 1: Filling The Filter Tank Start the mixer in the storage tank. This should be done 10 minutes before the circulation process in order to achieve an evenly distributed oil content in the storage tank. Open the storage tank outlet valve X and with valve 42 open (for circulation and overflow), start the feed pump. Open valve AI gradually to fill up the filter tank with unfiltered oil. Make sure that all other valves are closed. When the filter tank is full of unfiltered oil, which you can observe through sight glass near valve A2, open valve A3. Throttle valve AJ and close 42. Time taken for Phase J is dependent on filter and pump capacities, Page 4 of 123. Filtration Cycle Phase 2: Circulation Until A Clear Oil Is Obtained An initial layer of solids / foots must first be built on the filter leaves in order to get clear oil just before the actual filtration. With valves AJ and A3 open, and also with the pump running, continue to re-circulate until the oil in the sight-glass near filtrate outlet 43 is observed to be clear. Adjust valve AJ to obtain the desired circulation rate. The estimated time of circulation before a completely clear oil is obtained is about 5-6 minutes, Phase 3: Filtration Once the oil is clear, open valve A4 slowly. Close valve 43 simultaneously. Adjust valve AI again to obtain the desired filtration rate. This actual filtration period will last 1-3 hours until the maximum cake holding capacity is obtained. Please refer to section 1.2 Technical Specification on the cake volume allowed. However, there are two points to take note of: 1. Open valve 44 before closing A3. This is to maintain a constant flow through the filter cake to assure cake stability. 2, If the oil level in the storage tank reaches the minimum allowed, change over to circulation. Open valve 43 and close valve 44. Continue to circulate until the oif level reaches the operational level. Next, open valve 44 and close A3. ‘The filtration has ended and there is unfiltered oil remaining in the filter tank. This remaining oil is pumped back to the storage tank. During emptying of the filter tank, itis important to keep a flow of oil and/or air through the filter cake. This is to ensure cake stability. This is obtained by opening valves AS and A7 during the emptying of tank process. Next, stop the feed pump and close valve X, AI and Ad. Then open valves 45 and AI2. Use a slight over-pressure of air and throttle valve AZ? to maintain a slight over pressure on the filter tank. When the filter tank is empty, close valve AS and A12. Page 2 of 123. Filtration Cycle Phase 5: Air Blowing the filter Cake Air blowing of filter cake is only possible on a number of oils such as palm, palm kernel and copra, All other oil should be blown dry with steam in order to avoid ignition of the cake. Once the filter tank is empty, open valve 45 & 47. Next, air is blown through the cake and the cake will be dried up. Use air pressure that ranges between 0.5-1.5 bars. Air blowing of the cakes is important in two aspects: 1) Reduction of the oil content inthe filter cake, 2) Basier and quicker cake discharge during vibration process. Phase 6: Opening the butterfly Valve Close valve AS after drying the filter cake, Open valve 47 to depressurize the filter tank. Open butterfly valve 473 only after the air pressure in the vessel is released. Phase 7: Cake Discharge Proceed with the cleaning of the filter once the butterfly valve is opened. Open air inlet valve AJO and the vibrator will start operating. If the cake is well dried from the air ‘blowing process in Phase 5, one minute of vibration will be sufficient to discharge the cake from the filter leaves. Phase 8: Closing The Butterfly Valve Once the filter cake is discharged, close valve 410. Close butterfly valve A13 and close valve A7. Open valve 42 to put the filter tank under atmospheric pressure. Close valve A2 after about 5 minutes. Filter tank is now ready for the next filtration cycle. Page 3 of 123. Filtration Cycle Note: Change In Oil Quality During the filtration cycle, ifthe oil quality becomes poorer, proceed as follow: 1) Assume filter is in Phase 3 (Filtration Phase). 2) Open valve 43 and close 44 as soon as the minimum level is obtained in the storage tank, 3) Continue to cireulate for about 30 minutes. This is to accumulate as much foots as possible on the filter leaves, 4) If bridging is successful after a few minutes, proceed on with the filtration cycle. However, if the oil clarity is still bad after engaging in the above procedures, please refer to section 2.6 Trouble-Shooting Guide. Page 4 of 123. Filtration Cycle abo-Lo-teD hon sony MBI. HO POsOIE sowyoyy oup SUITE 1 2OyTL Taseyd TOP i oly pret) asda woLvaela sswip LaoIs 99 aR pamela cuso1o ana Nagoaatva. 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