When filtering solids from liquids, the smaller the micron rating, the more effective the filter and the greater the number of particles that are removed from the final filtrate. However, where there is a heavy sediment load, a fine filter with a low micron rating will quickly become saturated, meaning that the differential pressure will increase to a point at which the flow rate reduces and the filter will require changing.

For more information, please visit Ceramic Filter for Molten Metal.

In systems with high sediment loads that require a high-quality filtrate, several filtration stages may be needed, from coarser filters with higher micron ratings to smaller ratings further upstream. This way, each filter can work to maximum efficiency while lengthening the periods between change-outs, providing a lower operating cost.

We offer a range of filter cartridge options including specialised membrane versions delivering micron ratings as low as 0.05 microns, small enough to filter viruses.

Nominal versus absolute filters

Although the filter micron rating will give a good indication of its effectiveness to achieve the required levels of solid/liquid separation, the standard to which it will remove these particles must be factored in. The micron rating is based on the pore sizes within the media, but filters can be constructed from many different materials and these can flex and change according to different operating conditions. The 3D shape of the pore can, therefore, change and particles larger than the micron rating can occasionally pass through.

For this reason, filters are often categorised into two main types:

• Absolute &#; providing assurance that 99.9% of particles at or bigger than the micron rating will be stopped by the filter.
• Nominal &#; these filters are given a percentage rating which indicates the proportion of particles at or bigger than the micron rating that will be trapped by the filter.

Absolute filters address this issue by providing a filter efficiency rating at or above 99.9%, when used according to the manufacturer&#;s instructions. This ensures that particles greater than the micron rating will not pass through. The use of specialised materials and stringent construction methods ensure that these filters perform to an extremely high standard. For this reason, they are usually more expensive than their nominal equivalents and are often reserved for processes that require a very high-quality filtrate and for use in final-stage and polishing filtration stages.

We offer a range of absolute filters for every type of solid/liquid filtration process with absolute micron ratings from 0.05 micron up to 100 microns. Many of our absolute filters, such as our Deltapor MB melt-blown range, are FDA compliant and meet the requirements for food contact as detailed in European Regulation Number /. The polypropylene or nylon microfibers offer high throughputs, low pressure loss, high dirt capacity and a long onstream lifespan while bonded fibre construction minimises fibre migration and resists particle shedding, even under pulse conditions.

Nominal filters are a lower-cost alternative and provide great results in many applications. When selecting a nominal filter, the micron rating and the filter efficiency rating should be considered together. The micron rating will state the particle size, above which solid particles should be retained and the filter efficiency rating will give an indication of the percentage of these particles that should be stopped by the filter. A nominal filter with a 95% of 10-micron rating will stop 95% of particles at 10 microns or above.

We provide nominal and absolute versions for many of our filter cartridge range to ensure that you achieve the results you need while maintaining a low operating cost.

Testing to establish real-world results

Our filter cartridges undergo rigorous testing during manufacturing. Filters are tested in controlled conditions to establish beta ratios which give an accurate indication of the filter&#;s effectiveness and efficiency.

The filter is challenged with a control liquid which is known to contain a specific number of particles of a particular size, corresponding to the pore size of the filter. During the filtration process, the number of particles is measured upstream and downstream, using particle counters. The beta ratio is then calculated by dividing the upstream particles by the downstream measurement. The higher the beta ratio value, the biggest the differential on either side of the filter and the more effective the filter is at removing those particles. Our filters are available in a range of beta ratios, depending on your filtration requirement, with specialised food and beverage and pharmaceutical filters reaching beta ratios of up to .

Of course, these tests are robust and accurate, but they measure the performance of the filters under strict laboratory-controlled conditions. Our filtration products have a long history of success in a wide variety of challenging conditions across the process filtration lifecycle. Our experience and comprehensive customer portfolio mean that we can offer real-world information on all our filters, and we can help you select the best filtration solution based on your needs.

However, some of our clients, particularly in niche and specialised industries, are keen to test our filters in the real-world environment before they invest. For this, we offer a pilot testing facility . Our team of expert engineers can conduct full process filtration testing on your samples, on or off-site. We&#;ll provide a full report on every element of the filtration process and help you to choose the filter cartridge that offers the best results at the lowest operating cost.

Factors to Consider When Selecting an Industrial Filtration System

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There are numerous industries that make use of filtration systems, from pharmaceutical processing to food manufacturing to wastewater treatment. Selecting the right industrial filtration system involves many different factors including particle size of contaminants, operating conditions of the system, the chemical compatibility of the system, and the physical configuration of the housing unit. Filtration systems are an important part in an overall system so selecting a system is a decision that should be made with careful deliberation.

How to Choose an Industrial Filtration System

Choosing a filtration system can be a harrowing process. There are many factors to consider and it is not a decision to be made lightly as it can have far reaching effects. Below, we&#;ll talk about four important factors to take into consideration when choosing an industrial filtration system. Keep in mind: this is not a definitive list of determining factors &#; every operating system has its own unique factors to consider.

Particle Size

When selecting a filtration system, the first question you need to ask is &#;What are you filtering out?&#; Are the particles you are filtering out big or small? Organic or inorganic?

Filter sizes are sized using microns. Microns are a unit of length, and one micron is equal to one millionth of a meter. For example, beach sand is roughly between .3 and 60 microns, dust mites can be between 100 and 300 microns, and ground coffee tops out at about 400 microns.

By first identifying what you need to filter out, or if there are any industry standards you must follow, you can begin to narrow down which filter is best for you. It is also important to note that the smaller the micron rating the quicker it becomes clogged, which can cause damage to the system. If your system only requires a 50 micron filter, it may seem okay to get a 25 micron filter just to be safe, but you&#;ll need to consider the overall effects of that on the system.

To learn more about micron ratings, read our post on this subject here.

Operating Conditions

Operating conditions like temperature and pressure play a major role in what filtration system is best for you. If your system has liquid running through it that is hotter than 140°F, you&#;ll need to use a metal system rather than a plastic filtration system. Likewise, you need to be aware of the pressure limitations of your filter. If a 2&#; filter can handle 100gpm, and your system operates at 200gpm, that filter will not be able to withstand the pressure of your system.

Chemical Compatibility

Chemical compatibility is measured by the stability of two or more substances when they are mixed. If they do not show any change, they are compatible. Conversely, if they undergo any changes &#; physically or chemically &#; they are considered incompatible. When looking at chemical compatibility of filtration systems, you need to look at the compatibility of the liquid being filtered and the filter itself.

If the filter is not chemically compatible with the liquid flowing through it, it could result in degradation to the filter which would allow contaminants to continue to flow within the stream. When choosing a filtration system, it is important to note if any chemicals are flowing through the system and then research to ensure they are compatible with the filtration materials.

Physical Configuration of Housing

The physical configuration of the filtration systems housing comes in many different shapes and sizes. Not only are there a myriad of different systems to choose from (such as cartridge filters, single or multi-bag systems, and reverse osmosis systems), you also need to consider other physical constraints. Is the area for your filtration system big or small? If its small, a multi-bag filtration system (which is often bulkier) may not be the best choice.

You also need to decide if you want a self-cleaning filtration system or a manual system. Both have their advantages, and often the biggest decision-making factor between the two is money. Self-cleaning is a higher cost up front but can save you money in the long run. And certainly, you&#;ll need to consider other more practical things, like what is your end connection type or what materials are the rest of the system made up of.

Consider a System Carefully

As you investigate filtration systems, it&#;s important to consider all of your options and take your time making decisions. The filtration system is one of the most important components of an operating system. Consider what type of particles you will be filtering out and what the chemical compatibility of your system is then explore your options to find which system is the best fit for you. If you have any questions during this process, don&#;t hesitate to reach out. Our Customer Service is happy to help!

This post covers factors to consider for choosing a filtration system as a whole, but if you are trying to determine which type of cartridge or bag filters you need, we have blog posts to help you out with that as well. View them here and here.

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