Eaton Filters Curb Water Consumption, Feed Sustainability

Eaton Filters Curb Water Consumption, Feed Sustainability

The state of California was having a beef with a major meat packing company regarding the amount of water it was using. Perhaps more so than in any other area of the U.S., water is the lifeblood for social and economic wellbeing in this essentially arid state. Because of that, numerous legislative initiatives have been  implemented over the years to  better conserve water covering everything from the installation of more efficient sprinklers, the planting of draught-tolerant landscaping, to the upgrading of some 10 million public and private toilets.

Challenge
Flushed with the need to do its part to help curb water usage, the meat packing company sought recommendations from Eaton’s Filtration business on how to more efficiently reuse and recycle water at one of its facilities in central California. Engineers at the company and Eaton representatives eventually identified one area of the processing – known as a hide-on wash station – where water usage was especially high. Recycling the rinse water, they concluded, from the hide-on stations would significantly reduce consumption. However, recycling the rinse water required an especially robust filtration system due to the extremely harsh operating conditions at a hide-on station, where the filters had to dealwith high quantities of dirt, hair, fats and other impurities. High flow rates further complicated the formidable task.

Solution
The puzzle was soon solved with the installation of three Eaton DCF-1600 filters with twin pneumatic actuators. “We were asked to make a recommendation on the conditions we saw during a site visit,” says David Peterson regional sales manager for Eaton.

“Based on what I witnessed, no other filter was capable of handling the severe operating environment.”

Ideal for a variety of food applications, Eaton DCF-1600 filters are designed for the rigors of processing highly viscous, abrasive, sticky or otherwise hard to process substances. The filters, which operate at low differential pressure, easily accommodate a wide range of flow and retention requirements.

Additional features include:

• Elimination or reduction of disposable filter bags and cartridges for reduced operator handling, inventory costs and landfill waste.
• Reduction in product loss and more thorough containment purge in a highly concentrated waste stream.
• Reduction or elimination of operator intervention for safer operation.
• Virtually maintenance free with nearly 100 percent uptime.
• Compact design and lower capital cost to fit most installations.
• Stainless steel screens ranging from 15-micron slots to ¼-inch perforations to handle a wide range of filtration needs.
• Available with most popular cleaning discs.
The dual actuators on the DCF-1600 filters isolate the actuation mechanism from the filtrate with a bridged system resulting in a long operating life in just about any challenging condition.

Results

“The systems have been operating perfectly from the day they were installed,” says Peterson, “and the savings from water conservation have been huge.”
Because of the conservation, the company should also be safe if future restrictions develop for incoming water, which have occurred in California in the past due to ongoing water shortages. Meanwhile, discharged waste water has been effectively minimized with the reuse of recycled water.
Visitors from sister facilities have observed the DCF-1600 filters operating in California and have been impressed enough to investigate ordering their own installations, adds Peterson.

“Water reuse and recycling in the food processing industry is a recurring challenge,” says Peterson. “Thankfully, there are many areas where water can be filtered and reused with the right filtration system, including incoming water from wells, as well as water used in wash stations, cooling towers, storage tank cleaning and more.”

Less disposal of waste water also brings about important benefits to the environment, he notes.

Due to the flood of benefits still occurring today, accolades continue to pour in from all interested parties on the new beefy filters from Eaton.

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The Filtration of Process Water and Its Importance in the Petroleum Industry


Disposable Filter Media: When final product clarification is a key process objective, a general standard of particle removal is retention in the 0.2 – 200 µ range. Many disposable filter media meet this criterion. Disposable filter media, typically bags or cartridges come in a wide range of µ and fabrics. Woven and nonwoven polypropylene, cellulose, polyester, nylon, and other materials are all available.

Two types of efficiency ratings are typically used for disposable filtration media: nominal and absolute. Nominal ratings can vary from 50 – 90% removal efficiency, depending on the product and the manufacturer. Absolute ratings imply 100% removal of particles at a set rating; this actually means 98.7 – 99.99%, depending on the product and the vendor.

Bag fabrication has advanced over the past few years, improving the filtration capacity of bags and making them more efficient. Multilayer bags, some as much as an inch thick, are now on the market. The multiple layers increase the solids holding capacity of the bags and provide a larger surface area for filtration. These higher efficiency bags normally last longer, remove a higher percentage of contaminants (up to 99.9%) and can be rated as low as 1.5 µ.

Even with new designs in bag construction, cartridge filters trap particulate that a simple bag cannot, such as soft particles, which can be extruded through bags. The ‘depth’ design of cartridges (layer of rigid construction) means they have more surface area upon which to trap the dirt and enable significantly more dirt holding capacity when compares to a similar size bag. This makes cartridge the filter choice for absolute filtration.

While disposable media such as bags and cartridges usually have a relatively low initial cost, operating costs can be high if charge out is frequent. Media replacement and waste disposal costs can quickly outweigh any ‘savings’ from the lower acquisition cost. Conversely, for applications with low processing volumes or where media replacement is infrequent, bag or cartridge filtration may be the best choice.

Cleanable Filter Media: Several different types of cleanable filter media are available as alternatives to disposable media or as a prefilter in staged filtration systems. They include wire mesh, wedge wire, defined pore, perforated, and sintered metal filters. Cleanable media can often be used in the same applications as disposable bags or cartridges, sometimes with significant labor and cost savings. There are many applications where pressure or flow requirements make cleanable filter media a better choice. When comparing purchase price to operational expenditures, a typical payback can range from six months to one year.

Cleaning of this media type may be done manually, hydraulically or mechanically. Manual cleaning often requires the use of expensive cleaning compounds, and the filter media can be damaged during cleaning. Additionally, work force is obviously required for manual cleaning, and worker safety/exposure issues are raised. Hydraulic cleaning involves using either the process stream or another compatible source of liquid to backwash the filter media. This may be cost prohibitive if the liquid being filtered is very expensive, hazardous, and/or no compatible with an outside source of liquid to the backwashing. Disposal of large volumes of contaminated backwash liquid could also be prohibitive.

There are three main classes of cleanable filters: vibrating screens, backwashing filters, and mechanically cleaned filters. Of these three, only vibrating screens require manual cleaning, but they have limited use in the petroleum process, especially for water treatment.  Mechanically cleaned filters are ideal for highly viscous liquids. Again, this does not apply to most water treatment applications.

Backwashing filters work well in high volume applications, typically ranging from 100 gpm and upwards. A minimum pressure of 45 psi and a small volume of liquid are required for backwashing. For these reasons, backwashing filters are often found throughout the petroleum industry.

Ultimately, whatever the process water application, careful consideration and selection of filtration equipment can significantly improve overall system performance. Although most attention for filtration in the petroleum industry traditionally focuses on refining crude, water is a key process component and can help drive optimization. It will reduce maintenance costs, repair costs, and labor requirements. It will also extend the life of expensive and valuable equipment, improve a plant’s competitive position, and help to drive profits.

Eaton’s Newest Customer Success Story : Paint Manufacturer

The Eaton DCF-1600 mechanically cleaned filter was installed to remedy the problems associated with large particles and foreign fibers. The quality of finished paints improved while the company reduced process costs, and gained a safer and cleaner work environment.

Read the full success story today. Click to Read

Eaton’s DCF Mechanically Cleaned Filter

Dcf 400, 800Considered the most efficient mechanically cleaned filter on the market, the Eaton DCF-Series is ideal for highly viscous, abrasive, or sticky liquids. The DCFs operate at a consistently low differential pressure and deliver simple, reliable operation in which a low initial investment is a key driving factor.