INTRODUCTION mechanism, discharge manifold lower, which Isjhe moving plate at-

his article will cover the basic
T theory and components of a fil-
ter press alohg with a 'suggested*
1. Proper design for reduced
maintenance.
2. Avoidance of "downtime"
through proper maintenance.
3. Troubleshooting operating
problems.
4. Checklist maintenance sched-
ule.
THEORY OF FILTER PRESS
DEWATERING
Pressure filtration is the separa-
tion of suspended solids from a liq-
uid slurry, using a positive pressure
differential as the driving force. This
type of filtration can be classified
as either of the following hub cate-
gories. A cross-sect!on of the inter-
nal plate plumbing has been pro-
vided to enable visualization of
The head loss remains constant.
Thus, the filtration contlnues to de-
cline until the filtration rate has
dropped due to the build up of
cake. When a predetermined rate
of flow has been reached, the cy-
cle is terminated.
and feed piping. Popular options
are the automatic pump control
system and air blowdown. Explana-
tion of these items are as follows
(See Fig. 2).
STRUCTURAL FRAME:
The frame is made up of four
basic parts: the head, the cylinder
bracket, the side b a r s and the fol-
lower.
The head is one of the fixed ends
which allows connection to the fil-
trate and feed ports on the head
plate or connection plate. It also
provides the opposing force to the
closing cylinder.
The cylinder bracket is the mount-
ing surface for the hydraulic cylin-
der and is opposite the head end.
The hydraulics can be housed in a
cabinet built into the cylinder
bracket support legs. The side bars
connect the head and cylinder'
bracket and contain the pumping
and hydraulic force applied. The
side bars support and guide the fil-
ter plates and keep them properly
aligned. They also support the fol-
-..
,POLYPRBPYLENE PLATES,
I
I /
tached to the rod end of the cylin-
der.
_...
FILTER PLATES:
There are several types of filter
plates, but the most widely-used in
the metal finishing industry is the re-
cessed chamber plate. This type of
plate is either nongasketed or gas-
keted.
The non-gasketed plate is not
leak-proof; the gasketed is leak-
proof due to an O-ring seal around
the chamber and the filtration
ports. Both plates have the follow-
ing in common: recess chamber,
feed eye, filtrate ports, drainage
surface and stay bosses (Refer to
Fig. 3).
The chamber recess is actually
only half a chamber. Two plates
butted together make the whole
chambgr, This area of the plate is
where the sludge is deposited to
form a cake. The feed eye is simply
a hole through which sludge can
pass to fill the chamber.
The filtrate ports discharge the fil-
trate or the liquid part of the sub-
CLEAR FILTRATE

CONSTANT RATE:
The filtration rate is kept constant,
permitting the head loss throu(iyj!
the cake to increase continually
during the cycle until the maximum
Pumping head is reached and the FOI
cycle is then terminated.

THE COMPONENTS OF A
FILTER PRESS
A filter press conslsts of a struc-
tural frame, filter plates, filter me-
dia, closing mechanism, shifting
I \
FILTER CLOTH UNIFORMLY
OEPOSITED PARTICLES
Fig. 7. Cross section of chamber area during fill cycle.
L I

PNEUMATIC SHIFTER UNIT
HEAD
INTERMEDIATE PLATES
-HEAD LEG
stance being filtered. Filtrqte. p o r t s
are most commonly located at the
four corners of the plate. The drain-
age surface is located at the most
recessedpoint of the chamber and
is made up of ridges called "pips"
which allow the filtrate to drain to
the ports.
The stay bosses are a truncated
cone shape and are approxi-
mately the total thickness of the
plate. Their main function is to sta-
bilize the web of the plate. The lo-
cation, size and number are pri-
marily functions of the dimensions
and structuralmaterialof the plate.
, hand-operated hydraulic jack.
FILTER MEDIA OR CLOTH:
The filter media or cloths come j6'
many different material composi-
tions; for example, poiypropylene,
polyolefin, polyethylene. Cloths
also come in many construction
variations such as twill weave, plaln
weave, sateen, honeycomb and
many differentfinishes such as heat
set, scoured, single-glazed. Jhe
most widely-usedin the metgl finish-
ing industry is the U7 103 polypropyl-
40
4
RIGID PIPE '
Fig. 2. Typical filter press components.
ene, Oxford-weavecloth with a 2-3
cfm rating that has been scoured
and heat-set. ~
Cloths for non-gasketed plates
are hung over the plate, extending
from top to bottom, and are held in
place b y eyelets which fit over pins
on the plates. The gasketed cloth
has a sash cord sewn around the
perimeter which is caulked into a
groove providedon the plate.
CLOSiNG MECHANISM:
The closing mechanism can be
one of.two types: manual or auto-
matk. Manual closure is usually a
Automatic closure is usually an air-
operdted hydraulic system and is
sized accordlng to the surface
area used for filtration and pressure
that is being applied b y the feed
Pump.
DISCHARGE MANIFOLD:
The dlscharge manifold provides
an exit for filtrate and can be con-
structed of ductile iron, stainless
steel, PVC or CPVC. It Is also used to
INCOMING
AIR
MOUNTED AT WORKING
LEVEL FOR EASY ACCESS
CYLINDER BRACKET
HYDRAULIC PUMPING UNIT
INSIDE OF CABINET
U
- INCOMING AIR
insure that the press fills evenly,
which is usually achieved by re-
stricting the flow until initial filling
has been achieved; thus, the term
"even fill" manifold. The manifold
also provides a way to remove re-
sidual water remainingafter pump-
ing has-terminated, referred to as
"air blowdown".
SHIFTING MECHANISM:
The shifting mechanism can be
one of two types: semi-automatic
and fully automatic. The semi-auto-
matic plate shifter is actuated b y
means of a switch or push button
and must be manually positioned
with each plate to be shifted. The
automatic shifting mechanism shifts
one plate after another wlthout in-
terruption unless overridden by the
operator. The automatic mecha-
nism must still be viewed by the
operator to assure that the cake
has dropped.
AIR BLOWDOWN:
Air blowdown is used to remove
any excess liquid that is left in the
METAL FINISHING

FILTRATEPORT
Fig. 3. Filterpress plate.
I AIR QUALITY:
plumbing of the plates and the
manifold. It is accomplished by in-
troducing air through the upper dis-
charge port, through the filter cake
and out the lower discharge port.
DESIGN FOR REDUCED
MAINTENANCE
A solid frame will withstand the
hydraulic and pumping pressures.
Components (head, ,cyljnder
bracket and side bars) sRobld be
joined together withan accurately-
machined socket joint to prevent
twisting when pressurized. CIQsipg
surfaces will then be parallel to
avoid any side loading of the cylin-
der and thus extend the life of the
cylinder.
A properly-designed hydraulic
AIR'
IN
LOUVERS
Fig.4. Flow pattern of typical air
line filter is shown. Residue
Is removed periodically
either manually or automat-
ically.
AUGUST 1987
sy&n'will 'provide many yead 'of
trouble-free operation. In an air.
operated hydraulic system, con-
taminant removal devices such us
oil filters and air filters will help re-
duce maintenance(Fig. 4).
Quick change components,such
as relief valves, oil filters and air fil-
ter cartridges are Important.Modu-
lar construction can be disassem-
bled quickly and replaced. Air and
hydraulic modules should be sepa-
rate to avoid unnecessary replace-
writ. ..
AVOID "DOWN TIME" BY
PROPER MAINTENANCE
PRACTICES
The following procedures will
help keep the equipmentclean.
Correct plumbing or design of an
air system will eliminate the majority
of water, oil and particulates from
entering the filter press. This will ex-
tend the life of both hydraulic and
pneumatic components. The fol-
lowing practicesare suggested:
1. Plumb the air-feed line to the
filter press from the top of the main
line instead of the bottom. This will
prevent water that has condensed
and is sitting at the bottom of the
main line from being drawn down *
into the filter press (Fig.5).
2. A water leg should precede
the connectionwith auto drain and
should be tapped off the bottom of
the main line.
3. A properly maintained air filter
should filter anything that remaids;
however, if large quantities Df oil
-
Fig. 5. Proper air supply run.
'are:preseit, ah.011removal filter is
also recommended.
4. An air dryer is recommended if
extreme amounts of water are pres-
ent, especially in 'hot humid cli-
mates.
FILTER CLOTHS & GASKETS:
Clean cloths and gaskets are an
important part of achieving opti-
mum performance from your filter
press. During filtration, the filter
cloth is the Initial barrier that sepa-
rates solids from liquid. Therefore,
the filter cloth must remain porous
to provide high filtration rates.
During normal operation, the fil-
ter cloth may gradually become
plugged with minute particles in
metal finishing sludges.These partl-
cles penetrate the cloth and be-
come lodged in the depth of the
weave, which leads to decreased
filterability. These particles must be
removed periodically to maintain
high filtration rates and a drier
cake.
Filter cloth washing is required
when one of the following fqctors
indicates plugging has occurred.
1, Initial high filtration pressure.
2. Long filtration cycles.
3. Wet filter cakes.
There are several methods used
to wash cloths while they are stili in-
stalled in the press. The most com-
monly used in the metal finishing in-
dustry is acid washing which re-
quires the following:
1. An acid storage tank of suffi-
cient capacity to fill the press and
allow for recirculation, approxi-
inately 1.5 times holding capacity
-FROMTANK
OR DRIER
FILTER W/AUTO DRAIN
TO DRAIN
' WATER LEG
41

of the press (7.5 gallons per cubic.
foot).
2. A 25% solution 'of hydrochloric
(muriatic) acid. A lower or higher
concentration may be needed due
to solubility levels of entrapped
particles.
3. A low-pressure(20-30 p s i maxi-
mum) acid-reststant pump.
4. Necessary plumbing (hose or
rigid PVC pipe) to isolate the press
from the sludge stream and allow
for both recirculation to the acid
tank and final draining of spent,
Problems?
Pump will not cycle?'
%
Pump cycles without pumping or
does not deadhead.'
Pump continues to cycle offer it has
reached maximum hydraulic pres-
sure.*
Sludge pump stalls out indicating
Dress is full: however, when the Dress
is Opened, 'he filter is solid'near
the cloth but watery' in the center.
.* .
. 3. Oil in sluUge, forming an imper-
5 ,
Water leaks out between plates.
Filter cloths pull out of grooves during
operation.
Filter cloths pull out of grooves during
operation even though full cakes are
achieved.
'Automatic closure models only.
-\
Cycle
Date Time
42
i
'. b
sblution. A throttling valv0 ln-
stalled 1n.thereturn line to the acid
tank way be necessary to insure
complete top-to-bottompress fllllng
and washlng of cloths.
Note: This method is not recom-
mended for non-gasketedcloths.
ACID DIP WASHING:
The plates can also be cleaned
by immersing them in a muriatic
acid tank for 24 hours. (Devise a
method to keep plates sub-
meKm.) .. ..
Table 1. Troubleshootlna Guide -
Causes could b e . . .
1. Inadequateair supply.
2. Air filter plugged.
3. Air valve off.
4. Restrictionin air line.
1. Check-valve In pump body mai-
functions.
2. Low reservoir level.
1. Air pressuretoo high
1. Too low sludge pump air pres-
sure.
2. Sludge pump not stalled out long
enough.
meable layer.
4. Too high initial sludge pump pres-
sure, causing particlesto form too-
tightly on filter cloth.
5. Filter cloths plugged.
1. Gaskets loose or torn.
, 2. Low hydraulic pressure.
1. A full cake was not develdped
before wash or bl6wdown. CQUS-
ing cloth to be pushed out of
caulking grooye:
1. Improper size sash cord for cloth
~ or applikatlon.
"'Table II. Filtration log
Air 6lowdown Cake Results
Time Edge Center
- * .
' 'CUBRCATlhk &' WORKiNG FLUIDS:
I . The oil and filter In the filter
press should be changed periodl-
cally because the oil becomes dirty
andlor the oil additives begin to
break down, If water removal de-
vices are not installed or main-
talned, any water present In the air
could be Infiltrating the oil. With
proper water removal devices ln-
tact and with average use, the 011
should be changed every two
years. Do not use synthetic oils un-
I lassspecifled:
Solution. ..
1. Check air pressure and clean air
system parts.
2. Check air regulator.
I . Clean, inspect and replace, if
necessary.
2 . Fill reservoir with oil.
.t . Decrease regulatedair pressure.
1. Increase pressure 100 psi max-
imum.
2 . Stall until one strokelminimum is
reached.
. 3. Eliminate oil or add diatomace
ous earth body feed.
4. Start sludge pump at lower pres-
sure, then slowly increase.
5. Wash cloths with 25% muriatic
acid/75%watpr solution.
1. Reinstallor replace gaskets.
,. 2. Increaseto required psi.
1. Be sure chambers are completely
full before wash or blowdown. The
filter cake will'then support the
cloth. '
1. Future cloths should be made with
a slightly larger sash cord.
Filtrate
Clarity Operator
METAL FINISHING
 2. Very llttle lubrlcatlon is neces-
sary; however, the kllower rollers
and the cylinder guide 'rods (If the.
press is equipped with a plate
shifter) should be wiped down and
greased liberally at least once a
month.
TROUBLE SHOOTING
The lnformatlonin Table I pertains
to air-operated hydraulic closure
systems.
MAINTENANCE
SCHEDUL~NG
Refer to the following check-list
for maintenancescheduling.
DAILY MAINTENANCE:
Are there any holes in the cloths?
grooves? .
Are cloths secure in the caulking
Do cloths need to be washed?
(Refer to the sample filtration log
provided in Table II to assist In moni-
P-E-R Recovery may be the solution!
4 .
I The leading edge of metal recovery technology
A\
AUGUST 1987
'tiing && performance.) . . I
AllETthefe any leaks in hydraullcs
or pneumatics?
Is proper closing pressure always
reached?
Have water traps been "bled" on
air-feedlines and at press? '
MONTHLY MAINTENANCE: Multicell gives you:
Is relief pressure properly set? Dlatinpcurrent densities lev-
Have shlftergulde and extension eling power...throwing power at three different ratios
mechanisms been cleaned and ...anode and cathode efficimy..covering power at
greased? extreme low current densities...shield anode effects
...brightener consumption...plate samples for func-
Have air filter elements been tional les!s..
clednedwith detergentand water?' THE PLUS: reproducibleshield anode effects on
back of cat hode...suspended cathode reveals edge
YEARLY MAINTENANCE: current effect...uniform air dispersionon front and
Have filter cloths been replaced back of cathode and anode...calibrate at 267 and
500 ml..."non-attracting" magnetic stirring...color
If used approximately four times coded to avoid mixups...four models to choose from
daily? ...complete lineof accessories...satisfadonassured.
Have the oil and oll filter been (H m l w w l t h ad
~ caw $195.
changed?
Has air filter cartridge been
changed?
LqRRy "CORPORATION
13708 250th St, Rosedale. N Y 11422
S8lw (914) 739-7072 Pknl:(718) 525-8505
Have chamber gaskets been
changed (If hard or brittle)? MF Circle 078 on reader lnformatloncard
H Recovery of Gold, Silver, Palladium,
Rhodium, Copper, Cadmium, Zinc, etc.
H Efficient'; Inexpensive, easy to install
H Minimum space requirements A-
m Closed loop system with drag-out tank
Maintains residlial metal in ppm level
Alleviates poisonous sludge disposal problems
* * CoiofiiiSh CO., Inc. offers an entire line of units
c to match different production capabilities.
I
Circle 037 on reader lnformatloncard
43
 FEATURES
35 In Electtoless Nickel Deposits
The Interdlffwionof Phospho~s 19
JenyWt/teshowshowtoobtalnrellabledlebondadheshbycontrdllngthe
temperature and phosphomcontent.

45 Electrodepodtlon of Cadmium on MetallicGlass 27

M.KumarandSNageswardeteplnetheeffectof2 - ~ p t o e t h a n o l o n ~
.. .*
morphologyandelectrokineticsof cadmium electrodepoSmon.

33
52 instituteof MetalFinishingAnnual Technical Conference
HorddSllmanreportsonthelMPsannualconferencewh)chwasheldPpril28to
May 2 In BoumemouthEngland.
49
.L

Equipment Maintenance

15 APreventive MaintenanceProgramfor Rectifiers

Hugh N w m e provideso programfor maintainingrectifiersIncludingcalibrati~n
of meters,lnspeclioncleoningand testing.

23 OptimizingSpray600th Operations
John I(nnynslddixxlsses a systemsa p p r e h to spray booth WInteMnCe.
* .

39 Filter Press Maintenance

I d n Tigeondescrlbesthe basicsof fitterpress operation,shows howto avoM
downtimeandprovldeshlntsfortroubleshooting.

. ., -
i 1

-\ 't .

COVER
Courtesy of Betz Industrial, The Wder Management
DMslon of Betz Laboratorles,Inc. Trevose, PA Photoby
Robert Bauers.
AUGUST 1987