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ENHANCING THE PERFORMANCE OF ROTARY VACUUM DRUM FILTER

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 International Journal of Advanced Engineering Technology E-ISSN 0976-3945

Research Article
ENHANCING THE PERFORMANCE OF ROTARY VACUUM
DRUM FILTER
T. Sivakumar*, G. Vijayaraghavan*, A. Vimal Kumar**

Address for Correspondence

* Assistant Professor, Chemical Engineering, Adhiparasakthi Engineering College, Melmaruvathur
**Lecturer, Chemical Engineering, Arunai Engineering College, Thiruvannamalai
ABSTRACT
In the design and operation of filters used for the filtration of suspensions, washing and de liquoring of the formed filter cake, one is
interested for reasons of operating safety, maintaining the desired quality and profitability. The main focus is to calculate the
residual moisture content of the discharged filter cake and the compressor performance on parameters determined by products,
adjustment and design in alignment.
A common non-disposable device used for solid-liquid phase separation for continuous flow processing is the rotary drum filtration
unit. In fact, the rotary drum vacuum filter is considered to be the workhorse of the chemical process industry. In our paper we are
going to bring down the moisture content of the given slurries up to a certain level. Our objective is to reduce the moisture level of
whatever slurries that is taken as feed into the rotary vacuum drum filter. This will help in gain more cake formation in a single run
and thus the cost of handling also becomes less and it also adds to the economy of the process.
KEYWORDS: RVDF, Filtration, Drum Filters
1. INTRODUCTION to a point that it is cut-off and blow takes place to assist
The removal of solid particles from a fluid by passing the in discharging the cake. The valve has on certain filters
fluid through a filtering medium on which solids are adjustable blocks and on others a fixed bridge rings (see
deposited is said to be filters. Solid liquid separation is the Figure 2). Adjustable bridge blocks enable the
separation of two phases, solid and liquid, from a optimization of form to dry ratio within the filtration
suspension. The technology for carrying out this process cycle as well as the "effective submergence" of the
is often referred to as `Mechanical Separation' because the drum when the slurry level in the tank is at the
separation is accomplished by purely physical means. maximum.
This does not preclude chemical or thermal pretreatment The majority of drum filters have a valve with three
which is increasingly used to enhance the separation that bridge blocks and a single row pipe plate as shown
follows. Although some slurries separate perfectly well below and on the right[4]. The duty of the bridges is:
without chemical or physical conditioning, most slurries Vacuum and blow zones separating bridge: This
and pulps of a widely varying nature can benefit from Bridge cuts off the vacuum so it is slightly wider than
pretreatment, whether the separation is by sedimentation the internal pipe port.
(gravity or centrifugal), filtration or flotation[1] [2]. A Dead Zone Bridge: This Bridge opens to vacuum once
conditioning effect can be obtained using several a compartment submerges. Start-up assists bridge. At
processes such as coagulation and flocculation, addition start-up the upper vacuum zone is open to atmosphere
of inert filter aids, crystallization, freezing, temperature or and a cake may be formed only when closing the valve
pH adjustment, thermal treatment and ageing. Only the that controls this zone. Once the cake starts to emerge
first two operations are considered in more detail here due from the tank the valve is gradually opened and fully
to their importance and wide use. opened when the entire drum face is wrapped with the
1.1 ROTARY VACUUM DRUM FILTERS cake. Since in continuous operation both lower and
The Rotary Vacuum Drum Filter belongs to the bottom upper zones are under vacuum this bridge is slightly
feed group and is one of the oldest filters applied to the narrower than the internal pipe port so that the vacuum
chemical process industry. Therefore rotary vacuum drum is continuous and the cake is held onto the drum. The
filters are certainly used in to the best part of solid liquid rotary drum vacuum filter is a very versatile liquid/solid
separation process. The Figure 1, shows the basic separation device. It is used where a continuous
structure of the rotary vacuum drum filters and also its separation is desired of a solid from a liquid stream. It
components and their working parameters. A valve with a can be used in process applications where the solid is
bridge setting which controls the sequence of the cycle so the product or where the liquid is the product (and
that each sector is subjected to vacuum, blow and a dead sometimes when both phases are the product). In
zone [3]. When a sector enters submergence vacuum wastewater applications it can be used to dewater a
commences and continues through washing, if required, variety of sludge or to clarify wastewater.

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 International Journal of Advanced Engineering Technology E-ISSN 0976-3945

FIGURE 1: ROTARY VACUUM DRUM FILTER

FIGURE 2: VALVE BRIDGIN
Cake washing is used when a given cake purity is
required. It is also used to improve extraction of liquid
products or dissolved materials from the filter cake. Lab
or pilot testing can be used to determine the effectiveness blow is applied and to avoid the snapping out of the
and efficiency of cake washing on a rotary vacuum drum
Filter
1.2. CAKE FORMATION:
With the overflow weir set to a maximum the "apparent
submergence" is normally 33-35% so the slurry levels
between 04.00 and 08.00 hrs. Once a sector enters
submergence vacuum is applied and a cake starts to
form up to a point where the sector emerges from the
slurry. The portion of the cycle available for formation with the help of these materials we were able to
is the "effective submergence" and its duration depends
on the number of sectors, the slurry level in the tank
and the bridge setting which controls the form to dry
ratio[5].
1.3. CAKE WASHING AND DRYING:
After emerging from submergence the drying portion of
the cycle commences and for non-wash applications
continues to about 01.30 hrs where the vacuum is cut-
off. If cake washing is required the wash will be
manifolds will be located from about 10.30 to 11.30 hrs
and the remaining time to vacuum cut-off at 01.30 hrs
is the portion allocated to final cake drying[5].
After vacuum for the entire sector is cut-off air blow
commences at about 02.00 hrs in order to facilitate cake
discharge. The blow, depending on the position of the
tip of the scraper blade, wills cut-off at approximately
03.00 hrs. Drum filters are normally operated with a
low pressure blow but on certain applications a snap
caulking bars or ropes wire winding of the cloth is
recommended.
2. MATERIALS AND METHODS
The materials that we took for the analysis of the
slurries are vacuum pump, beaker and water along with
the heating medium. We used pH meter to find the
initial pH value of the slurries. We had taken two
slurries in order to reduce the moisture content. Finally
perform the specified task. The Chemicals used are
Calcium Hypochlorite and Calcium Carbonate

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 International Journal of Advanced Engineering Technology E-ISSN 0976-3945

2.1 Experimental procedure: measured and these results are used in for the
2.1.1 Standardization of pH Value calculation to find out the initial moisture content. The
The pH value was analyzed using a pH meter with a glass readings were tabulated in Table 1 and Table 2.
membrane electrode. The variation of pH over the time
during the course of the experiment was analyzed using
the pH meter. According to the requirement of the
company we are decreasing the pH by adding wash water
during the process of analyzing.
2.1.2 Analytical method
The given slurry was filled in a rubber corked round
bottomed flask. The filter medium is chosen in such a
way that the cake deposition should be more and the
filtrate also should be clear. Nylon made filter medium
was used in this experiment. The feed was heated at a
temperature of around 45 to 60o C for around thirty
minutes. After the heating process the initial weight of FIGURE 3: ROTARY VACUUM DRUM FILTER
the plate was taken then slurry which was heated up MODEL
was measured along with the plate. Now, the weight of 3.2.1 Calculation of form filtration rate: (Kg/h/ft2)
the dry cake and wet cake was easily calculated and are Filtration Rate = (Dry solids/1000) x (1/form time) x (1/
tabulated. Finally, the moisture content of the slurry is leaf area)
found out[6][7]. With the help of the filtrate area we For First Test (31.5/1000) x 3600 x (1/5) x (1/
can easily design the RVDF for the given slurry. Some 0.1) = 230.8 Kg/h/ft2
parametric changes are done to reduce the moisture 3.2.2 Calculation full scale filtration rate: (Kg/h/ft)
content of the given slurries. Filter Rate = Form filtration factor x Submergence x
3. RESULTS AND DISCUSSION Scale up factor
3.1 Analysis of calcium hypochlorite = 226.8 x 0.8 x 0.33 = 59.8 Kg/h/ft
By the experimental methods as said earlier the initial Leaf area is found out by measuring the outer surface
moisture content of the calcium hypochlorite slurry is area of the filtering medium.
found out. First the weight of the wet and dry cake is

TABLE 1: TO FIND THE CAKE WEIGHT OF Ca(OCl)2

WT. OF
TEST INITIAL PLATE
PLATE + WET WT. OF PLATE + DRY CAKE(g)
NO. WEIGHT(g)
CAKE(g)
1 34.90 119.80 66.4
2 34.80 158.80 81.6
3 32.90 181.7 89.2
4 32.60 202.8 98.0

TABLE 2: TO FIND THE INITIAL MOISTURE CONTENT

FILTERING TIME CAKE WEIGHT
TEST (Sec) (g)
NO FORM WASH DRY CAKE CRACKS WET DRY % MOISTURE
1 5 30 60 YES 84.9 31.5 62.8
2 10 30 60 YES 123.9 46.7 62.3
3 15 30 90 YES 148.8 56.3 62.16
4 20 30 90 YES 170.2 65.4 61.57

TABLE 3: TO FIND FILTRATION RATE OF Ca(OCl)2

TEST NO FORM FILTRATION RATE FULL SCALE FILTRATION RATE
(Kg/h/ft2) (Kg/h/ft)
1 230.8 59.8
2 182.12 44.38
3 138.12 35.67
4 98.34 26.7

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 International Journal of Advanced Engineering Technology E-ISSN 0976-3945

The Vacuum pressure is maintained at 500 mm Hg. calculation to find out the initial moisture content. The
Finally the vacuum pressure during the experiment is readings were tabulated in Table 4,5 and 6.
said to be decreased to 450 mm Hg during the process.
Now the graph is plotted between Form filtration rate
vs Time is drawn with the noted values.
Filter Area =
(Slurry flow x % dry of solids) / Filtration Rate
= 35.6 ft2
So, now we can calculate the rotary vacuum drum filter
Area = πr2 = 3.14 x 4 x 4 = 50.24 ft2
Therefore this 4ft x 4 ft. rotating drum would be the
suitable for the given slurry.
This holds good for the process.
3.3 Analysis of calcium carbonate
By the experimental methods as said earlier the initial
moisture content of the calcium Carbonate slurry is FIGURE 4: FORM FILTRATION RATE VS
found out[7] [8]. First the weight of the wet and dry TIME CURVE
cake is measured and these results are used in for the
TABLE 4: TO FIND THE CAKE WEIGHT OF CaCO3
TEST NO. INITIAL PLATE WT. OF PLATE + WT. OF PLATE + DRY
WEIGHT(g) WET CAKE(g) CAKE(g)
1 34.60 91.10 43.5
2 37.80 118.3 50.5
3 38.90 120.5 52.1
4 35.60 124.6 49.5

TABLE 5: TO FIND THE INITIAL MOISTURE CONTENT OF CaCO3

FILTERING TIME (SEC) CAKE WEIGHT(g) %
TEST
MOISTURE
NO FORM WASH DRY CAKE CRACKS WET DRY
1 5 30 60 YES 34.10 16.10 52.8
2 30 30 60 YES 43.50 21.00 52.3
3 45 30 90 YES 60.7 30.40 50.16
4 60 30 90 YES 76.8 38.00 50.2

TABLE 6: TO FIND FILTRATION RATE OF CALCIUM CARBONATE

FORM FILTRATION FULL SCALE
TEST NO RATE FILTRATION RATE
(Kg/h/ft2) (Kg/h/ft)
1 38.64 10.20
2 25.2 6.65
3 18.21 4.81
4 11.28 4.03

FIGURE 5: CALCIUM CARBONATE FORM FILTRATION RATE VS TIME

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 International Journal of Advanced Engineering Technology
Now the graph is plotted between Form filtration rate
vs Time is drawn with the noted values.
The best fit is drawn after plotting the graph and the slope
is found out to be the filtrate area of the given slurry.
The Vacuum pressure is maintained at 500 mm Hg.
Finally the vacuum pressure during the experiment is said
to be decreased to 450 mm Hg during the process.
Filter Area = (Slurry flow x % dry of solids) /
Filtration Rate
= 41.66 ft2
So, now we can calculate the rotary vacuum drum filter
Area = πr2 = 3.14 x 4 x 4
= 50.24 ft2
Therefore this 4ft x 4 ft rotating drum would be the
suitable for the given slurry. This holds good for the
process. Now certain parameters are changed and the test
is carried out.
3.4 Parameters varied:
In order to decrease the above moisture content further we
have change some of the variable parameters in order to
obtain the low moisture level.
3.4.1 Coagulants and flocculants added:
The two words are often used interchangeably because
both processes lead to increase of the effective particle
size with the accompanying benefits of higher settling or
floatation rates, higher permeability of filtration cakes.
Coagulation is a process which brings particles into
contact to form agglomerates [9]. The suspension is `de-
stabilized' by addition of inorganic chemicals such as
hydrolysis coagulants like alum or ferric salts, or lime,
and the subsequent agglomeration can produce particles
up to 1 mm in size. Some of the coagulants simply
neutralize the surface charges on the primary particles,
others suppress the double layer (`indifferent' electrolytes
such as NaCl, MgSO4) or some even combine with the
particles through hydrogen bridging or complex
formation. Flocculation uses flocculating agents, usually
in the form of natural or synthetic polyelectrolytes of high
molecular weight, which interconnect and enmesh the
colloidal particles into giant flocs up to 10 mm in size.
Flocculating agents have undergone very fast
development in the past three decades and this has led to a
remarkable improvement in the use and performance of
many types of separation equipment [10]. As such agents
are relatively expensive the correct dosage is critical and
has to be carefully optimized. As surface charges are also
affected by pH, the control of it is therefore also essential
in pretreatment.
The natural process of bringing the particles (and also the
polyelectrolyte’s) together by Brownian motion (called
`perikinetic flocculation') is often assisted by `orthokinetic
flocculation' which increases particle collisions through
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E-ISSN 0976-3945
the motion of the fluid and velocity gradients in the
flow. This is the idea behind the use of in-line mixers or
paddle-type flocculators in front of some separation
equipment such as gravity clarifiers. The resulting free
draining sediment can then be subjected to a controlled
breakdown over a period of time, ultimately leading to
a complete collapse of the cake due to mechanical
squeezing between the belts [11]. This is one of the
changes that can make sure of easier surface absorption
of the cake from the slurries.
3.4.2 Vacuum parameters and suction box:
The present invention, in combination with a rotary
drum vacuum filter/washer, improves dewatering
capability without major modification of design or
layout of a standard filter/washer as typically installed.
The improved combination comprises a suction box
having an apertured outermost surface adjacent an
accurate portion of the rotary drum, having supporting
structure and vacuum means independent of the rotary
drum filter, but located as close as possible to the
periphery of the drum consistent with its free rotation.
Additionally, a wire, felt, or cloth belt is wrapped
around both drum and suction box so that the belt
contacts the outermost apertured surface of the suction
box while remaining in contact with that portion of the
rotary drum not adjacent the suction box [12]. The belt
is tensioned sufficiently so that rotation of the rotary
drum causes the belt to move along with it sliding over
the suction box apertured surface. Thus the dewatering
capability of an existing rotary vacuum filter, after
modification by the apparatus of this invention, is
improved since the substantially insoluble cake or web
in contact with the rotating belt may be subjected to a
vacuum means independent of the relatively weak
barometric leg means typically operating on the rotary
drum. The added dewatering capacity allows better
washing of impurities from filter cakes or fibrous webs
through increased solution displacement from the cake,
utilizing an existing rotary vacuum filter, with only
those modifications suggested. The present invention
may be modified by the addition of a steam hood
positioned over the suction box supplying steam of
substantially zero velocity to the cake or web, which
steam is pulled into the cake as it passes over the
suction box increasing the temperature of both solids
and filtrate thereby further improving dewatering in
accordance with the above-indicated Simons article. An
apparatus for improving the dewatering capability of a
rotary drum vacuum filter or washer is described in
which a suction box, independently supported above the
filter drum, having an apertured outermost surface, and
a vacuum means operating upon the box, is combined
 International Journal of Advanced Engineering Technology E-ISSN 0976-3945

with a foraminous belt, tensioned to contact the suction 7 and Table 8. Thus by adjusting the variable
box apertured surface and that portion of the drum surface parameters the moisture content of calcium
not adjacent the box such that rotation of the drum causes hypochlorite is decreased. Therefore no problem of
the belt to rotate with the drum, sliding over the suction corrosion or short circuit due to low speed of motor was
box[13]. In operation, a cake or fibrous web that is occurred. There was no wear and tear of the filter
formed upon the belt while it is in contact with the filter medium. Thus we have obtained the result and the
drum surface, partially submerged in a slurry of the moisture content of the calcium hypochlorite was
material to be recovered, is subsequently subjected to the reduced by 62% to 50 %. Similarly a test for calcium
suction box vacuum means as the belt-supported web carbonate was also performed and is tabulated as in
passes over the apertured surface. A discharge box at the Table 9 and table 10. Thus by adjusting the variable
trailing edge of the suction box is supplied with parameters the moisture content of calcium
pressurized air to blow the cake or fibrous web from the hypochlorite is decreased. Therefore no problem of
foraminous belt surface at the product discharge point. corrosion or short circuit due to low speed of motor was
3.4.3 Speed of the drum: occurred. There was no wear and tear of the filter
By changing or adjusting the speed of the drum, the drum medium. Thus we have obtained the result and the
rotates much slower and the cake adheres to the surface in moisture content of the calcium hypochlorite was
large amount. Thus by doing this the surface area of the reduced by 50% to 39 %.
cake formation will suck out the cake rotating on the 4. CONCLUSION
drum [14]. The polypeptide sheet can withstand high Rotary vacuum drum filter holds good for this
corrosion. So, by this process the drum is protected by the experiment. We have finally found that by adjusting
polypeptide sheet and therefore can withstand wear and some of the variable parameters in the setup, decreases
tear even at low drum speed. By doing all these changes the moisture content and also it is found that whichever
we can test out process. Now through analytical method slurry is taken, with the help of rotary vacuum drum
the moisture content of the calcium hypochlorite and filter it is easy to reduce the moisture content. Lab
calcium carbonate is calculated and compared with the testing is often the best way to determine the correct
initial moisture content. Now the moisture content of filtration characteristics of a given material.
calcium hypochlorite under same vacuum pressure and
temperature was calculated and found out to be as in table
TABLE 7: TO FIND THE CAKE WEIGHT OF Ca(OCl)2
TEST NO. INITIAL PLATE WT. OF PLATE + WET WT. OF PLATE + DRY
WEIGHT(g) CAKE(g) CAKE(g)
1 34.90 67.00 51.00
2 34.80 78.20 55.80
3 32.90 93.7 63.30
4 32.60 109.4 63.00

TABLE 8: TO FIND THE MOISTURE CONTENT OF Ca(OCl)2

FILTERING TIME CAKE WEIGHT
TEST (SEC) (g) % MOISTURE
NO CAKE
FORM WASH DRY WET DRY
CRACKS
1 15 30 60 YES 34.10 17.15 50.01
2 30 30 60 YES 43.50 22.2 50.3
3 45 30 90 YES 60.7 30.8 50.16
4 60 30 90 YES 76.8 37.65 50.6

TABLE 9: TO FIND THE CAKE WEIGHT OF CaCO3

WT. OF WT. OF
INITIAL
TEST PLATE + PLATE +
PLATE
NO. WET DRY
WEIGHT(g)
CAKE(g) CAKE(g)
1 34.90 78.80 61.4
2 34.80 87.90 67.10
3 32.90 103.8 75.7
4 32.60 119.4 85.29

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 International Journal of Advanced Engineering Technology E-ISSN 0976-3945

TABLE 10: TO FIND THE MOISTURE CONTENT OF CaCO3

CAKE
FILTERING TIME
TEST WEIGHT %
(SEC)
NO (g) MOISTURE
CAKE
FORM WASH DRY WET DRY
CRACKS
1 15 30 60 YES 34.10 17.15 40.01
2 30 30 60 YES 53.10 32.2 39.3
3 45 30 90 YES 70.9 42.8 39.36
4 60 30 90 YES 86.8 52.65 39.30

The rotary vacuum drum filter is essentially a hands-off 10. Peuchot, C., `New standard designation for
machine that requires very little operator attention. Also, process cartridge filter efficiency’, Filtration &
it runs at a very slow speed (typically between 0.25 to 4.0 Separation, April, 217-223 (1997).
rpm). Thus by our experiment it is found out that the 11. Puchen, E., Process Rotary filter efficiency’,
moisture content of calcium hypochlorite and calcium Filtration & Separation, April,417-453 (1997).
carbonate are reasonably decreased from 10 to 20 percent. 12. Purchas, D. B., Solid/Liquid Separation
Thereby it is well understood that the cake formation is Technology, Uplands Press, Croydon (1961).
easier when compared to other filters. Therefore the 13. Purchas, D. B., Solid/Liquid Separation
performance of rotary vacuum drum filter is increased Technology, Uplands Press, Croydon (1981).
with respect to moisture content.
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IJAET/Vol.II/ Issue IV/October-December, 2011/41-47

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