Optimization For Existing Tilting Pan Filters

Metalcraft

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Metalcraft – Located in Tampa Florida

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Metalcraft

Metalcraft Manufacturing

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Metalcraft Services

Filter Pans

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Metalcraft Car Frame

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Metalcraft Bearing Pedestals

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Level Track

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Metalcraft Services

Installation of New Filter Components

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Metalcraft Services

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Optimization for Existing Tilting PanFilters

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Reliability / Mission Time

• RELIABILITY speaks of intended function over time.

• MISSION TIME is critical to maximize acid production

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Filter Mission Times

• Maintenance turnaround to turnaround

• Down day to down day (PM the filter)

• Scheduled wash cycle to wash cycle

• Scheduled cloth change out to cloth change out

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Wash Cycle to Wash Cycle Mission Times

• Acid production is critical

• Interval times are critical

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Cloth Change Mission Times

• Acid production is critical

• Intervals - Most Critical

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Filter Performance Optimization

This is mechanical approach for existing tilting pan filters, offering increased mechanical reliability and increased recovery of P₂O₅. Results are, a reduction in maintenance costs and increased production dollars.

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Objectives for Filter Optimization• Increase acid production

• Minimize dilution

• Increase P₂O₅ recovery

• Lower maintenance costs / Increase mission times

• Improve cloth cleaning efficiencies 19

Filter Optimization

Step 1• Initial operational and maintenance benchmarks

established.• A detailed study and mapping of the filter is

completed.

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All aspects of the filter and its parts are measured21

Filter Optimization

Step 2• Measured data is integrated into the modeling

software.• Study of the filter in the “as found” condition

begins.

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Filter Mapping Process23

Filter Optimization

Step 3• The filter is accurately modeled in its optimized

condition. • Demonstrates the recommended changes

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Filter Optimization

Step 4• Client report submittal, steps planned in harmony

with client goals• Report includes optimized proposal package.

(How can Metalcraft best support changes the client would like to see?)

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Filter Software Modeling – Design – Mapping Process

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Components for Optimizing Existing Tilting Pan Filters

• Cloth spray headers

• Cam roller turnovers

• Enlargement of filtration area (pans)

• Filter valve timing

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Cloth Spray Headers

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Metalcraft Services

Nozzle Placement and Spray Patterns are Critical for Cloth Spray Header Efficiencies

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Cloth Spray Header Optimization

• Nozzle Design and Efficiency

• Conflicting Sprays

• Delivered Flow and Pressure to Header

• Loop Design with Cleanout

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Nozzle Design and Geometry

Vee Jet Flat Jet

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sAddress cleaning for allareas of the pan - Corners

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Typical Cloth Spray Header Installation

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Metalcraft Services

Cam Turnover Sections

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Cam Turnover

• Designed for accurate and simple field adjustment

• Assures proper operation

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Metalcraft Services uses modeling software for both detailed design work and problem solving.

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Cloth Spray Evaluation

3 D Modeling

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Increased Filtration Area

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Increased Filtration Area

• Considering new pans for an existing filter? • Build them with additional filtration area!

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Filtration Area Increased to 13.92 s/m

Filtration Area Increased

.46 s/m Per Pan

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Optimization for the Central Valve

• Is the valve timed correctly?

• Is dilution being addressed?

• Are wash and feed boxes located correctly to maximize filter efficiency

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Central Valve

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Optimization of Central Valve

• Adjustment / Repair of compartment baffles

• Replace Seal and Wear Plates

• Machining of Poly Ring and Timing Crown surfaces in place

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Metalcraft Services

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MCS 4/2010Metalcraft Services of TampaMetalcraft Services of Tampa MCS 4/22/2010

Filter Performance Optimization Results

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Tilting Pan Filter Project Success – Example 1

Production and Down Time Cost Savings

• Savings of $0.9 Million per Year• Recovery of 3500 Tons of Phosphoric Acid Per

Year• Reduced Cloth Usage and Overtime Cloth Changes

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Tilting PanFilter Project Success – Example 2

Production and Down Time Cost Savings

• Reduction of Filter Down Time Per Month• Increase P₂O₅ Recovery• Overall Filter Improvement Annual Savings - $2.2

Million Per Year

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Other Filter Components for Optimization

Car Frames

Bearing Pedestals

Level Tracks

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Car Frames

• Heavy Duty T316L Stainless Steel Design

• integrated Wear Track – Minimal wear to bottom flange of the frame

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Improved Joint Design For Car Frames

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Car Frame Bull Gears

Integral Bull Gear bolts directly to the frame

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Filter Pans in Progress

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Objectives for Filter Optimization• Increased acid production

• Minimize dilution

• Increase P₂O₅ recovery

• Lower maintenance costs / Increased Mission Times

• Improved cloth cleaning efficiencies 66

www.metalcraftservices.com

METALCRAFTLeading with Vision

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