Replacing conventional Sparkler Filters to Contufilt-AC in a Chemical Industry

Case Study

Background: A leading chemical manufacturing company faced ongoing challenges with traditional sparkler filters in their production process. Frequent maintenance, by-pass of material, product losses, and safety hazards prompted the company to seek an advanced filtration solution.

Challenges with Sparkler Filters:

The conventional sparklers come with their own challenges. And users continue to live with these due to no alternate solution. This customer was as unhappy as others with their sparklers. Diva Envitec Engineers visited the site to evaluate the situation. The following reasons were the main areas of concern.

Manhours Lost: Extensive manual intervention was required for cleaning and maintenance, leading to operational inefficiencies.

Leakages: The open and closing design caused frequent leaks, resulting in product wastage and contamination risks.

Exposure to Atmosphere: Operators were regularly exposed to hazardous chemicals, raising safety concerns and compliance issues. The manual handling of chemicals posed health risks to workers.

Boxing Up a Sparkler: Reassembling the filter after cleaning was cumbersome and led to extended downtimes. Sometimes due to bypass the boxing had to be rre-started. It usually took 3-4 hours to assemble the system with two operators.

Tedious Process: Cleaning and replacing filter elements required significant effort and caused production delays.

Loss of Product: Inefficient filtration led to substantial product loss, impacting overall yield.

Solution: Adoption of Contufilt-AC

To address these issues, the company approached Diva Envitec and opted to replace their sparkler filters with Contufilt-AC, a closed-system filtration solution.

Approach by Diva Envitec Engineers: upon the request of the client, Diva Envitec engineers conducted trials using a pilot plant to evaluate key filtration parameters such as flux rate and ease of cake release. By systematically analysing performance data, they were able to narrow down the most suitable filter media type for the application. With the right choice of media, the customer was able to discontinue the use of filter aids such as kieselguhr and Celite, leading to a significant reduction in waste generated per batch. This optimised approach further improved process efficiency, reduced operational costs, and minimised environmental impact.

Happy Customer

The overall Product Recovery Increased. The closed-system design reduced product loss and enhanced recovery efficiency.

They were able to reduce the downtime. The self-cleaning, backwashable mechanism minimised maintenance-related downtime, allowing for uninterrupted operations.

Finally the main impact was in improved Product Quality. The enclosed design prevented contamination, ensuring consistent product quality and meeting regulatory standards.

Here are the main reasons why they chose Contufilt-AC:

Enhanced Efficiency: The automated backwashing reduced manual intervention and maintenance efforts.

Safety and Compliance: The enclosed system ensured a safer working environment and compliance with industry regulations.

Cost Savings: Reduced downtime and product loss translated into significant cost reductions over time.

By transitioning to Contufilt-AC, this chemical company successfully eliminated operational inefficiencies and improved overall process reliability. The advanced technology provided a safer, more efficient, and cost-effective filtration solution, making it the preferred choice for modern industrial applications.

Are you facing similar problems with your conventional Sparklers? Talk to our Engineers and find a more efficient solution.

High Productivity means High Profit.