Prime Producer of Porous Filter in China

Porous metal filters are special filtering tools used in applications where normal filtration equipment fails.
Typically, the metal has undergone a sintering process to make it a porous or powdered structure to ensure a better and more efficient filtration process.

Technically, sintering is the method of metallurgy that is implied on metal or alloys to solidify them in a powdered form.

Moreover, the technique involves heating metal or alloy below its melting point to make an intense solid with a definite number of pores.

there is a wide variety of porous filters, but the main types used in various industrial applications  are briefly discussed as follows:

·         Sintered Porous Metal Filter

Such porous metal filters have pores to complete the filtration task and are manufactured to retain great mechanical and high-pressure resistance.

Furthermore, making these filters is complex and carried out by using sintering plastic and high molecular polymer powder at high temperatures.

Moreover, they have a particle size retention ranging from 5 to 200 microns with a pressure drop of 70% and can work efficiently at temperatures below 80 degrees Celcius.

·         Porous Stainless Steel

Another popular type is porous stainless steel, in which grade 316 steel is used to manufacture high-performance and high-quality filters.

Subsequently, these porous steel filters are produced with excellent pressure and temperature resistance and the ability to work in harsh conditions.

·         Porous Discs

These are the porous filters in the form of filter discs to easily fit in the working environments.

Typically, these filters are manufactured with exact pore sizes and numbers to ensure their efficiency for specific applications and conditions.

Moreover, they are specifically designed to generate effective outcomes from filtration, separation of particles, and extraction of elements.

·         Sintered Metal Filter

These special filters are designed to meet high industrial and commercial requirements due to the use of a range of materials.

Typically, they have wide ranges to use effectively and efficiently filtrate gases, liquids, and semi-solids.

·         Porous Bronze Filter

These types of filters are manufactured with spherical bronze powder and are popular for their efficiency for noise reduction and turbulence proofing.

Moreover, they are a reliable option for a variety of industries to provide workers with a peaceful working environment with highly efficient filter elements.

Figure 1 Porous Metal Filter

Porosity is a measure of pores on the filter surface of the filter and determines the efficiency and capability of the filter.

Typically, it is responsible for the removal of particles with a definite size by prohibiting them from passing through the filter.

Technically, the filter with higher porosity will consist of more open structures (pores), resulting in maximum flow with the minimum pressure drops.

However, it is not the case that a filter with a high porosity rate will be more efficient and useful than the one with a low porosity rate.

While thinking about purchasing the right material with suitable porosity for the porous metal filter, it is important to consider the following aspects to get the correct product:

1.    Size of Pores

Microns or Pore size is one of the most important factors to consider before finalizing your porous metal filter material.

If the material is rated as 5 microns, it is more likely to stop almost all the particles with 5 microns or above.

2.    Pressure Drop

This refers to the ability of the porous material about how much pressure loss it can resist during the process.

Generally, a suitable porosity metal is the one that offers the minimum pressure drop to support uniform flow through the filter.

3.    Temperature Resistance

Usually, the porosity of the material is affected by the temperature it is working in.

Therefore, it is essential to analyze whether or not the filtering materials are capable of providing efficient and useful outcomes.

4.    Strength

The best porosity of filter would be the one capable of withstanding harsh environmental and other conditions. They must be strong enough to bear with changing conditions.

Moreover, they should be capable of promoting the exact amount of efficiency and strength for both forward and reverse flow.

Figure 2 High Porosity Porous Filter

To calculate a porosity filter, it is necessary to know about the different aspects related to the porosity of a filter.

Typically, filter porosity is classified into three major classes.

1. Primary Porosity refers to the measure of the empty spaces created by the metal itself during its manufacturing.
2. Secondary Porosity refers to the pores created in the filter after its manufacturing.
3. Effective Porosity is the spaces created in the filter that allow the effective and constant filter flow from it.

Calculating Porosity

Basically, porosity is the measure of gaps or spaces in the filter which decide which particle to flow from it and which part to be stopped.

Typically, it is the ratio between the volume of gaps in the filter to the total volume multiplied by 100 to get it in percentage.

Porosity = (Volume of Empty Gaps/Total Volume of Filter) X 100

Other Methods:

Following methods are used to calculate the porosity, which are described as follows:

·         Direct Methods

This is the simplest method for calculating the porosity of a material.

Calculate the entire volume of the porous filter and measure the volume of a skeletal filter (with no pores in it).

Now, calculate the difference between them to obtain the porosity.

Porosity= Total Volume (with pores) – Skeletal Volume (without pores)

·         Computed Methods

Another method is associated with modern computer technology by obtaining a 3D image of a porous filter’s external and internal dimensions.

Furthermore, implement the defect analysis technique using computer software to obtain the porosity of a filter.

·         Water Evaporation Technique

This technique involves the calculation of porosity by determining the difference between the weight of the saturated filter in water to the weight of the dried filter.

Their difference indicates the number of pores in the filter.

The difference between porous bronze and porous stainless steel filters is that the bronze filter is the most commonly used porous filter and comprises a spherical bronze powder.

On the contrary, a porous stainless steel filter comprises various grades of steel with varying properties and resistance qualities under different circumstances.

Moreover, the bronze filter is widely used in multiple applications due to its embeddability, lubricity, and cheap costs.

While Stainless steel metal powder are highly efficient and durable filters used in challenging working conditions.

Furthermore, the bronze porous filters show great structural stability and high mechanical strength, while stainless steel filters are stronger due to the irregular shape of metal powder.

The porous bronze filters possess a self-supporting property with high resistance power under high-pressure differences.

On the other hand, the porous stainless steel filters offer high resistance against high pressures and are efficient and stable air purification filter under elevated temperatures.

Figure 3 Porous Bronze Filter

·         Process of Manufacturing

Typically, the bronze filter is manufactured with spherical bronze powder with variable sizes, forms, and distribution, which plays a vital role in its efficiency.

While stainless steel filters are produced with a metallurgical material produced in powder, and the filter’s properties depend on its shape, pore filters and its distribution, and size.

Typically, the bronze powder is generated by a gravity sintering method, i.e., the powder is molded and then sintered.

On the contrary, stainless steel is compressed, molded to create a solid structure, and its pore size can be determined by the type of powder used and force applied during pressing.

While during the sintering of both bronze and stainless steel, the temperature is applied below the melting point to produce a highly porous filter.

Moreover, these porous filters give high characteristic features, shapes, and pore sizes and the ability to withstand high temperatures, pressure, and corrosion. 

Figure 4 Porous Stainless Steel Filter

The process used to make sintered porous bronze filters requires high pressure and other precise conditions to produce a solid bronze filter.

Typically, the process requires the use if heavy machines and advanced technology to get the perfect product.

Usually, the following steps are required to produce sintered porous bronze filters:

Step 1: Preparing the Powder

The primary step involved in producing a bronze filter is generating the spherical bronze powder from its raw material.

Consequently, these raw materials are pressed with high pressure and adequate strength to ensure their breakage into smaller and desired particle sizes and shapes.

Usually, the amount of strength and differential pressure exerted on the material is also dependent on the size, shape, purity, and individual characteristics of the materials.

Step 2: Injecting for Casting

Once the desired spherical powder is obtained for the formation of a bronze filter, it is injected for the die-casting to give it a robust shape.

Moreover, high external pressure is used to compress the powder into a strong shape with desired mechanical properties.

Subsequently, the porous bronze metals can also be used to make custom filter design depending on the application’s needs.

Step 3: Heating on Furnace

Once the powder adopts the shape of the mould, it is taken out from it and placed on the furnace for further heating.

Here, it is heated under its melting point to ensure the permanent shape of the filter. When it is done, a porous structure bronze filter is formed.

VIDEO LINK:

Figure 5 Porous Bronze Filter Manufacturing

To order quality porous filters from Chinese manufacturers, it is necessary to look for reliable and trustworthy suppliers.

One of the leading suppliers of China is SHENGYE for their premium quality and high-performance products worldwide.

Moreover, you have to brief them about the following aspects, and the rest is their cup of tea. This information includes:

1. What kind of filtration process do you need to be done?
2. Nature of the material passing through the filter.
3. Are there any corrosion-related issues?
4. What will be the working conditions you will be working in? Like temperature, pressure, and moisture content in the environment.
5. What is the nature of the particles that need to be captured over a porous filter?
6. What type of shape, size, efficiency, tolerance do you need in the porous filter?
7. Tell them about the ideal fluid flow, porosity, and pressure drop during the filtration process.
8. Also, brief them about the overall systematic pressure.

Once you have filled their form or talked to their representative and explained your requirements, they will make sure you get what you have demanded.

After sending the application request, their team will contact you in the minimum time to acquire about base materials, field of application, and your required pressure range.

Moreover, the porous filters manufactured by them consists of high performance, larger lifespan, are easy to clean and maintain, and offers removal of a larger number of particles.

They use modern technology and advanced filter techniques to manufacture porous metal filters at affordable rates.

Figure 6 High Quality Porous Filter

The quality certifications of Chinese manufacturers are awarded to the suppliers after a proper and strict factory audit and certify specific standards.

Many manufacturers like SHENGYE follow strict quality standards to ensure their consumers get the right products and their workers stay safe while on the job.

The most popular certifications followed by SHENGYE are as follows:

·         ISO 9001

This is the most important standard followed by the Chinese manufacturers, which is associated with the commitment to complete customer satisfaction.

Moreover, it implies the company’s strive for regular improvement to enhance their services.

·         ISO 14001

Over the past few years, this certification has been made compulsory for the suppliers to ensure a better environment rather than the quality of their products.

·         SA 8000

This certification is a difficult task for the companies to maintain; it includes the inspection for:

1. Child labour.
2. Health and safety of employees.
3. Maintenance of discipline.
4. Freedom of association.
5. Continuous working hours.
6. On-time payment to employees.

·         OHSAS 18001

This certification is associated with the health and safety of the company’s workers. It includes the aspects like what amount of pollution the workers are exposed to.

Moreover, it also notices what the company takes steps to reduce the stress for its workers.