The Leader of Sintered Disc Filter Supplier in China

Sintered discs are another type of filtration device used for separating two materials without involving contaminants in the process.

Moreover, sintered discs, as opposed to filter papers, are constructed with multiple layers of porous material layered as per the specifications.

Consequently, these multiple layers are overlapped in the vacuum sintering furnace to ensure high performance.

Furthermore, the construction of a powdered filter is done in such a way as to minimize the problems such as instability, poor rigidity, and deformation.

Significantly, the performance of sintered disc filters is higher than other filters.

Moreover, the sintered discs are widely used in the following processes:

1. Diesel Engines.
2. Textile Dope Filtration.
3. Chemical Fiber.
4. Water Filtration.
5. Food Processing.
6. Plastic Extruder.

Figure 1 Sintered Filter Disc

The porosity grades of sintered discs mean their credibility and efficiency are reasonable, moderate, non-satisfactory, or wrong.

Technically, the porosity grades measure the fractional part to the entire disc volume and identify which particle will pass through it and which one will stay.

Therefore, determining the quality and efficiency of the sintered disc is relatively possible with porosity grades.

Typically, the porosity grades in sintered discs are named from 0 to 5, where the lowest one consists of more coarse properties and vice versa.

Consequently, the highest number indicates that the filtration process will be finer and will generate effective outcomes.

However, each grade is designed for a specific type of application and benefits the users to use the porosity grade according to need and requirements.

The machining processes of sintered discs are simple and implemented to ensure the filters’ high performance and long life.

Mainly, the porous discs are employed individually on a perforated tube with a medium spacing between washers to create a space for better flow.

Subsequently, the efficient flow between the tube and discs results in the complete machining of the discs.

To replace a new sintered disc, you have to follow a series of easy steps.

Before starting, make sure you have the essential tools to open the unit and access the sintered disc.

Free the holding clamp of the disc and pull out the tight cylinder from it.

Now that you have reached the disc replace it with a new one, tight the cylinder back to its position, and fasten the clamp again.

The applications of sintered discs are widely distributed in all industries. Some of them are discussed as follows:

1.   Chemical Industry

The chemical industries require the use of sintered filter discs for nuclear power manufacturing.

Notably, its distinctive filtration characteristics make it a prime choice by the industrialist for many essential operations.

2.   Petroleum Industry

Due to its different pore sizes and capability of retaining various types of contaminants, sintered filter discs are effectively used in petroleum refining and petrochemical industries.

3.   Power Production Industry

Typically, the sintered discs are helpful in the production of hydroelectricity as it filters out the contaminants from the water that is reaching the turbines.

4.   Food Industry

Usually, the sintered media filtering discs are used in the food and beverage industry for extracting natural juices and nectars.

Consequently, these sintered discs ensure no food nutrients are eliminated during the washing process as well as no contaminants could attack the packaging of the food and beverages.

5.   Gas Generation Industry

Sintered filter discs are the better choice for the filtration of gases and getting rid of dirt and debris.

Basically, the discs are capable of producing pure gases without chemically being involved in the process.

Figure 2 Sintered Disc Applications 

No, you don’t need to pay a mold fee to buy a sintered disc.

The sintered disc is placed between the carbon molds that hold it to perform the process of filtration.

If the discs are damaged, you can easily buy a new one and replace it in a unit without paying the mold fee.

To choose the sintered disc, it is essential to keep the following aspects under consideration.

1.   Compatibility

Essentially, the primary criteria for selecting the right sintered disc is to ensure that the liquid that has to be filtered and sintered disc material must be compatible with each other.

Technically, the excellent compatibility among them will result in minimal to no chances of reacting together.

2.   Number of Holes

The number of holes present on the sintered filter disc determines the credibility and efficiency of the filter.

Notably, the filter disc should contain a higher number of holes to enhance productivity.

3.   Size of Holes

Generally, the pore size is present on the sintered filter disc. The smaller the size, the higher the efficiency of the filter.

Figure 3 Choose Right Sintered Disc

Sintered disc work depends on the pore size and pressure flow of the entire system as it is responsible for the practical completion of the task.

First, the sintered disc’s filtration compartment is filled with liquid, which is pushed through the pores of the plate with high pressure.

Moreover, the fluid particles with a smaller size will quickly pass through the pores of the filter pores while leaving behind the contaminants and impurities.

The unmatched pore sizes of these contaminants, however, will result in a contamination-free fluid due to their large diameter.

Additionally, the pressure drop is crucial in pushing fluid through sintered filter discs.

Figure 4 Sintered Disc Works

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Sintered discs are made of the following three materials, which are discussed below:

1.   Bronze Metal

Commonly, bronze is the prior choice of the buyers due to its low-cost acquisition and considerate tensile power, heat resistance, and mechanical strengths.

Furthermore, bronze consists of variable corrosion resistance properties depending on the type of fluid used.

2.   Stainless Steel

Stainless steel disc is also suitable for making sintered filter discs due to its excellent heat and corrosion resistance properties.

The grades 304, 304L, 316, and 316L are mainly widely used in multiple applications for various purposes.

Figure 5 Stainless Steel Sintered Disc

3.   Other Materials

Nickel alloys are useful for filtration under extreme to medium conditions, in addition to the metals mentioned above.

The nickel alloys Monel, Hastelloy, and Inconel, are primarily utilized while filtrating in extreme environmental conditions.

The sintered disc pore sizes vary depending on the application and type of filtration process.

Typically, the pore size ranging from 40µm to 100µm is helpful in mercury filtration and preparative works.

However, the pore sizes from 16µm to 40µm work more efficiently for medium precipitates operations.

Moreover, the sizes from 1.0µm to 1.6µm are helpful for ultra-fine filtration outcomes like in biological solutions. They remove bacteria from the fluid on decomposition.

Figure 6 Sintered Disc Pore Size

The sintered disc features are very beneficial while operating at a commercial level. Some are described below:

1.   Backwashing Property

The basic working principle of sintered filter disc depends exclusively on the backwashing property.

Once the desired pressure is obtained in the unit, the operator opens the valve to allow liquid flow.

However, the fluid can also enter the backwashing state, which is carried out by the one-way diaphragm at the bottom of the filter and closing the main channel.

To ensure the lamination surface is impurity- and contamination-free, a water jet spray is released over it.

Once the backwashing is completed, the water valve is shut off, and the unit is switched back to the filtration state.

Interestingly, the backwashing and filtration process in sintered filter disc is an automatic process that is fast with efficient outcomes.

2.   Well-Structured and Exact

Sintered filter discs are widely used due to their highly well-structured, precise, and accurate program.

Moreover, the user can choose the type of sintered disc according to the requirements without compromising efficiency.

Apart from filter discs, other types of sintered metal filter elements are also available at BLUE with equal efficiency and high-performance capabilities.

Some of the sintered filter elements are described as follows:

1.   Sintered Stainless Steel Filters

BLUE manufactures sintered porous stainless steel discs using grades 316 and 304 with alloying elements carbon or molybdenum.

These 304 and 316 stainless steel discs are suitable for the filtration processes that require excellent corrosion resistance and welding operations.

2.   Sintered Metal Filter

Sintered metal filters are manufactured in different shapes and sizes with heat and corrosion-resistant properties for filtration gases, liquids, and solids.

3.   Sintered Filters

SHENGYE manufactures high-quality sintered filters for various filtering operations and equipment including sewage filtration, mufflers, and multiple industrial applications.

Determining pressure drop across sintered disc is necessary to maintain the efficiency level of the process and obtain desirable results.

Basically, the pressure drop measures the pressure among the fluid particles from starting point to the ending point.

The temperature change can also be calculated as the pressure change as the liquid passes through the sintered metal filter disc.

You should measure the flow rate and the Cv factor of the filter before calculating the pressure drop across it.

For example, a 1-inch sintered filter disc with a Cv factor of about 8 will work efficiently with a pressure of 4psi under 16gpm flow rate.

The features to look for in a sintered filter disc are stated below:

1. Primarily, the sintered discs should be manufactured with different grades of stainless steel, namely, 304, 306, 304L, and 306L.
2. Moreover, these filter discs must provide high precision particle efficiency with variable accuracy levels.
3. Additionally, the sintered filter discs should be able to withstand high temperatures up to 1000 degrees Celsius.
4. The multiple layered filters inside the disc enhance the rigidity and improve the unit’s mechanical and structural strength.
5. The sintered metal filter discs must have longer life spans with equal efficiency with the special allowance of washing and backwashing.
6. Low-pressure drop and enhanced filtration accuracy should be enabled in the unit to deliver results quicker and faster.

You can specify a sintered disc according to your requirements. Some technical aspects of the filter discs are described as follows:

1.   Dimensions

The sintered metal filter discs are manufactured in a variety of sizes based on the application’s requirements.

In SHENGYE, the user must provide the actual pore size and weight specifications and efficiently do the job.

2.   Raw Material

Typically, the user can customize the raw material they want to use according to the application and environmental aspects.

Not to forget, each material has distinct specifications and behaviors according to the atmosphere and other conditions.

3.   Pore Size

Primarily, the sintered filter discs are manufactured with multiple pore sizes to enhance the capabilities and outcomes.

Every user and manufacturer must know which max pore size is suitable for which kind of application.

4.   Resistance Capabilities

The use of the sintered disc can be analyzed depending on the resistance power against heat, pressure, and corrosion.

Mainly, stainless steel disc is used for high corrosion resistance, heat transfer, and reliability.

The available sizes and designs of sintered discs vary according to the necessity of the application and filtration process.

Normally, the sintered disc can be made as little as the size of the pinhead.

On the contrary, manufacturing a larger sintered filter disc is also feasible if the application demands it.

Furthermore, there are no size and design restrictions when it comes to the manufacturing of the sintered filter discs.

Additionally, this also implies the thickness of the sintered disc, which also varies from application to application depending on needs.

Figure 7 Sintered Disc Designs and Sizes

BLUE tests the quality of the sintered disc after the complete manufacturing of the sintered discs.

Furthermore, a team of scientist has passed these products through a series of quality control checks to ensure they are ready to be delivered to the consumer.

1.   Fouling Tests (Long-Term)

In this test, the sintered discs are subjected to a long-term filtration process without the possibility of back pulsing.

Moreover, the test analyzes the amount of time required by the filter to filter out a certain quantity of a liquid.

2.   Component Fouling Test

The component fouling test is carried out to determine the resistance of the sintered metal disc against specified temperature rating conditions and its corrosion resistance.

3.   Evaluation and Cleaning

The cleaning and evaluation tests are carried out to ensure the response of filter discs against cleaning operations.

Additionally, it is useful in determining the efficiency of the filter discs under certain circumstances.

You should replace a sintered disc after prolonged use or if the filtration disc is damaged.

Moreover, for the intense disc clean process of the sintered metal filter disc that doesn’t work out and its efficiency is not improved, then it is the right time to replace the disc.

Another significant indication of replacing the disc is the frequent pressure drop, making the filtration process time-consuming.

Subsequently, you might notice a decrease in the performance and less efficient outcomes by the filter disc.

Possibly, the presence of contaminants and other impurities in the filtrate may also indicate the need to change the filter disc.

There are two types of sintered discs that are described below:

1.   Porous Sintered Filter Disc

Typically, the porous sintered filter disc consists of a high number of pores to incorporate more efficient and high results.

Eventually, the disc has high mechanical strength, which enhances the unit’s temperature and pressure tolerance.

2.   Pleated Sintered Filter Disc

Unlike the porous sintered discs, this type possesses numerous pleats to assist the filtration process of various liquids.

Consequently, it provides a higher surface area for the liquid for more filtration outcomes in lesser time.

Figure 8 Porous Metal Filter Disc

The available filtration grades of the sintered disc vary from the type of applications and their usage.

Typically, the utilization and application of sintered metal filter disc are based on the microns’ size, which determines their efficiency for a specific type of application.

Moreover, the operator can use the pore size of the filter disc as small as 0.1 micron size and as bigger as 100 microns based on the desired requirements.

Notably, it is essential to keep in mind during the coarse filtration process that the finer micron level will result in greater filter material contaminants to be eliminated during the process.

The sintered disc cost varies according to the sizes, quality, and design of the product.

Subsequently, the higher the quantity and quality of the product, the higher the amount the buyer has to pay for the batch.

Furthermore, it must be noted that the price of the sintered metal disc also depends on the type of the disc.

Typically, the buyer has to pay from $0.30 to $30.00, depending on the efficiency of the product.

However, it must be noted that the prices of the sintered metal filter disc vary depending on the brand qualities and other customization options.

Sintered discs are suitable for high-pressure applications due to their high mechanical properties.

Moreover, the porous filter discs are constructed with solid metal or metal alloys to ensure high tensile and mechanical strength.

With the help of the strong characteristics, the sintered disk is capable of resisting elevated pressure.

Because of their high temperature and pressure resistance properties, the sintered discs are helpful in many applications that require elevated temperatures.