Top-tier Supplier of Sintered Disc in China

A sintered disc is another kind of filtration tool mainly used to separate one material from another without the involvement of contaminants.

Unlike filter papers, the sintered discs are manufactured with multi-layers of wire mesh fitted with perfect filter layerings.

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

Furthermore, the construction of a wire mesh 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 wire mesh filters is higher than other filters, including sintered metal filters, ceramic, sintered metal powder, and 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 the process of filtration 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 installation methods of sintered discs vary based on the application type and operation it is used on.

Generally, the sintered discs are incorporated in tubes, and the liquid to be filtered is passed through it.

Moreover, the tubes are reinforced with compartments to ensure the filter’s stable position and proper completion of the operation.

Primarily, the installation starts with opening these filter chambers and placing the sintered filter disc in them.

Once the filter disc is correctly placed in the tube, the reinforcements are kept tightly to ensure the filter stays in the proper position and efficiently performs the task.

Lastly, close the tubular chamber when the placement and reinforcement of the metal filter disc are done.

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Sintered discs can be cleaned by various techniques based on what kind of dirt and contamination is on the filter.

Commonly, the following methods are used for the cleaning of the sintered discs:

1.   Detergent Cleaning

The simplest method of cleaning the sintered disc is to soak it in the detergent solution and let it rest for a few hours.

Essentially, it loosens the contaminants’ grip over the filter surface, and it will be easy to remove them from it.

2.   Furnace Cleaning

Another technique used for cleaning these filter material is Furnace Cleaning, which involves using biological compounds to remove the debris and contaminants from the filter.

However, the method is highly effective for the removal of polymer materials from the filter surface.

3.   Circulation Flow

Generally, the Circulation Flow method is also used for the sintered disc cleaning.

Technically, the process utilizes the pressurized flow of a cleaning solution to pass through it, resulting in the cleaned filter disc.

4.   Hydroblasting Technique

For the complex and intense contamination on the disc, the method used is called Hydroblasting Technique.

Generally, a high water jet is introduced to remove the particles from the filter disc with ease.

5.   Ultrasonic Bath

Sintered discs can also be efficiently cleaned with the help of Ultrasonic Baths.

Typically, the process includes the ultrasonic waves passing through the filter and triggering the particles to leave the surface.

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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 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 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

Sintered discs get manufactured through three main steps. These steps are discussed as follows:

1.   Obtaining Materials

To manufacture long-lasting and durable sintered filter discs, it is necessary to buy from the original manufacturers.

Moreover, it is also possible to personally make the desired combination of metal powder by using simple techniques such as grinding, atomization, or chemical decomposition.

Additionally, it is clever to decide the durable materials for making an alloy as it will retain its physical properties even after completing the task.

2.   Filter Design

Another critical step is to pour the powder into the desired mold or cast to shape it according to the requirement or application.

Technically, the powder is pressed under high pressure and definite temperatures to ensure the powder melts and adopts the shape of the cast.

3.   Impact of High Heat

The last step is to remove the solid metal filter and place it on the furnace for further heating.

At this stage, low temperature ensures the product consists of high porosity, strength, and rigidity in a filter disc shape.

Figure 3 Sintered Disc Manufacturing

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.   Mesh Number

Typically, the mesh number is the number of holes present on the sintered filter disc. It determines the credibility and efficiency of the filter.

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

3.   Mesh Size

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

Figure 4 Choose 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.

Initially, the fluid is released in the filtration compartment of the sintered disc with pressure high enough to push the liquid through the pores of the disc.

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

However, these contaminants will create hindrance and disturbance against the unmatched pore sizes due to their large diameter resulting in a contaminant-free fluid.

However, pressure drop also plays a vital role in pushing the fluid to pass through the sintered filter discs.

Figure 5 Sintered Disc Works

The material used for making sintered disc mainly of three types, 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 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 6 Stainless Steel Sintered Disc

3.   Other Materials

Apart from the metals discussed above, nickel alloys are also helpful for extreme filtration conditions.

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 7 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.

Furthermore, a water jet spray is released over a lamination surface to ensure the impurities and contaminants on its surface are eliminated.

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

Mainly, the extensive usage of sintered filter discs is their highly well-structured program with accuracy and precision.

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

Figure 8 Sintered Disc Features

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 stainless steel filters using grades 316 and 304 with alloying elements carbon or molybdenum.

Both of these elements are suitable for the filtration processes that require excellent corrosion resistance and welding operations.

2.   Porous Metal Filter

Porous metal filters are manufactured in different shapes and sizes for water treatment, automotive, food and beverage industry, and chemical filtration tasks.

3.   Metal Powder Filters

Generally, the metal powder filters are porous filters with a broad micron range from 0.2-100 microns with enhanced breathability and uniform distribution of pore sizes.

Comparing sintered disc to the sintered metal filter plate is difficult as both have distinctive characteristics and distinct usage among various applications.

Primarily, the sintered filter disc consists of a disc shape, while sintered metal filter plates can be of any shape.

Additionally, these materials possess impressive filtration efficiency with variable pore sizes that prohibit contaminants from passing through them.

Moreover, sintered discs can be incorporated with multiple layers of wire mesh and metal powders for enhanced productivity.

Different kinds and grades of metals can also be used for the effective manufacturing of sintered discs and plates.

Typically, stainless steel, bronze, titanium, copper, and nickel are utilized to construct sintered plates and discs.

Consequently, both filters exhibit elevated accuracy levels with high mechanical strength to resist high-pressure operations.

Figure 9 Sintered Metal Filter Plate

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.

Moreover, it can also be analyzed as the change in pressure while the liquid moves through the sintered metal filter disc.

For calculating the pressure drop across the unit, the filter Cv factor and flow rate should be measured.

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 you should consider in 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 has to 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

Based on the material’s resistance against corrosion, heat, and pressure, the use is analyzed. Mainly, stainless steel powder 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.

Typically, the sintered metal filter disc can be manufactured as small as the size of a pinhead.

Consequently, it is also possible to construct the sintered filter disc as large as your application demands.

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 10 Sintered Disc Sizes and Designs

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 filter disc against specified temperature 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 determines the efficiency of the sintered filter discs under certain circumstances.

What are the Benefits of the Sintered Disc?

The benefits of the sintered discs are briefly described below:

1.   Anti-Corrosive Property

Primarily, the significant benefit of using sintered discs is its anti-corrosion property under water and harsh chemicals.

Subsequently, the filters are used in any extreme circumstances without the fear of it being damaged.

2.   Efficient Filtration

The sintered filter disc provides a high level of filtration accuracy to eliminate stubborn impurities and contaminants.

3.   Thermal Resistance

Moreover, the sintered filter discs are widely used in applications with high thermal shocks to enable high-performance filtration operation.

4.   Pressure Drop

Generally, the sintered filter discs are manufactured with high porosity to maintain a reasonable pressure drop throughout the process.

Figure 11 Sintered Disc Benefits

Outside-in filtration and inside-out filtration of the sintered disc are compared based on the techniques as both processes are used in the process of filtration.

Generally, outside-in filtration is a technique where the filtration has occurred in the outside layer of the sintered discs.

Typically, this type of filtration is used in applications with continuous liquid flow.

Subsequently, inside-out filtration is a process where the filtration occurs inside layers of the filter discs.

Technically, this type of filtration is applicable for contaminants with low speed.

Yes, you can perform inside-out multimode filtration with the sintered disc by the standard filtration technique.

Typically, this method involves the filtration of the liquid inside the sintered metal filter disc.

Moreover, the process is helpful for applications that require a continuous flow of fluid during the process.

By the end of the process, the contaminants are collected from the outer sides of the system without bothering the unit.

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

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

Another significant indication of the need to replace 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 Metal 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 Metal 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 12 Porous Sintered Filter Disc

To determine the filtration efficiency of sintered discs, it is necessary to analyze the pore size and number of pores on the sintered filter disc.

Consequently, it is helpful to evaluate the filtration capacity and efficiency of the sintered metal filter disc.

Moreover, the properties of an exemplary filter disc can be identified by its high contaminant retention factor and low-pressure drop throughout the process.

Furthermore, the primary advantage of using the sintered filter discs is it is easy to determine its abilities by calculations.

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

Typically, the use of the sintered metal filter disc depends on the microns’ size, which determines its efficiency for a specific type of application.

Moreover, the operator can use the pore size of the filter disc as small as 0.1 microns and as large as 100 microns depending on the application.

Notably, it is essential to keep in mind during the coarse filtration process that the size of the micron should be smaller than the size of the contaminants to eliminate them.

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 price range of the sintered metal filter disc varies based on the brand qualities and additional customized options.

The difference between the mesh filter discs and fiber filter discs is their comprehensive utilization over a wide range of applications.

Moreover, the sintered mesh filter discs are specifically designed for efficient and cost-effective filtration processes for gases and liquids.

On the other hand, the fiber filter discs are manufactured with fiber materials for the filtration and washing of gases and liquids.

Furthermore, the mesh filter sintered discs provide a sufficient area for completing the operation.

On the contrary, the fiber filter sintered discs are available in both flat and pleated versions thus have elevated efficiency levels.

The powder filter disc and mesh filter disc consist of prominent differences in terms of construction and application.

Typically, the filter mesh disc is manufactured with powdered metal substance deposition to enhance the filtration process.

On the other hand, the mesh filter disc is constructed with numerous pleats and pores to perform the filtration process.

However, powder filter disc and mesh filters are popular choices to achieve highly accurate and efficient filtration outcomes at affordable rates.

Install sintered discs according to the requirement and application needs.

Mostly, the sintered metal filters are installed in tubes from where the fluid is passed from one side to another for the completion of the task.

Moreover, the tubes are constructed with built-in compartments along with the reinforcement to hold the sintered disc together and provide stability to the unit.

Consequently, the installation is carried out by opening the filtration chambers and placing the disc in them.

For additional security, the correct reinforcement appliances and holders are incorporated to ensure the sintered filter disc stays in the proper position.

Many manufacturers like SHENGYE manufacture high-quality tightening reinforcements to keep the sintered filter discs at an exact position for accurate outcomes.

After tightening the holders and reinforcements, close the filtration chamber, and the unit is now ready to use for medium filtration to high filtration operations.

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

Moreover, the sintered metal 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 metal disc is capable of resisting elevated pressure.

Due to its high temperature and pressure resistance properties, the sintered discs are helpful in many applications that require elevated temperatures.