Types of Filtration Manual Screen Changer - Strengths

 Manual Screen Changer  Sizes: 30 mm to 150 mm

 Hydraulic Screen Changer  Low capital costs

 Low operating costs

 Dual or Single Piston
 Streamlined flow paths
 Continuous Belt/Ribbon Type
 Minimum residence time
 Multi-Segment Rotary Disc
 Small in size
 Large Area - Candle Element

Manual Screen Changers - Weaknesses Hydraulic Screen Changer - Strengths

 Process Interruption  Sizes: 70 mm to 380 mm

 Low operating costs
 Line shutdown
 Low capital costs
 Air entrapment
 Streamlined flow paths
 Limited open area  Minimal residence time

 Seal leakage/replacement  Industry acceptance

Hydraulic Screen Changer - Weaknesses Belt Type Screen Changer - Strengths

 Process interruptions

 Air entrapment  Constant differential pressure

 Heated standby screen
 Streamlined flow paths
 Limited open area
 Minim al residence time
 Complicated hydraulics

 Seal leakage/replacement  Low operator intervention

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Belt Type Screen Changer - Weaknesses Piston Screen Changer - Strengths

 Limited size ranges  Sizes: 30 to 450 mm

 Capital costs  Continuous filtration
 Operating costs  Sealless design
 Sophisticated controls  High open area
 High contamination  Uses round screens
 Temperature dependent sealing  Low capital & operating costs
 Head/differential pressure limitation  Variety of special applications

Piston Screen Changer - Weaknesses Rotary Screen Changer - Strengths

 Sizes: 30 mm to 250 mm
 Cost relative to hydraulic
 Very constant pressure
 Some pressure variations
 Streamlined flow paths
 Operator skill level
 Minimum residence time
 Size and installation
 High automation
 Increased residence time
 Low operator intervention

Rotary Screen Changer - Weaknesses Large Area Filtration - Strengths

 Too loose - leakage  Sizes: 5,000 PPH and up

 Too tight - lockup/galling  5 microns at 90% efficient

 High capital cost  Difficult applications

 Sophisticated controls  Single and dual vessel

 High differential pressure  Depth filtration - gels

 Pressure/viscosity dependent bolt torque

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Large Area Filtration - Weaknesses Application Factors

 Required level of filtration

 Capital cost
 Screen change frequency/on stream life
 Operating cost
 Effect of pressure variation on process
 Safety  Frequency of normal line shutdown
 Large installation area  Material waste & downtime during start-up
 Overall process pressures

The Piston Screen Changer Continuous Production

 One or two screen pistons in a housing  All screens in operating position

 1 or more removable breaker plates  Screen change - move out of polymer flow
 Tolerances/sealing length resist leaks  All material flows through second screen
 One or more converging flow channels  Each screen/channel sized for total output
 At least one screen in flow at all times  Viscosity decreases, pressure rise minimal
 Optional Automatic Positioning System  Avoid excessive pressure before change

Screen Change - Pressure Rise Over Time Automated Venting

 Venting grooves - front, back and top

 Complete venting of the screen cavity

 Precise positioning via ultrasonic

 Automatic timing and sequence

 Minimize any loss of die pressure

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Venting of Screen Cavity
Support Plates/Breaker Plates

 Breaker plate - 56% open area

 Support plate - Up to 98% open area

 Vertical ribs support screens off breaker

 Use large holes in breaker plate

 Low pressure drop, full screen utilization

High Open Area Breaker and Support Plate

Four Screen - Backflush

Four Screen – Backflush, cont. Mounting Configurations

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Moving Toward Standardization Continuous Piston Applications

 Single piston, continuous

 Dual piston, continuous
 Backflush
 Four screen, dual piston, continuous

500 PPH, HDPE Strand Pelletizing 1500 PPH, PS Inline Thermoforming

 Single piston, (2) 3.0” screens  Single piston, (2) 6.94” screens

 Screw pull through  6” extruder, w/ gear pump

 Replaced slide plate
 Lower cost system
 No loss at screen change
 No process interruptions
 Higher contamination levels
 Lower total and delta-P
 Finer filtration level
 250 mesh screens  Less scrap to handle
 No dropped strands at change  12.5% increase in line productivity

Single piston, two screen, continuous

3,000 PPH Inline Sheet Thermoforming

 Dual piston, (2) 6.94” screens

 Two piece food container
 HIPS bottom/PET top
 Replace slide plate

 Increase line production

 Increase filtration to 150 mesh

 Lower pressure/longer screen life

Dual Screen

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 Dual piston, two screen, continuous
18,000 PPH SAN Polystyrene Production

 Dual piston, (2) 10.63” oval screens

 No loss of production

 Lower maintenance cost

 Increase filtration levels

 Eliminate candle cleaning

 Replace slideplate with candles

Dual piston, oval two screen, continuous

3,500 PPH Polypropylene Recycling

 Dual piston, (2) 9.07” screens

 Bail wrap and fiber waste
 200 mesh filtration
 Reduce screen costs
 Up to 80 Back Flushes
 Lower maintenance costs
 Automate with Back Flush

Larger Area Lower Cost

Dual piston, two screen, continuous

2000 PPH, PET Fiber Production

 Dual piston, (4) 6.94” screens

 Continuous polymerization
 High IV PET
 Low total and delta-P
 Explosion proof design
 Extend spin pack life
 Improve overall filtration
 Increase production

Back Flush

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 Dual piston, four screen, continuous
3500 PPH, PET Staple Fiber Production

 Dual piston, (4) 9.07” screens

 200 MM Extruder
 PCR PET, 0.8 IV
 Extend spin pack life
 Increase production
 Low pressure variation
 Improve overall filtration

Continuous Ribbon Type Ribbon Function

Payback Payback, cont.

Inputs
Scr een Change s per d ay 1 1 1 Co ntin ou s
Extru sion Flow Rate ( lb/h r) 10 00 Nor ma l op er atio n extr usi on r ate i n lb s/ho ur
Time to Chang e Sc re en (hr) 1 0.3 0.1 0
Mat erial Co st ($/ lb) $0.4 0 Ra w mat eri al p ol yme r cost
%of lost Ma te rial R ecov er ed 80 % Mater ia l rec ov ere d for i n ho us e re proc ess in g Machine Ti me Los s ($) $5 00 $1 50 $5 0 $0

Machine Ti me Co st ($/ Ho ur) $5 00.0 0 Oper atin g co st for extru si on l in e /hr Mat erial Los s ($) $3 20.0 0 $9 6.00 $3 2.00 $0.0 0

Labor R ate $4 5.00 La bor r ate for e ac h op er ator as si gn ed to l in e Labor Co st ($) $4 5 $1 4 $5 $0

Scr een Change s per d ay 1 Num b er of scr ee n ch an ges i n n orm al 2 4 hr per io d
Scr een Cost ($/y ear ) 12 25 12 25 12 25 15 50

Base d o n 3.5 " sc re en p ack @

$3.5 0 /pa ck or 2 r ol ls of
scre en/y ear @ $7 75. 00 e a

Results

Manual Sc re en Hyd raulic Sc re en KC N Continuous

Cost pe r Sc re en Ch ange $8 67 $2 61 $8 8 $0
Fixed Sc re en Change r Change r Scr een Change r
Flow Rate (l b/hr ) 1,00 0 1,00 0 1,00 0 1,00 0 Screen Change Cost per
Mat erial Co st ($/ lb) $0.4 0 $0.4 0 $0.4 0 $0.4 0 Yr $304,675 $92,505 $31,885 $1,550

%of lost Ma te rial R ecov er ed $0.8 0 $0.8 0 $0.8 0 $0.8 0

Machine Ti me Co st ($/ Ho ur) $5 00.0 0 $5 00.0 0 $5 00.0 0 $5 00.0 0
Labor R ate $4 5.00 $4 5.00 $4 5.00 $4 5.00

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Rotary/Wheel Type Rotary Function

Duplex Large Area Filtration System Duplex Large Area Operation

Duplex Large Area Operation Duplex Large Area Operation

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Duplex Large Area Operation
Pricing – Manual, Hydraulic, Ribbon

Sty le/Type 3-1/2 inch 4-1/2 inch 6 inch 8 inch

Manual $ 7,115 $ 8,210

Hy draulic $ 13,200 $ 15,000 $ 19,400 $ 31,500

Continuous Ribbon $ 23,700 to $ 26,500 to $ 32,500 to $ 60,600 to

$ 29,500 $ 39,100 $ 46,500 $ 71,600

Pricing courtesy of Key Filters, Woonsocket, RI

System Pricing – Piston/Rotary Backflush Pricing – Piston/Rotary

Supplier Model Screen Dia. Total Area Price Options Comments Equipment Model Screen Total System Options Comments
Supplier Diameter Area Price

Maag Pump CSC-176 2 x 176 mm 488 cm2 $ 54,295 Cart, $3380 Dual piston, continuous
Maag Pump CSC - 4 x 125 mm 500 cm2 $ 77,190 Cart, $3140 Dual piston,
Sy stems Guard, $3170
Sy stems 125/BF-4F 4 x 148 mm 692 cm2 $ 101,260 Guard, $2395 continuous
Control, $7670
CSC – Cart, $3380
148/BF-4F Guard, $3170
Gneuss SFXmagnus 1 x 90 mm 346 cm2 $ 79,540 Cart, $2680 Continuous rotary type
90 Controls, $8750 Controls required
Gneuss RSFgenius 1 x 150 mm 359 cm2 $ 157,530 Cart, $3530 Continuous rotary
150 Controls, $9860 ty pe
JLS TSK 6.1 2 x 140x190 530 cm2 $ 53,400 Cart, $3000 Dual piston, continuous,
Controls required
International mm Guard, $2100 with rectangular
screens
PSI – Polymer CSC-148/BF 4 x 148 mm 686 cm2 $ 89,760 Cart, included Dual piston,
PSI – Polymer CSC-148 2 x 148 mm 343 cm2 $ 47,480 Cart, included Dual piston, continuous
Sy stems continuous
Sy stems CSC-176 2 x 176 mm 485 cm2 $ 57,375
Kreyenborg VL-176 2 x 176 mm 488 cm2 $ 36,300 Cart, $2700 Dual piston, continuous Kreyenborg K-SWE- 4 x 125 mm 500 cm2 $ 86,630 Cart, $2840 Dual piston,
Guard, included 125/BF Guard, $1795 continuous

Non-backflush, sized for 2000 pph of PS sheet extrusion Backflush, sized for 2000 pph of PS sheet extrusion

Filtration System Suppliers

Company Melt Filtration Products Location

JLS International Continuous Piston, Large Area Charlotte, NC

Kreyenborg GmbH Continuous and Backflush Piston Atlanta, GA/Germany
Dy nisco Manual, Slide Plate, Continuous Piston Hickory , NC

Key Filters, Inc. Manual, Slide Plate, Continuous Ribbon Woonsocket, RI

Gneuss GmbH Slide Plate, Continuous and Backflush Rotary Charlotte, NC/Germany

PSI - Polymer Sy stems, Inc. Manual, Slide Plate, Continuous Piston Hickory , NC

HiTech Continuous Ribbon Hackensack, NJ

Econ GmbH Continuous and Backflush Piston Greenville, SC/Austria

MAAG Pump Sy stems Manual, Slide Plate, Continuous Piston, Large Area Charlotte, NC
Erema GmbH Continuous and Back Flush Piston Topsfield, MA

Patt Filtration Continuous Ribbon Quebec, Canada