Wire mesh filters are an integral element to the filtration and fluidization of various materials and substances. To ensure optimal performance, many filter system operators rely on filter media that provide maximum durability.
POROSTAR filter discs are designed to deliver the perfect balance of durability and performance, which is why it is widely used when attempting to extract filter cakes. That said, as with any filter media, POROSTAR filter discs will need to be repaired or replaced.
W.S. Tyler has been a trusted manufacturer and supplier of woven wire filter solutions for over 140 years and is here to help you avoid lengthy downtime.
It's for this reason that this article will provide insight into:
- What a POROSTAR filter is
- Common elements that can damage your POROSTAR filter
- How to tell when you need to send your filter disc in for repair
- How filter discs are repaired
- The factors that dictate filter disc repair cost
What Is a POROSTAR Filter?
Porostar is best defined as a woven wire mesh laminate consisting of several layers of wire cloth that are diffusion bonded together. During the diffusion process, the geometric integrity of the mesh is maintained, leaving you with a porous filter plate that features precise pore openings and maximum stability.
What Can Cause Your Filter To Need Repair?
The particular material you are working with is one of the most significant factors that affect the service life of a POROSTAR filter plate. Naturally, abrasive materials are known to cause the surface of the filter plate to wear quicker than non-abrasive material.
This is particularly true within nutsche filters, as these abrasive materials can easily damage the mesh as the scrapping mechanism rotates and pushes the particles against the surface of the mesh. This is why, when extracting filter cake, it's essential to be mindful of any residual material that has hardened.
It would help if you also looked for corrosion damage when working with various chemicals. Over time, certain chemicals may eat through the multiple filter layers and affect the performance of the mesh.
What Signs Indicate You Need to Repair Your POROSTAR Filter?
A key indicator that your filter plate has been damaged is if you detect particles with a diameter larger than the pore size of the filter plate. This indicates that you have some sort of hole or break in the filter that must be patched.
You also need to be mindful of the pressure throughout your filter system.
If your pressure reads higher than usual, this is an indicator that several pores throughout the filter plate are plugged. On the other hand, if your pressure reads lower than usual, odds are there is a hole somewhere on the filter plate.
Of course, the easiest way to detect a fault throughout your filter plate is by visually inspecting it between uses.
How Is a POROSTAR Filter Repaired?
Before sending your filer plate in for repair, it is vital that you clean the filter plate thoroughly. This will ensure all chemicals and particles that may hinder any welding applications are removed.
Now, when repairing a filter plate, either the POROSTAR material is replaced and inserted into the flange ring in its entirety or portions of the mesh are replaced, depending on the severity of the damage.
If only a portion of the filter needs to be replaced, the damaged area is cut out, and a new portion of POROSTAR is fitted and welded onto the filter disc.
To that end, anytime you are working with a filter that has a diameter of 1.2 meters or smaller, it is recommended that the entire filter material is replaced.
In terms of lead times, filter disc repair typically takes around two weeks after receiving the filter if POROSTAR material is in stock.
NOTE: The weld seams created when portions of a filter disc are repaired have little to no effect on filtering performance.
How Much Does a POROSTAR Filter Disc Repair Cost?
The overall cost that you can expect to pay to repair your filter disc depends on several factors. This includes whether you are replacing the entire filer material or just a portion, the material of the filter, and the diameter of the filter all contribute to the cost.
That said, because all these factors must be checked in detail, there is no fixed price for filter disc repair.
Prolong the Lifespan of Your Filter Disc With the Suitable Alloy
POROSTAR woven wire mesh laminates, much like any other material, eventually wear or endure damage that requires the filter to be replaced. This entails either replacing the filter material in its entirety or simply replacing the portion of the filter that is damaged.
Having said that, if you continue to see repeated damage being caused to your filter disc because the material is either too abrasive or corrosive, you may want to explore the possibilities of their alloys. While stainless steel is a widely used and popular alloy to use when implementing woven wire mesh solutions, you may find that other alloys, such as Hastelloy, deliver filtration performance that is much more stable.
As a prominent wire mesh supplier, W.S. Tyler takes pride in help customers design wire mesh solutions that are tailored to their exact needs.
For more information on the different alloys available as well as the benefits that they deliver, read the following article: