| Nine Measurable Ways Self-Cleaning Filters Can Eliminate Waste, Lower Costs, and Improve Process/Product Quality
Traditionally, engineers have opted for disposable media filters because of their lower initial cost. While initial cost may be lower for small batch operations, the same is not necessarily true for continuous operations.
That is because you would need a completely redundant filtration system, including piping, valves, supports, and service connections – not an insignificant expense by any means – to maintain production.
With Ronningen-Petter brand cleanable (self-cleaning) filter systems, media is cleaned and regenerated while the unit remains on-line. This means a simple single-piping arrangement, minimal valving, and fewer connections – for a lower total system cost and reduced waste.
What follows are nine compelling reasons to select a cleanable media filter for new installations, or to replace your existing disposable filter with a Ronningen-Petter brand cleanable filtration system.
1. No cartridges or bags to landfill or incinerate
With cleanable (self-cleaning) filter media, you only have to deal with the unwanted solids. And, as you will learn later, you may not have to contend with them, either.
Cleanable media offer an effective method of eliminating waste at the source and significant monetary savings, too.
Just how significant? You can begin to get an idea by following this example. It assumes the application requires a typical 12-cartridge filter using 10-inch cartridges.
First, we know that a 55-gallon drum can hold 180 cartridges if carefully filled. Assuming you replaces these cartridges daily (which would not be unusual); you will fill one drum every 15 days – or about 20 drums per year.
The cost for disposing of non-hazardous waste is already $400–$800 per drum. And the cost for disposing of hazardous waste is fast approaching $1,000 a drum. When you multiply this cost by the number of filters at your plant, you can begin to see the savings.
Consider this, too: If, in anticipation of changing regulations, you are treating all your non-hazardous waste as hazardous waste to avoid future fines and clean-up costs, it is easy to see how the reduced waste volume made possible by cleanable media can begin paying immediate dividends.
2. Cleaning frequency occurs only when media loading necessitates
You may be throwing out more cartridges than necessary with disposable media. That is because disposable media are typically changed on a time cycle (e.g., once a shift, once a day, or once a week), regardless of whether the media need replacement.
Ronningen-Petter brand self-cleaning filters, however, can be automated to clean at precisely the right time – rather than just when it is convenient. That is because cleaning is controlled by the pressure differential between inlet and outlet headers as contaminants build up on the filter screen.
When the pressure reaches a predetermined level, the screens are cleaned automatically – only as needed, when needed. And that means less waste in your process.
3. Even “waste” from Ronningen-Petter brand filters may not be waste
The Ronningen-Petter brand cleanable media is used over and over. But what happens to the contaminants and the liquid used to clean the media? In many applications, the cleaning liquid can be recycled back into the system, where the contaminants are harmless.
When the filtration system is matched to the application parameters by a knowledgeable supplier, this sort of benefit becomes possible. In other cases, the liquid can even become a fuel source.
In still other applications, the contaminants are separated from the cleaning liquid and concentrated. If the contaminants are undispersed or oversized product, it may be possible to recycle them back into your process as raw material.
Or maybe your contaminants – and even your cleaning liquid – represent a source of valuable raw material to someone else. Not only would this eliminate your waste, it would also represent a source of income.
This trend is becoming increasingly common in the petroleum and chemicals industry as raw material costs escalate. Of course, as a last alternative, the contaminants can be disposed. But even here, you only dispose of the contaminants, not the media. And that means far less waste and far lower disposal costs.
4. No absorbed process liquid to contend with
Keep in mind that disposable media, especially cartridges, act like a sponge and soak up your process liquid. Thus, every time you dispose of a cartridge and its contaminants, you are also disposing of your process liquid.
Cleanable media eliminate this source of waste. In addition, if you are processing valuable liquids, you are throwing away revenue.
5. No spilled liquid to flush away
With disposable media filters, a certain amount of liquid is routinely spilled when transferring spent media from the filter to a drum. Quite often, workers simply hose this process liquid to a drain, which adds to your waste treatment costs.
Again, because you do not dispose of cleanable media, you eliminate this potential for spillage – and its associated treatment cost.
| The labor-intensive cartridge: 15 tedious tasks |
| 1. Prepare and sign purchase orders for new cartridges. |
| 2. Cartridges arrive at shipping/receiving dock. Sign receipt forms. Move boxes of cartridges off dock to receiving area. |
| 3. Arrange for forklift driver to move cartridge boxes from receiving area to inventory. Prepare paperwork. |
| 4. Operator needs new cartridges. Arrange for forklift driver to transfer box of cartridges from inventory to site. |
| 5. Operator shuts down or re-routes process flow and dons protective clothing. |
| 6. Operator unwraps cartridges; disposes of packaging material in proper refuse container. |
| 7. Operator opens cartridge filter (and releases emissions) to remove soaked cartridges. Removes compression seals first; then cartridge; then seal plates; then more cartridges; then more seal plates. |
| 8. Operator throws cartridges into steel drum. |
| 9. Operator inserts new cartridges and checks alignment – otherwise leakage and/or bypassing can occur. |
| 10. Operator closes filter and re-starts process flow. |
| 11. Operator hoses down area. |
| 12. Operator changes out of protective clothing. |
| 13. Arrange for forklift driver to transfer cartridge-filled drums to shipping/receiving dock. |
| 14. Contact waste haulers for pick-up. |
| 15. Prepare MSDS forms to ensure proper disposal. |
6. Positive sealing helps prevent wasted process liquid
With disposable media filters (primarily cartridges), there are numerous opportunities for contaminants to bypass the media, travel downstream, and ruin your product.
For example, knife edges used to seal cartridges can get nicked and permit solids to bypass the media, thereby contaminating your downstream process.
Contamination can also happen if cartridges are not stacked properly in the housing, which is a common problem.
In some cases, even the media themselves can shed and cause downstream contamination (this means, at the very least, re-filtering the liquid, assuming you discover the problem before your customer does; or it could mean disposing of the liquid, which drives up your disposal costs.
Looking for a solution?
All Ronningen-Petter brand self-cleaning filters have positive elastomeric-to-metal seals. These seals virtually eliminate the possibility of solids bypassing the media and producing an off-spec product.
And, because media are seldom removed from the housing, opportunities for seal failure are virtually eliminated.
7. Dramatically reduce your emissions
With disposable media filters, you have to open the filter every time the media are replaced. This can potentially expose workers and the environment to VOCs (volatile organic compounds) or other toxic emissions.
However, because Ronningen-Petter brand filters are cleaned in place (or self-cleaning), you open the filter only when you want to inspect the media – which drastically reduces emissions and their potential risks.
8. Reduce your future liability
Remember that what you landfill today may comply with current regulations, but future legislation could make you responsible for a costly clean-up five or 10 years from now. This threat is greatly minimized with cleanable media by concentrating your waste stream.
9. Less packaging for replacement media means lower costs
Packaging material may not be considerable and it may not be hazardous – but it is waste, it must be disposed of, and it does add to your costs. Switching to cleanable media eliminates this.
As you can see, there are plenty of ways in which cleanable media can help minimize waste and bring down your costs. If this article has piqued your interest in self-cleaning filters, please send me a note and we can discuss your filtration alternatives. You may be surprised at how easy it is to implement, and the cost savings can be enormous.
My next article will illustrate how other businesses are already benefiting from Ronningen-Petter brand Mechanically Cleaned (Self-Cleaning) Filter technology.
-- by Ask Filter Man
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