Optimization & upgrading of operating disc, drum & pan filters
Filter revamps from BOKELA are the best way to benefit from our unique know-how when using filter equipment from other OEMs. Filter revamping is a specialist program for filter optimization and a very economical alternative to a new filter investment. Filter revamps enable you to optimize the process and operation of your running filter system in the fastest and most economical way. Inadequate filter performance, excessive maintenance and high operating costs of existing filters are eliminated quickly and at low cost. In this way you can achieve higher production goals, meet higher product quality requirements and improve the reliability, operational safety and reduce the operating cost of your filter system.
Our filter revamping program has already demonstrated its feasibility and cost-effectiveness 100 times in various reference applications. Disc, drum and pan filters from numerous OEMs have been successfully optimized in many areas of application. Increase of filter performance of up to 150 % has been achieved.
- 30 % up to 150 % solids capacity increase
- reduced cake moisture
- improved filter operation, maintainability and safety
- higher filter availability
- significant savings in investment – only 10 % to 30 % of costs for new filter investment
- fast realization covered often under the maintenance or operational budget with no need for capital expenditure approvals
Filter Types, OEMs & Applications
|vacuum disc filter||EIMCO, Dorr Oliver, KHD, Krauss Maffei, Thune, Denver|
|vacuum pan filter||EIMCO, Dorr Oliver|
|vacuum drum filter||EIMCO, Dorr Oliver, KHD, Krauss Maffei, Bird Young, Jord, Envirotech, Chemical Plant & Eng., Nivoba, BHS|
Example: Disc Filter Revamping
Typical modifcations of a disc filter
Depending on your target and available funds, a filter revamp can be carried out from a smaller up to a larger package of modifications.
Economy of filter revamps
Revamping vs New Invest
The costs of a filter revamping range from 25 % to 75 % of the price for a new filter. However, it has to be taken into account that the total costs of a new filter investment requires 3 to 4 times the price of the new filter itself due to the additional costs for building, piping, electrics, auxiliary services and engineering.
|Cost Comparison - Revamping vs New Invest|
|Modifications||Cost for revamping related to purchase of new filter||Cost for revamping related to costs for new filter incl. building, installation and commissioning|
|Small Package||25 [%]||approx. 10 [%]|
|Large Package||75 [%]||20–30 [%]|
Example: revamping of 5 disc filters in an Alumina refinery
In an Alumina refinery five disc filters are operated for Al-hydrate seed filtration. Due to a planned increase in production, the filter capacity needed to be increased by 40 %. This corresponded to an additional capacity of two new disc filters of the same type. Instead of installing two new filters, the customer engaged BOKELA to optimize the five existing disc filters with the target to achieve 40% increase in solids throughput.
The necessary increase in performance has been achieved by optimizing four disc filters with a small optimization package and 1 filter with a large optimization package of modifications. The costs for this optimization were only 23 % compared to the total costs for installation of 2 new filters.
|Costs for new filter installation*|
|2 new filters||150 %|
|Building, piping, auxiliary units & engineering||280 %|
|Total cost for new invest||430 %|
* related to total cost for revamping which is set to 100 %
Minimisation of vacuum losses
The aim of a filter revamp is to improve the filter performance in terms of throughput and residual moisture, to solve operating and maintenance problems, to reduce maintenance and operating costs, and to increase availability and operational reliability. In order to exploit the existing potential, all relevant filter components and auxiliary equipment are analyzed. Depending on the objective, most of the filter components can be converted so that they correspond to the latest BOKELA design.
Most of these modifications are made to address capacity and performance issues related to hardware bottlenecks and poor hardware design which results in high vacuum loss.
At the same time, the main problems for the operation and maintenance of the filters are eliminated, such as high wear on many components, poor lubrication, poor access for work during filter operation or for maintenance work.
Why Filter Revamping?
New invest means …
- a lengthy pre-planning phase
- technology and market research (screening)
- OEM research
- complex engineering (new filter systems usually require a new building with new piping, cabling, auxiliary units ...)
- acceptance problems by operating personnel, since new & unknown equipment
Sequence of Filter Revamping by BOKELA
The economic way to get old filters back on track – step by step
Assessment of the improvement potential through BOKELA expert
BOKELA offer for the appropriate revamp package to meet customers requirement
Order placed by customer
Engineering and manufacturing of optimization package
Delivery of optimization package
Installation of optimization package
Re-commissioning of optimized filter(s)
Performance test to verify customer's requirements are met
Disc Filter Revamping
Cake discharge before …
Drum Filter Revamping
Cake discharge before …
Pan Filter Revamping
Cake wash before …
Do you have any questions?
Benefit from our expertise – get in touch with us.
We would be happy to help you out and support you with regard to analyzing and taking a look at implementation issues, optimization potential and other aspects of your filtration system.
Naturally, we keep all your information confidential as stated in our data protection declaration.