Probably, you could be having many questions on stainless steel filter discs.
Well, today’s guide has a list of all FAQs on filter discs that will help you understand everything about these accessories.
So, if you want to be an expert in stainless steel filter discs, read this guide:
- What is Stainless Steel Filter Disc?
- Where can you use Stainless Steel Disc Filter?
- How do you Manufacture Stainless Steel Filter Disc?
- Which Grade of Stainless Steel is suitable for Filter Disc?
- What are the Features of Stainless Steel Filter Disc?
- How does Stainless Steel Filter Disc Work?
- What is Stainless Steel Filter Disc Specification?
- Which are the available Types of Weaving of Stainless Steel Filter Disc Mesh?
- How do you Classify Metal Filter Discs?
- What are the Advantages of Stainless Steel Filter Discs?
- Which Industries use Stainless Steel Disc Filter?
- Are there Disadvantages of using Stainless Steel Filter Disc?
- What is Sintered Filter Disc?
- How do you Clean Stainless Steel Wire Mesh Filter Disc?
- Which Factors should you Consider when Choosing Stainless Steel Filter Disc?
- How do Define Filtration Level of Filter Disc?
- How does Stainless Steel Filter Disc compare to other Types of Filter Systems?
- How can you Install Stainless Steel Disc Filter in Filtration System?
- Do Stainless Steel Disc Filter guarantee Accurate Filtration?
- Is there Shape Limitation for Stainless Steel Wire Mesh Filter Disc?
- Are there Self-cleaning Stainless Steel Disc Filters?
What is Stainless Steel Filter Disc?
Stainless steel filter disc
Also known as stainless steel wire mesh filter disc, it is among the different various metal filtration discs.
It is mainly utilized for filtration in diesel engines, pressure filter, chemical fiber and plastic extruder, textile dope filtration, mine, water, foodstuff and other industries.
Stainless steel filter disc facilitates screening or separation of one substance from another, therefore, making it possible for you to remove unnecessary contaminants from solid or fluid.
The manufacturing process of the stainless steel filter disc involves three main stages.
The initial step entails the selection of high quality stainless steel wire which is subsequently punched or weaved.
Ultimately, a suitable material is chosen to wrap the edge.
Stainless steel disc filter
Stainless steel wire mesh filter discs come in different shapes, materials, weaving techniques, filter precision, and edge wrapping materials among other features.
You can design this type of metal filter disc to fulfill your specific needs like flow rate, filter particle size, physical space limitations, and contact liquid.
Where can you use Stainless Steel Disc Filter?
- Filtration of air: air regulator components, air conditioner, filtering corrosive gases, among other applications.
- Filtering Liquid: beverages, cleaning water polluted with ceramics, filtration of corrosive liquids, disposal of sewage water, etc.
- Filtration of solid: food processing industry, coal, glass, among others.
- Filtering oil: you can filter a range of oil such as those in hydraulic systems, refining, edible, petroleum, etc.
- Filtration in other fields: insulation industry, textile industry, chemical industry, pharmaceutical industry, metallurgy, and automotive industry.
- Filtration in irrigation systems: stainless steel filter discs are fitted in micro-irrigation equipment. It can be in the form of micro-irrigation filter discs or automatic flushing micro-irrigation filters.
How do you Manufacture Stainless Steel Filter Disc?
The process of manufacturing stainless steel filter disc consist of the following procedures:
· Testing of the Materials
This step entails testing the quality of materials utilized in the production of this type of metallic filter disc.
It involves determining the type of stainless steel you will use and the materials for wrapping the edges.
· Wire Testing
In this stage, you test the wire strands that you will use to weave the mesh of the stainless steel filter disc.
· Channel Regulations
In this stage of manufacturing stainless steel filter disc, you modulate the parameters such as size and number of a micron.
The procedure puts the variables in place prior to starting the process of manufacturing.
There are various weaving techniques for metal filter disc based on the use of the stainless steel filter disc.
The choice of method of weaving relies on the specifications of the customer.
· Quality Testing
This procedure entails examining the quality of the stainless steel wire mesh filter disc.
Quality testing ensures that the product conforms to all relevant standards and is safe for use.
Which Grade of Stainless Steel is suitable for Filter Disc?
The key grades of stainless steel appropriate for production of stainless steel type of metal filter disc comprise of:
- Stainless-steel 304which constitutes nickel and chromium metals that are non-ferrous elements.
- Stainless-steel 304Lwhich has a higher quantity of carbon content in comparison to stainless steel 304.
- Stainless steel 316 which comprise of manganese, silicon, carbon, nickel and chromium elements.
- Stainless steel 316Lwhich has a lower quantity of carbon content in comparison to stainless steel 316.
What are the Features of Stainless Steel Filter Disc?
Filter disc system
SS disc filter system offers excellent resistance to both alkali and acid.
Therefore, this makes it a perfect solution for hostile environments such as filtering sour gases.
- Physical properties: high strength, high dirt holding potential, accurate filtration rating, high tensile force, resistance to high temperature, resistance to high pressure, resistance to wear and abrasion.
- Chemical properties: Resistance to acid and alkali
- Process properties: precision punched burr-free, uniformly controlled porosity, easy loading, and unloading, compatible with most fluids, long service life, weldable, reusable and cleanable, among others.
How does Stainless Steel Filter Disc Work?
Knowing the in-point and out-point is important in understanding the working principle of stainless steel filter disc.
The right linkage between these two points ensures the efficient performance of the stainless steel wire mesh filter disc.
The fluid involved in the filtration process flows into a suction section through the filter casing.
As fluid moves, the filter mesh captures and retains the unwanted particles.
This operation goes on until the filter basket gets full that it cannot retain more contaminants.
To ensure an efficient filtration process, you remove the filter basket and clear out the contaminants.
To clean the filter mesh basket, you can either stop the filtration process or clean the basket concurrently as the operation carries on.
Whatever way you choose relies on the type of stainless steel filter disc you are utilizing.
Consequently, the filtered fluid flows via the outlet and is fit for use based on your application.
It is important to note that pressure plays a crucial role in making sure there is an efficient filtering of the fluid.
What is Stainless Steel Filter Disc Specification?
Wire mesh filter disc
When specifying a stainless steel filter disc, make sure you are clear on the following parameters to your supplier.
- Filter disc materials: copper wire, aluminum wire, black wire, brass wire, stainless steel wire, galvanized steel wire, phosphor bronze wire, etc.
- Disc diameters
- Wire diameters
- Shape of the disc: it may include ring/round, crescent, rectangular, oval, square or any other shape.
- Types of weaving: there are many options such as plain Dutch, plain weave, twilled Dutch, etc.
- Layers: single or multiple layers.
- Edge processing methods: wrapping edge, spot welding, or no edge processing.
- Marginal materials: rubber, copper, stainless steel, aluminum, etc.
- Filter precision
Which are the available Types of Weaving of Stainless Steel Filter Disc Mesh?
There are different weaving types applicable for metal filter discs.
Let’s look at the commonly used weaving types for stainless steel filter disc:
· Plain Weave
This is the most often used and simplest weaving type for stainless steel wire mesh filter discs.
Each warp wire passes one after another above and below the wires running diagonally across the mesh at right angles.
The weft and warp wires utilized have a similar diameter.
You can use plain weave stainless steel filter mesh in a broad variety of applications.
· Twilled Weave
Twilled Weave stainless steel filter disc mesh is manufactured by weaving every fill wire alternately above and below two warp wires.
Staggering on consecutive warp wires gives the pattern an impression of parallel diagonal lines.
This method of weaving stainless steel filter mesh facilitates the use of proportionally heavier wires in a specific mesh count than is achievable in plain weave.
Twilled weave stainless steel wire mesh filter disc has a wide application able to support immense loads and finer filtrations.
· Dutch Plain Weave
In this type of stainless steel filter disc mesh weaving, you use bigger warp wires than weft wires.
Dutch plain weave utilizes coarse mesh within the warp and comparatively smaller wire within the fill.
This weaving type has a greater strength coupled with very fine holes, mainly utilized as a filter cloth.
Dutch plain weave stainless steel filter disc has a high resistance to pressure load and high filtration level.
· Dutch Twilled Weave
This method of weaving filter disc mesh involves a blend of the features of the twilled weave and Dutch weave.
Fill wires are woven alternately above and below two warp wires creating a coarse mesh in one direction and a fine mesh in the other.
Dutch twilled weave has finer holes in comparison to the twilled weave and can support greater loads compared to the Dutch weave.
You can use this weaving type in applications that involve the filtering of heavy material.
· Reverse Weave
You produce this type of stainless steel filter disc weave by using a fine mesh having a comparatively smaller wire within the fill and a coarse mesh in the warp.
Reverse weave leads to greater strength with the metal filter disc having very fine holes.
The shape and location of the holes assist retention of particles and enhance filtration process.
· Five Heddle Weave
This type of weaving of stainless steel filter disc mesh is done by passing every fill wire alternately above and below five warp wires.
It is staggering of the pattern on consecutive warp wires, which give the image of parallel diagonal lines.
Five heddle weave facilitates the use of proportionally weighty wires in a specific mesh count than is achievable in other types of stainless steel filter mesh weave.
Filter disc mesh of this type has a variety of applications and can support greater loads.
How do you Classify Metal Filter Discs?
You can classify metallic filter discs based on:
Stainless steel filter disc
- Material for filter disc is stainless steel although you can find other made from different materials such as copper, galvanized steel, etc.
- The technology: woven wire mesh filter disc, expanded metal filter disc, and perforated metal filter discs.
- Edge processing method: edge wrapping filter, spot welding filter.
- Weaving type: twill weave filter disc, plain weave filter disc and Dutch weave filter discs among other weave types.
What are the Advantages of Stainless Steel Filter Discs?
Stainless steel filter disc is highly durable making it the ideal choice for your applications.
It is long lasting since it does not react with a number of fluids.
This makes sure that you have full potential of your stainless steel wire mesh filter disc.
The longevity as well reduces your operating costs in the long term.
Stainless steel wire mesh filter disc gives you the freedom to use it in a variety of applications.
This is due to the unique chemical and physical properties of stainless steel filter discs.
These properties comprise of their corrosion, acid and alkali resistance, operating pressure and temperature and compatibility with various fluids.
This type of metal filter disc ensures efficiency in its performance.
The efficiency of stainless steel filter disc guarantees that you attain the desired level of filtration.
· Ease of Cleaning
Wire mesh filter discs made of stainless steel high level of hygiene since they are easy to clean.
This makes it possible to use them in hygiene-sensitive applications like in the food and beverage industry.
Moreover, the silvery appearance of stainless steel boosts the aesthetic appeal of the filter disc while ensuring the general hygiene of your operations.
Which Industries use Stainless Steel Disc Filter?
Stainless steel filter disc often find application in the following industries:
Filter disc system
· Mining Industry
The mining industry extensively uses filter mesh made from stainless steel.
This type of metallic filter discs plays a crucial role in the separation of mineral deposits from their primary cores.
This enables the removal of pure minerals like diamonds and gold.
In addition, they as well aid in the filtration of sludge to prevent environmental pollution.
· Chemical Industry
The essence of stainless steel filter disc in the chemical industry is to facilitate proper blending and filtration of the different chemicals used.
Correct mixing and filtration of chemicals make the end product to satisfy the needed chemical levels and standards.
Furthermore, proper filtration avoids the adverse negative impacts of final product having the wrong chemicals.
· Food Industry
Stainless-Steel filter discs find extensive use in the food and beverage industry as it is crucial in the manufacture of consumer-friendly products.
This is due to the ease of cleaning this type of metal filter disc which in turn promotes hygienic working conditions.
In soft drinks, the metallic filter mesh is employed in fruits and chemical filtration to get the needed proportions.
Additionally, they help in the removal of impurities in the production of confectioneries.
· Pharmaceutical Industry
Drugs are delicate products that need a suitable hygienic process of production.
The high efficiency of filtration using stainless steel filter disc guarantees removal of unwanted substances and particles from the ingredients of the drugs.
This is coupled with the hygienic conditions provided by stainless steel due to the ease of cleaning it.
· Industrial Water Filtration
In the filtration of industrial water, metal filter discs made of stainless steel play an essential role in the removal of unwanted particles.
Besides, they remove harmful chemicals from the water prior to injecting it back into the system.
This ensures efficient usage of water through recycling.
Are there Disadvantages of using Stainless Steel Filter Disc?
Yes, some of the disadvantages of stainless steel filter discs include:
The initial cost of buying a stainless steel filter assembly is comparatively high.
This means that you should prepare sufficiently before buying one for your operations.
· Frequent Maintenance
This type of metal filter disc needs to be maintained frequently for it to continue working efficiently.
The maintenance includes frequent removal of dirt and cleaning, which usually a lot of time and resources.
What is Sintered Filter Disc?
Sintered stainless steel filter disc
Also referred to as a sintered wire mesh filter disc, sintered filter disc is a blend of several layers of filter discs like perforated or woven filter mesh.
The woven or perforated layers of filter mesh are vacuum sintered to form one sinter filter disc.
This is one of the commonly used filtration media which normally has between 3 to 8 layers.
Typically, it has five layers which consist of skeleton layer, support skeleton layer, dispersion layer, filtration control layer and cover layer.
Based on the material used to make it, you can classify it into:
- Copper sintered filter disc
- Bronze sintered filter disc
- Galvanized steel sintered filter disc
- Stainless steel sintered filter disc
Still, SS sintered filter discs are the most popular.
Sintering is a procedure that creates fusion bonds all contact parts of the woven or perforated wire mesh in high temperature and vacuum environment.
It maintains the consistency of the original weave and determines micron rating of the filter mesh, size, and shape of holes.
Depending on which provides high strength rigidity, sintered wire mesh filter discs can be mono- or multi-layered.
You can find them in various shapes such as square, oval, toroidal, round or fan-shaped.
Moreover, based on customers’ specifications, you can add outer rings to the sintered metal filter discs.
Sintered type of filter disc finds use infiltration process in various industries.
Guaranteeing long service life, you can use them in fluid filtering in chemical fiber, petrochemical, food, and pharmaceutical industry among other industries.
How do you Clean Stainless Steel Wire Mesh Filter Disc?
There are several methods of cleaning stainless steel filter disc, with the choice of each method depending on your type and level of operation.
Let’s look at some of the common methods of how to clean metal filter disc.
Disc filter system
1) Blowback and Backwash Flushing
This is the simplest method of cleaning filter discs and is the routine technique recommended for stainless steel wire mesh filter discs.
For backwash flushing to work successfully, it depends on the reverse flow of fluid to dislodge and carry particles away from the media structure.
The fluid used is normally filtrated or another process compatible fluid.
Blowback and backwashing technique relies on loose attachment of the particles on or within the holes of the filter mesh.
When you use gas as the pressure source instead of liquid, it generates much turbulence as the generated pressure force the gas/liquid mixture through the filter disc mesh.
This dislodges trapped particles and aid in removing them from the mesh structure.
2) Soak and Flush
This method of cleaning stainless steel filter disc refers to the use of a detergent solution.
In this technique, you allow the filter disc to soak adequate enough for the action of the detergent to loosen particles then you flush them out of the filter media.
You can carry out this procedure in process stainless steel filter discs or with small components in a laboratory.
3) Circulation Flows
In this method of cleaning wire mesh filter disc, you need a cleaning system to help in pumping and circulating a cleaning solution across the filter mesh until it is clean.
The circulation is usually in the opposite direction from which the filter disc mesh was soiled.
You must filter the cleaning solution before returning it to the filter media.
4) Ultrasonic Baths
In this technique, you require special equipment that employs ultrasonic sound waves to trigger off particles and remove them from the filter mesh.
You can use laboratory models of this equipment to easily clean small stainless steel filter discs whereas bigger ones need big tank equipment with high power inputs.
Ultrasonic cleaning, in conjunction with the right detergent solution, is the most efficient method of cleaning filter discs, particularly in the case of deeply embedded particles.
5) Furnace Cleaning
This is a simple technique of cleaning metallic filter discs by volatilizing or burning biological or organic compounds.
It is most effective for removing polymer materials.
Furnace stainless steel filter disc cleaning is suitable for substances that leave no residual ash, otherwise, you will need additional cleaning method to remove the ash residue.
6) Hydro Blasting
Hydro blasting cleaning techniques usually supersedes other cleaning techniques when the particles have grossly obstructed the holes of the filter mesh.
You can employ this method to clean, for example, filter discs in cross-flow tubes.
The high-pressure water jet removes the trapped particles through high-energy impaction.
It does not go very deeply into the filter mesh, however, in most instances, the obstruction may be only at the filter media surface.
It is commonly applied in plants, usually used to clean heat exchanger tubes.
Which Factors should you Consider when Choosing Stainless Steel Filter Disc?
Selecting the right filter disc to ensure the efficiency of your filtration system, therefore, you should consider the following factors when choosing a stainless steel filter disc:
· Type of Filter Media
There are different filter media types such as random metal fiber, photo-etched, and sintered filtration media, with each having its own advantages and disadvantages.
Therefore, you need to choose a stainless filter disc with the right filtration media for your applications.
· Type of Stainless-Steel used
Stainless steel comes in various kinds, with each type having its advantages that are fit for different purposes.
For that matter, it is crucial to ascertain the individual characteristics of the material used to make a filter disc before buying one.
Such characteristics consist of pressure and temperature limits and reactions to other compounds and conditions.
· Mesh Number
This is the number of holes per inch of a stainless steel filter mesh.
If the mesh number is big, it indicates that there are numerous holes per inch of the filter disc mesh.
It as well signifies that the individual holes are small in size and vice versa.
· Mesh Size
The mesh size designates the size of individual holes on the mesh of the stainless steel filter disc.
It is always measured in millimeters, microns or fractional inches.
· Strand Diameter
This is a crucial consideration when selecting a stainless steel filter disc.
When a wire has a broad strand diameter, it signifies that it has tiny mesh holes.
In short, the larger the diameter of the strand, the greater the mesh number of the stainless steel wire mesh filter disc.
The diameter of the strand is a percentage of the overall surface area of the stainless steel filter mesh, i.e., the percentage open area.
Therefore, when you have a greater percentage of open area, it indicates that the filter disc has a high flow.
· Filament Diameter
This parameter affects the mesh openings and the percentage open area of the filter mesh.
· Fluid Compatibility
You should make sure that the stainless steel filter disc is well-matched with the fluid you want to filter.
This helps in avoiding any reaction between the filter disc and the fluid involved since any reaction will impact negatively on the quality of the filtration process.
How do Define Filtration Level of Filter Disc?
The quality of filtration is based on the size and amount of particles that the filter disc is capable of retaining.
High quality filtration basically implies cleaner fluid. Higher quality filtration simply means cleaner water.
This relies on the geometry of the channels, consisting of angle, length, size, and number of created intersection points.
Typically, stainless steel filter discs are color coded to indicate the filtration level.
Normally, the quality of filtration is measured in microns, dependent on the tiniest size of particle filtered.
Tin most cases, it ranges from 25 microns for the finest filtration level to 400 microns for the coarsest level of filtration.
At times the filtration quality is denoted as the similar mesh size of a proportional screen filter.
Usual mesh sizes span from 40 to 600 and when applying mesh sizes, 600 is the finest or highest filtration level and 40 is the coarsest.
How does Stainless Steel Filter Disc compare to other Types of Filter Systems?
1. Mesh Filter Disc
Filter discs of this type are available in pleated and flat models. Your choice of the type of mesh filter disc to use will depend on requirements of your application.
This is the best type of filter system for cleaning and safeguarding liquid and gas flow systems.
They are economical and can offer an exceptional increase in the filtration area for the similar installation.
2. Fiber Filter Discs
There exist various types of fiber filter discs available for use in both liquid and gas filtration systems.
They as well come in flat and pleated versions suitable for different application requirements.
The flat fiber filter disc is a cost effective one that helps you save space and money.
However, it might not be efficient to utilize it in fluids with little contaminants.
On the other hand, you can opt for pleated fiber filter disc which has a smaller footprint, very low pressure drop and a bigger area of filtration.
The designs come with different micron ratings and filtration rates.
3. Powder Filter Discs
This type of filter system comes in different sizes and designs, with sizes varying in thickness and diameter.
The production of powder filter discs having diverse porosity employ the powder metallurgy technique.
They have different micron grades ranging from 0.003 to 200 micrometers and density from 35% to 75%.
4. Manual Filter Disc
If you want an efficient filter system that requires minimal maintenance, then a manual filter disc is the ideal choice.
It comprises of several plastic rings that adhere together to form a cylindrical filter element.
The rings, as water moves across the manual filter disc, compress and efficiently obstruct the contaminants.
In the process, it hinders the obstruction of the filtration system with many contaminants.
Note that manual filter disc works effectively as stand-alone equipment though you can as well combine it to create a chain of filter discs.
They come in various sizes spanning from ¾” to 6” having varying micron ratings from 40 to 200.
5. Automatic Filter Disc
This type of filter systems has the same working principle as manual filter disc, with the only dissimilarity being in the cleaning system.
It comes with an automatic backwash flush cleaning mechanism that is instrumental in removing trapped particles from the automatic filter disc.
· Bag Filter
Also referred to as a baghouse, fabric filter, or baghouse filter system is an air pollution control gadget and dust collector.
It eliminates gas or particulate matter ejected from commercial activities out of the air.
Pharmaceutical producers, steel mills, chemical manufacturers, food producers, power plants and other industrial facilities usually use bag filters to control air pollutants emission.
Majority of baghouse filters utilize long, cylindrical bags or tubes fabricated from felted or woven fabric as a filtration media.
At times you can use pleated, nonwoven cartridges as filter media in place of bags in applications where gas temperature is 121 °C or below and there is comparatively low dust loading.
There are exist various types of bag filters including reverse air, pulse jet, and shakers type, with pulse jet bag filter being the most efficient one in terms of filtration quality.
This is a micro-filter having size ranging from 1 to 25 um (micron).
It is composed of thin plastic fibers or some other tiny filtration medium that is fixed about a central tube to create a standard-size cartridge.
However, the filter media of can be made from several materials, with some produced from wound strands of a substance such as polypropylene.
This type of filter system has a cartridge enclosed inside a housing and utilized to eliminate pollutants, chemicals and unwanted particles from liquids.
The cartridge is subjected to solvent, water or liquid that requires filtration, as it moves within the housing and goes across the filter element.
It can as well eliminate submicron particulates.
How can you Install Stainless Steel Disc Filter in Filtration System?
Installing a stainless steel filter disc is a straightforward operation that you can perform on your own.
However, you will need to follow the installation guideline to take you through the process of installation.
Alternatively, you can engage a technician to assist you with the procedure.
You need to make sure that you have all the tools required to open the filter disc housing and ensure that the filtration system is under no pressure, since this might lead to injury.
In addition, you should wear the right protective clothing like gloves.
To install the stainless steel filter disc, open the top casing of the filter disc housing by freeing the holding clamp.
Pull out the tightening cylinders and install the filter discs, after which ascertain if the discs are of the right number.
After installing the filter discs, make sure that they align properly in the system.
Return in position the tightening cylinder, then fasten the butterfly nut that clasps the stainless filter disc.
Finally, replace the top casing of the filter housing and then fasten the holding clamp appropriately.
Do Stainless Steel Disc Filter guarantee Accurate Filtration?
Yes, stainless steel wire mesh filter disc ensures accurate filtration thanks to its very fine gauge mesh.
The mesh traps solid contaminants, which enables high filtration accuracy and facilitates easy backwash flushing.
Is there Shape Limitation for Stainless Steel Wire Mesh Filter Disc?
No, you can find stainless steel filter discs of various sizes, shapes and weaving types.
They come in various shapes such as square, oval, round, toroidal, and rectangular among others.
All can be manufactured based on your specific requirements.
Are there Self-cleaning Stainless Steel Disc Filters?
Yes, there exist self-cleaning filter disc filtration systems.
The systems are perfect for applications that Use costly process fluids.
Or, applications that involve high replacement and/or disposal cost of filter media and where it is undesirable to expose the employees or environment to the process fluids.
There are different self-cleaning filter discs types; the first being mechanically washed disc filter systems.
It physically removes trapped particles using a scraper off the surface of the filter mesh.
Second, there are backwashing disc filter systems capable of restoring the filter media by reversing flow across it.
Back flush filter systems can extract suspended solid particles of roughly a micron or greater.
Self-cleaning stainless steel filter disc functions efficiently in process with water-like jet at flow rates usually of hundreds to thousands of liters every minute.
All self-cleaning stainless steel filter discs are pressure filters since they require specific lowest working pressure.
Additionally, these systems produce a waste flow that you need to take care of through either discarding or reprocessing.
In short, stainless steel filter discs play an important role in hydraulic system.
All you need is to understand the technical specification and application requirements.
Additionally, FilSon team is also ready to help you make the right choice when it comes to stainless steel filter discs.