Belt Filter Slurry Redistribution for Crack Sealing
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Solution Overview
Problem
Existing belt filters in the chemical industry face challenges such as inadequate washing of filter cakes, filter cake cracking during filtration, and unequal filtration results, which affect impurity removal and cake discharge efficiency.
Innovation Solution
A method and apparatus that involve re-slurrying the discharged filter cake with a second aqueous solution to form a second slurry, which is then redistributed onto the filter cake for additional washing and sealing, enhancing impurity removal and cake discharge by increasing cake thickness and reducing air exposure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If vacuum is increased to prevent filter cake cracking, then filtration reliability is improved, but energy consumption increases
Solution Approach 1:
The patent applies preliminary action by redistributing slurry onto the filter cake before the vacuum filtration process to pre-seal cracks and prevent air exposure. This preliminary sealing action allows the use of lower vacuum levels while maintaining filtration reliability, as the crack prevention is achieved before vacuum application rather than by relying on high vacuum alone.
2Manufacturing precision
If washing phase is extended to remove more impurities, then product purity is improved, but processing time increases
Solution Approach 1:
The patent implements continuity of useful action by redistributing slurry onto the filter cake and maintaining vacuum filtration continuously. This continuous action ensures thorough impurity removal without requiring extended washing phases, as the slurry redistribution and vacuum filtration occur simultaneously and continuously, improving both purity and process efficiency.
3Reliability
If filter cake thickness is increased to improve sealing, then reliability is improved, but cake discharge difficulty increases
Solution Approach 1:
The patent applies parameter changes by controlling the thickness and distribution of the slurry layer redistributed onto the filter cake. By optimizing these parameters, the system achieves sufficient sealing to prevent air exposure and cracking while maintaining a structure that facilitates easy cake discharge, balancing sealing requirements with discharge operability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces impurities by over 30% and improves cake discharge by sealing cracks, allowing for better liquid removal and reduced air exposure, facilitating easier cake removal and maintaining consistent slurry density for subsequent drying processes.
Implementation Method 1
filtering at least part of the first aqueous solution the first slurry through the filter cloth to form a filter cake onto the filter cloth
Implementation Method 2
passing washing liquid through the filter cake and the filter cloth to form a washed filter cake onto the filter cloth
Implementation Method 3
The filtration of the liquids through the filter cloth is often enhanced by creating a partial vacuum on another side of the filter cloth than onto which the filter cake is formed
Data Source
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AI summary
The method for processing a first slurry comprising first aqueous solution and at least one hydroxide, oxide ,oxyhydroxide or carbonate of one or more metal elements, said one or more metal elements including at least one of Ni, Co and Mn, comprises repeating steps of distributing the first slurry onto a filter cloth of a belt filter, filtering at least part of the first aqueous solution through the filter cloth to form a filter cake, passing washing liquid through the filter cake and the filter cloth to form a washed filter cake and discharging the washed filter cake from the filter cloth. The method further comprises repeating steps of re-slurrying at least a part of the discharged filter cake to a second slurry, distributing a first portion of the second slurry onto the filter cake and/or washed filter cake on the filter cloth.