Multilayer Metal Mesh and Powder Composite Filter Element
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Solution Overview
Problem
Current metal filter elements used in high-pressure and high-temperature conditions in the petrochemical and steel industries suffer from low filtration flux and filter fineness, leading to equipment damage and reduced yield.
Innovation Solution
A method for producing composite filter tubes and elements made of multilayer metal mesh and metal powders, involving the creation of a layered metal mesh structure with increasing mesh density, sintering, and the application of a metal powder filtering layer via electrostatic or common spraying, followed by rolling and welding to form a tubular filter element with low filtration resistance and high pressure-withstand capability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If filter fineness is increased to meet catalyst leakage prevention requirements, then filtration quality improves, but filtration flux decreases leading to higher energy consumption
Solution Approach 1:
The filter element is segmented into multiple functional layers: a supporting layer made of metal mesh and a filtering layer made of sintered metal powder. This segmentation allows each layer to perform its specialized function - the mesh provides structural support and initial filtration, while the metal powder layer provides fine filtration with high flux capability
Solution Approach 2:
The invention uses composite materials combining metal mesh and sintered metal powder in a layered structure. The metal mesh offers mechanical strength and coarse filtration, while the sintered metal powder provides fine filtration pores for high flux, creating a composite filter that achieves both fine filtration and high productivity
2Productivity
If filtration flux is increased to reduce energy consumption, then energy efficiency improves, but filter fineness decreases leading to catalyst leakage
Solution Approach 1:
The filter element is segmented into multiple functional layers: a supporting layer made of metal mesh and a filtering layer made of sintered metal powder. This segmentation allows each layer to perform its specialized function - the mesh provides structural support and initial filtration, while the metal powder layer provides fine filtration with high flux capability
Solution Approach 2:
The invention uses composite materials combining metal mesh and sintered metal powder in a layered structure. The metal mesh offers mechanical strength and coarse filtration, while the sintered metal powder provides fine filtration pores for high flux, creating a composite filter that achieves both fine filtration and high productivity
3Power
If metal filter elements are used in high pressure conditions, then processing capability improves, but filter fineness decreases causing equipment damage
Solution Approach 1:
The filter element is segmented into multiple functional layers: a supporting layer made of metal mesh and a filtering layer made of sintered metal powder. This segmentation allows each layer to perform its specialized function - the mesh provides structural support and initial filtration, while the metal powder layer provides fine filtration with high flux capability
Solution Approach 2:
The invention uses composite materials combining metal mesh and sintered metal powder in a layered structure. The metal mesh offers mechanical strength and coarse filtration, while the sintered metal powder provides fine filtration pores for high flux, creating a composite filter that achieves both fine filtration and high productivity
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
The composite filter elements exhibit a significant increase in filtration flux by 10-50% and improved pressure resistance, enhancing the overall performance and yield of S-Zorb and hydrotreating units.
Implementation Method 1
put the layered structure in a vacuum furnace for 10 ̃30 hrs uninterruptedly sintering at 900 ̃1500° C. to obtain a multilayer metal mesh
Implementation Method 2
make a metal composite layer made of metal powders with a mesh number of 100 ̃600 on a side with higher mesh number through electrostatic spraying or common spraying and casting method
Implementation Method 3
sinter the metal composite layer together with the multilayer metal mesh at 900 ̃1500° C.
Implementation Method 4
weld a middle seam of the tubular filter element with an argon arc welding machine or plasma welding machine
Implementation Method 5
weld a middle seam of the tubular filter element with an argon arc welding machine or plasma welding machine
Data Source
AI summary
A method for producing a composite filter tube and filter element made of a multilayer metal mesh and metal powders, including: knitting to obtain metal meshes of different mesh numbers, obtaining a layered structure by means of a lamination method, then putting the layered structure in a vacuum furnace for sintering processing, sintering a metal composite layer to obtain a composite filter sheet and tube made of a multilayer metal mesh and metal powders with a multilayer metal mesh as a structure support layer and a metal powder sinter structure as a filter layer, then rolling the composite filter sheet and tube into a tubular filter element by using a shaping machine, and welding to obtain a composite filter tube and filter element product made of a multilayer metal mesh and metal powders.