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Industrial filter cloth application: horizontal vacuum belt filter, nickel industry filter slag
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Detailed Description
- Industrial filter cloth application: Horizontal vacuum belt filter for nickel industry slag filtration
Filter type: Horizontal vacuum belt filter
Application industry: Nickel industry
Material description: Slag
Application research of industrial filter cloth in horizontal vacuum belt filter for nickel industry slag filtration
I. Challenges in slag processing in the nickel industry
Against the backdrop of the booming global new energy industry, nickel, as an important metal for battery materials, has seen rapid development in its mining and smelting industry. Especially in the hydrometallurgical process (such as HPAL process), after leaching, precipitation, and separation of nickel ore, a large amount of high-humidity, fine-grained slag will be produced. This slag not only has a large volume and high water content, but also has certain corrosiveness and viscosity, which poses considerable challenges to solid-liquid separation.
Traditional processing methods often fail to achieve a good balance between efficiency, filtrate clarity, and filter cake moisture content. Among many separation technologies, horizontal vacuum belt filter has been increasingly used in the treatment of nickel industry slag due to its continuous operation, thorough dehydration, and stable operation. In this process, industrial filter cloth as a key filtration medium, its performance directly determines the filtration effect and operating cost.
II. Principle and characteristics of horizontal vacuum belt filter
A horizontal vacuum belt filter is a continuous negative pressure filtration equipment suitable for handling large flow rates, fine particles, difficult-to-settle, and easily blocked slurry materials. Its working principle is as follows:
- Slurry distribution : Nickel slag slurry is evenly spread on the filter cloth surface;
- Vacuum suction : The vacuum system creates a pressure difference through the filter cloth, causing the liquid phase to quickly permeate through the filter cloth, and the solid particles are retained on the filter cloth surface to form a filter cake;
- Washing and drying : The filter cake is washed by spraying water, and the water content is reduced by air blowing or drying;
- Filter cake removal : The filter cloth automatically discharges the cake by rotation and then enters the next cycle.
This process puts high demands on the mechanical strength, corrosion resistance, filtrate permeability, and regenerability of the filter cloth. Especially under the conditions of fine particle size, strong corrosiveness, and easy blockage of nickel slag, it puts even more stringent tests on the performance of industrial filter cloth.
III. Key points of industrial filter cloth application in nickel slag filtration
1. Filter cloth selection should match process characteristics
In horizontal vacuum belt filters, nickel slag is often weakly acidic or contains ammonia liquid, which has a certain corrosiveness. The filter cloth must have the following characteristics:
- Excellent chemical stability ，acid and alkali resistance;
- Fine pore structure ，suitable for intercepting fine particles with a particle size of 5~25 microns;
- High mechanical strength ，able to withstand tension and wear under repeated operation;
- Good stripping performance ，facilitating automatic filter cake shedding and reducing downtime for cleaning.
Taking Xiamen Citius (Xiamen Citius) as an example, it provides customized single-filament and multi-filament composite filter cloths for nickel industry users, using high-strength PET and PP modified materials, and through special weaving technology to achieve " High throughput + Low blockage + Easy cleaning ” goals.
2. Improve filtrate clarity to meet environmental protection and recycling needs
In the nickel industry production process, the filtrate often contains recoverable metal ions, requiring high clarity. High-quality filter cloth, through optimized pore size distribution and surface treatment technology, can achieve a filtrate turbidity of less than 50NTU or even lower, which is conducive to subsequent solution recovery and environmentally compliant discharge.
3. Reduce operating costs and improve stability
Nickel slag filtration is a high-frequency, high-load operation. The stability of the filter cloth performance directly affects the operating efficiency and maintenance frequency of the production line. Xiamen Citius (Xiamen Citius) through a triple quality control system (fiber screening → weaving control → finished product inspection), ensures the consistency and durability of filter cloth batches, with an average lifespan increase of 15%~25% ，effectively reducing the replacement frequency and downtime risk.
IV. Typical application case sharing
A nickel slag processing line project in Indonesia HPAL Project
- Filtration equipment ：6 large horizontal vacuum belt filter
- Materials processed ：Wet-process residue from nickel laterite ore smelting, solid content approximately 20~30%
- Filter cloth selection ：Xiamen Xiadias (Xiamen Citius) Custom-made composite fabric, pore size 8~12μm ，covered with PTFE layer
- Application effect ：
- Filter cake moisture content stable at 28% or below;
- Improved filtrate clarity 30% ，can be directly reused in the washing section;
- Filter cloth replacement cycle from the original 20 days extended to 30~35 days;
- Overall processing cost decreased by approximately 12%。
- Filter cake moisture content stable at 28% or below;
This project shows that the reasonable selection and combination of high-performance filter cloth can significantly improve the filtration efficiency of nickel ore slag and optimize the resource recovery rate of the entire process.
V. Future Development Direction and Technological Trends
1. Functional surface modification technology
With the development of nanomaterials and functional finishing technologies, the filter cloth surface can be endowed with hydrophobic, hydrophilic, oil-resistant or anti-scaling properties, and will perform more stably in complex nickel industry conditions.
2. Intelligent monitoring and operation data analysis
Although industrial filter cloths have not yet fully achieved " intelligent monitoring ” ，but combining the operation data of the filter press (such as vacuum degree, filtrate flow rate, pressure difference change, etc.) to indirectly monitor the filter cloth status will become an important direction for improving maintenance efficiency.
3. Modular replacement and standardized production
In response to the global capacity expansion trend of the nickel industry, modular filter cloth structural design and mass-reproducible manufacturing capabilities will become one of the key competitive advantages for suppliers to participate in overseas projects in the long term.
VI. Conclusion
In the process of the nickel industry developing towards high efficiency, greenness, and intelligence, solid-liquid separation, as a key node for resource recovery and environmental protection standards, its technical level directly affects the economic efficiency and sustainability of the project. Horizontal vacuum belt filter presses, with their continuous and efficient characteristics, show great potential in the treatment of nickel ore slag. As its " core medium ” ，the quality of industrial filter cloth directly determines the filtration quality, operating cost, and equipment life.
Xiamen Xiadias (Xiamen Citius) and other companies, relying on years of R&D accumulation in the field of filtration materials, are continuously optimizing the structure and functional design of filter cloths to provide customized, high-performance, and sustainable filtration solutions for the nickel industry, helping the high-quality development of the new energy materials industry.
📞 For technical support or sample testing services, please contact Xiamen Xiadias (Xiamen Citius) ：
- Email: wyl@citius-filter.com
- WhatsApp: +86-13950107241
- Official website : www.citius-filter.com
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