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By-product Gypsum (Calcium Sulfate) Efficient Treatment Technology and Analysis of Filter Cloth Application
Release time:
2025-08-25
Among many solid-liquid separation devices, the horizontal vacuum belt filter ( Horizontal Vacuum Belt Filter, HVBF ) has gradually become the mainstream equipment for calcium sulfate treatment due to its continuous operation, automation, and strong adaptability. Industrial filter cloth and vacuum filter cloth, as the core media, ensure the stable operation of the entire filtration process. Xidiase, with rich experience in filtration technology and equipment matching, provides reliable calcium sulfate treatment solutions for many chemical plants.
1. Industry Background of Calcium Sulfate Treatment
1. Main Sources of By-product Gypsum
- Flue Gas Desulfurization : Wet desulfurization in thermal power plants produces a large amount of desulfurization gypsum;
- Phosphate Fertilizer Industry : Phosphoric acid process produces phosphogypsum as a by-product;
- Titanium Dioxide Production : Sulfuric acid process produces calcium sulfate as a by-product;
- Salt Chemical Industry and Other Processes : Reaction of sulfuric acid with calcium-containing substances produces gypsum precipitate.
2. Necessity and Challenges of Treatment
Calcium sulfate slurry usually has fine particles and high moisture content. If piled up without treatment, it not only occupies space but may also cause environmental risks (such as acidic leachate and heavy metal pollution). The main challenges in actual processes include:
- Low solid-liquid separation efficiency; traditional sedimentation or filtration cannot meet the demand;
- Filtrate must meet discharge or reuse standards;
- High moisture content in filter cake leads to high transportation and utilization costs;
- Impurities such as chloride and fluoride ions need to be removed to meet downstream application requirements.
These issues determine the need for an efficient, stable, and sustainable solid-liquid separation process.
2. Principle and Advantages of Horizontal Vacuum Belt Filter
1. Working Mechanism
The horizontal vacuum belt filter is a kind of continuous vacuum filtration equipment , driven by vacuum suction to separate solids and liquids. Its operation process can be divided into the following stages:
- Feed Distribution : Calcium sulfate slurry is evenly spread on the running filter cloth;
- Filtration and Cake Formation : Under the suction of the vacuum box, liquid passes through the filter cloth into the vacuum system, and solids gradually form a filter cake layer;
- Multi-stage Washing : The filter cake is backwashed through a spray system to remove soluble impurities;
- Dehydration and Drying : The filter cake is further dehydrated under vacuum, and some processes add hot air drying;
- Discharge and Cleaning : The filter cake is scraped or backflushed off at the discharge end, and the filter cloth is cleaned online for reuse.
2. Process Advantages
- Continuous Operation , with large processing capacity, suitable for large-scale disposal of by-product gypsum;
- Fast Filtration Speed , with high filtrate clarity, facilitating reuse;
- Multi-stage Countercurrent Washing Capability , effectively removing impurities and improving gypsum purity;
- Low Moisture Content in Filter Cake , beneficial for transportation and utilization;
- High Degree of Automation , requiring little manual intervention and low maintenance costs;
- Strong Adaptability , capable of handling calcium sulfate slurries from different sources and with different properties.
Therefore, this equipment has obvious advantages in chemical plants for calcium sulfate treatment.
3. Role of Industrial Filter Cloth and Vacuum Filter Cloth in the Process
Although the equipment itself determines the overall process framework, whether it can operate stably and achieve ideal filtrate and filter cake ultimately depends on the coordination of industrial filter cloth and vacuum filter cloth.
In the horizontal vacuum belt filter, the filter cloth serves as both the filtration medium and the conveyor and support carrier:
- Solid-liquid Separation Effect : The weaving process and structure of the filter cloth determine the particle retention rate and filtrate clarity;
- Operational Stability : The filter cloth needs to operate for a long time under multiple conditions such as tension, friction, vacuum suction, and washing;
- Cleaning and Regeneration : The filter cloth must maintain good backwashing and self-cleaning performance to avoid vacuum loss due to clogging;
- Service Life and Economy : Extending the filter cloth's service life means fewer equipment shutdowns and lower maintenance costs.
Xidiase focuses on overall matching in filter cloth design rather than relying solely on material optimization. For example, through multi-layer weaving technology, the filter cloth can ensure filtration accuracy while maintaining high air permeability, thereby improving system operation efficiency.
4. Xiamen Citius' Practical Application in Gypsum Sulfate Treatment
1. Process Adaptation
Xiamen Citius provides customized filter cloth and equipment parameter adjustment solutions based on the slurry characteristics of different industries. For example:
- Optimizing filter cloth channel design to improve washing efficiency for the high fluoride and phosphorus impurity content in phosphogypsum;
- Using zoned vacuum filtration to ensure uniform filter cake formation for the poor particle uniformity of desulfurization gypsum;
- Enhancing filter cloth surface treatment to reduce adhesion for the high viscosity of titanium white gypsum slurry.
2. Improvement of Filtrate and Filter Cake Quality
Through multi-stage countercurrent washing, chloride ion and sulfate content in the filtrate are significantly reduced to meet recycling standards; filter cake purity is improved to meet the requirements of downstream building materials, cement, and other industries.
3. Benefits Demonstration
- Environmental Benefits : The filtrate can be recycled, reducing external pollution;
- Economic Benefits : Filter cake moisture content reduced to 40% approximately, lowering transportation and storage costs;
- Social Benefits : By-product gypsum is realized as a resource, promoting the circular economy.
Xiamen Citius' solutions have helped multiple chemical plants transform gypsum from " Waste ” into " Resource ” , creating a good demonstration effect.
Conclusion
As an important by-product in the chemical industry, gypsum sulfate's efficient treatment and resource utilization not only affect corporate economic benefits but also directly relate to environmental protection and sustainable development. In this process, Horizontal Vacuum Belt Filter has become the preferred equipment for gypsum sulfate treatment due to its advantages of continuous operation, automation, and efficient washing. Meanwhile, Industrial Filter Cloth and Vacuum Filter Cloth as key components in the system ensure stable and efficient equipment operation.
Xiamen Citius continuously explores in practice, providing reliable solutions for chemical enterprises through technological improvements and customized services, promoting the transformation of by-product gypsum from " Environmental Burden ” into " to Usable Resource ” Looking ahead, with the development of green chemistry and intelligent manufacturing, industrial filter cloth and horizontal vacuum belt filtration technology will demonstrate their value in more fields.
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