China Leaf Disc Filter Factory
Custom Leaf Disc Filter in China
Leaf disc filters are used as filters or screen elements in most applications. Typical fields of application include filtration of extruded polymers and use as elements in solid, liquid, or air filtration applications.
We use die-cutting technology to produce large quantities of leaf and individual filters, and our laser systems specialize in producing wire mesh. All meshes can be used to make black filters, from the finest twill Dutch weave to highly rigid square meshes.
The system often includes an automatic backwash mechanism to clean the discs and maintain continuous operation. Leaf disc filters are employed in water treatment, irrigation systems, industrial processes, and aquaculture to ensure liquid purity and protect equipment.
Advantages include high efficiency, automatic cleaning, durability, and scalability. Regular monitoring and compatibility of materials with the filtered liquid are crucial for optimal performance. These filters are essential for maintaining clean water and processing fluids in various applications.
ProductS
Advantage of Leaf Disc Filter
High Filtration Accuracy
Leaf disc filters are known for their high filtration accuracy. This makes them particularly effective. They are effective in various industrial and agricultural applications.
Corrosion ＆ Abrasion Resistance
Leaf disc filters have a combination of corrosion resistance and abrasion resistance. This combination makes them highly suitable. They are suitable for demanding industrial applications.
Long Service Life
The long service life of leaf disc filters is the result of their robust construction, efficient cleaning mechanisms, high dirt-holding capacity, low maintenance requirements, modular design, and resistance to harsh operating conditions.
Custom Leaf Disc Filter
Creating a custom leaf disc filter involves cutting uniform leaf discs, infiltrating them with a sodium bicarbonate and soap solution, and using a syringe to create a vacuum to ensure infiltration. Place the discs in a petri dish with the bicarbonate solution under a consistent light source.
Start a timer when the light is applied; photosynthesis will cause the discs to float due to oxygen production. Record the floating times as a measure of photosynthetic rate. Ensure uniform disc size and proper infiltration for consistent results. Keep light conditions constant and include a control group with distilled water for comparison. This method allows for the study of photosynthesis rates and the impact of different conditions on plant biology.
Leaf Disc Filter Structure
The polymer leaf disc filter comprises the main body, hub, and star support frame.
Main Body
- Protective layer. Usually, it’s constructed from stainless steel, serving as a shield for the filter media.
- Filtration layer. Take on the primary role in filtration.
- Support layer. Provide crucial support to the filtration layer.
- Drainage layer. Direct the clean melt to flow towards the center tube.
- Mesh support layer. Provide support for the entire mesh structure.
Support Frame
- Maintain the spacing between adjacent disc filters and ensure even fluid flow towards the center tube.
Hub
- Hard hub
- Semi-hard hub
- Soft hub (it is not recommended for micron rating at10 um and below)
Leaf Disc Filter Working Principle
Insert the multiple installed leaf disc filters into the horizontal filter housing. Contaminated melt enters through the inlet and flows towards the filter elements from both the top and bottom. Gel impurities are captured on the filter surface, allowing only clean melt to flow into the center tube via the hub holes, and then out of the vessel.
Leaf Disc Filter Technology Help you Know Better
Specification
Materials | stainless steel 304/316L, Monel, or other alloys |
Forms | sintered metal fiber, sintered metal powder, sintered wire mesh, etc |
Filtration Accuracy | 0.5 micron to 200 microns |
Tolerance Temperature | up to 400°C |
Pressure Differential | 5 MPa to 12 MPa |
Outer Diameter | 6 inches to 12 inches |
Inner Diameter | 38.2 mm to 85 mm |
Thickness | 6.5 mm to 10.5 mm |
Operation Pressure | 30 MPa |
Porosity | 70% to 85% |
Ordering Quantity | 50pcs |
Note: the above sheet is for reference purposes; custom sizes are available.
Specification of Polymer Leaf Disc Filters
O.D. (inch) | O.D. (inch) | I.D.(mm) | Thickness(mm) | Filter Area (m²) |
6 | 152.4 | 38.2 | 6.5 | 0.032 |
7 | 177.8 | 38.2 | 6.5 | 0.048 |
7 | 177.8 | 47.6 | 6.5 | 0.046 |
7 | 177.8 | 63.5 | 6.5 | 0.044 |
7 | 177.8 | 85 | 6.5 | 0.038 |
10 | 254 | 47.6 | 7.2 | 0.082 |
10 | 254 | 85 | 6.5 | 0.08 |
12 | 304.8 | 63.5 | 6.5 | 0.13 |
12 | 304.8 | 85 | 6.5 | 0.12 |
12 | 304.8 | 85 | 7 | 0.12 |
12 | 304.8 | 85 | 7.5 | 0.12 |
Note: Other specifications are available upon request.
Specification of Polymer Leaf Disc Filters
O.D. (inch) | O.D. (inch) | I.D.(mm) | Thickness(mm) | Filter Area (m²) |
6 | 152.4 | 38.2 | 6.5 | 0.032 |
7 | 177.8 | 38.2 | 6.5 | 0.048 |
7 | 177.8 | 47.6 | 6.5 | 0.046 |
7 | 177.8 | 63.5 | 6.5 | 0.044 |
7 | 177.8 | 85 | 6.5 | 0.038 |
10 | 254 | 47.6 | 7.2 | 0.082 |
10 | 254 | 85 | 6.5 | 0.08 |
12 | 304.8 | 63.5 | 6.5 | 0.13 |
12 | 304.8 | 85 | 6.5 | 0.12 |
12 | 304.8 | 85 | 7 | 0.12 |
12 | 304.8 | 85 | 7.5 | 0.12 |
Note: Other specifications are available upon request.
Leaf Disc Filter Design
In the design of leaf disc filter, the leaf disc filter is made of sintered stainless steel (316L) wire mesh laminate or sintered metal non-woven felt media. Has good corrosion resistance acid and alkali resistance, has a very strong structure, is not easy to damage, so has a long service life, or the ideal choice for polymer film production.
The shape is designed with a unique disk design, and the unique design of the leaf disk assembly maximizes the effective filtration area even at limited capacity, thereby reducing the retention time of the polymer, as well as reducing the risk of polymer degradation and providing fast, efficient filtration for polymer melt filtration applications.
Because of good design, all disc filters have high mechanical strength and are suitable for long term operation.
Leaf Disc Filter Size
Leaf disc filter is made of stainless steel sintered felt or other metal fibers, with a rating range of 0.5 to 200 microns, a diameter of 200 mm to 3000 mm, and an OD range of 111mm, 178mm, 222mm, 305mm, etc. Multilayer sintered wire cloth as the filter medium disc filter, has good strength, accurate filtration accuracy, long life, can be repeatedly cleaned.
Because the size has a wide range of options, so can enable customers to have a variety of choices. The central shaft of the filter has three kinds of hard, semi-hard and soft, with excellent mechanical strength, high temperature resistance and strong corrosion resistance.
Filter filtering accuracy is uniform and stable, because of good design, can make the effective filtration area to reach the maximum, so as to realize the effective use of space and filter device miniaturization.
Materials of Leaf Disc Filter
Stainless Steel: Often chosen for its exceptional corrosion resistance, strength, and durability. Stainless steel effectively filters out debris while maintaining its structural integrity over long periods of use.
Nylon: Known for its strength and abrasion resistance, nylon is used in disc filters for its durability and ability to withstand harsh environmental conditions.
Aluminum: Lightweight and corrosion-resistant aluminum leaf filters suit applications requiring weight and moderate durability.
Brass or Bronze: These metals are chosen for their corrosion resistance and aesthetic appeal, making them popular in disc filters for durability and aesthetic applications.
The choice of material for leaf disc filters depends on several factors, including the type of liquid, environmental conditions, durability requirements, and cost considerations. Each material offers unique properties to meet the specific filtration requirements of different industries and applications.
Production Technology of Leaf Disc Filter
Leaf disc filter adopts a unique stainless steel fiber felt manufacturing process, which exceeds the international level of similar stainless steel fiber sintered felt.
The filter adopts the structure of multi-layer sintering together, which can work for a long time and save the operation cost. The top and bottom can filter the medium, single thickness is thin, but the combined filter area is large. It expands the filtration area at a high flow rate. Widely used in high viscosity filters. The problems of polymer stagnation, polymer degradation and gel generation were effectively solved.
The filter can effectively block and filter the crystal points in the melt, and cut the gel, greatly improving the quality of high-end film materials. Also has the characteristics of high temperature resistance, high strength, greatly improve the service life and filter replacement cycle, improve the production efficiency.
Why DEZE Filtration to Customize Your Leaf Disc Filter
DEZE Filtration’s Custom Leaf Disc Filter stands out for its tailored design, offering precise solutions to diverse filtration needs. This customization ensures high efficiency. It optimizes surface area for filtration. The robust construction endures harsh conditions. This results in long-term reliability. It also leads to low maintenance requirements.
Versatility is a key advantage. These filters can be engineered to handle a wide range of fluids. They can also handle various temperatures. Additionally, they can handle different pressures. This versatility makes them suitable for various industries and applications.
Despite being custom-made, DEZE maintains cost-effectiveness. It does so without compromising on quality. It also does not compromise on performance.
Scalability allows these filters to accommodate both small-scale and large industrial operations. Alongside the product, DEZE likely offers comprehensive technical support, aiding in design, installation, and maintenance, further enhancing the value proposition.
Overall, DEZE Filtration’s Custom Leaf Disc Filter delivers tailored, efficient, and reliable filtration solutions, backed by quality construction and technical expertise, making it a preferred choice across industries seeking optimal filtration performance.
DEZE Custom Leaf Disc Filter For Applications
Polymer Filtration: In polymer processing, leaf disc filters are used. They are used to remove impurities and contaminants. They remove these from polymer melts or solutions. This is done before further processing. This helps in enhancing the quality of the polymer product and maintaining consistent properties.
Compound Processing: Leaf disc filters play a crucial role. They play this role in compound processing industries. These industries include rubber and plastic manufacturing. They are employed for filtering. They filter out foreign particles and contaminants. They do this from compound mixtures. This ensures the final product meets quality standards.
Film Manufacturing: Leaf disc filters are utilized. They are utilized in film manufacturing processes. They are used to purify the liquid solutions or melts. These solutions or melts are used to create films. By removing impurities and solid particles, these filters contribute. They contribute to the production of high-quality films. The films have desired optical properties. They also have desired mechanical properties.
Chemical Engineering: Leaf disc filters are widely used. They are used in chemical engineering applications. They are used for separating solids from liquids or gases. This occurs in various chemical processes. They help in maintaining product purity. They help in reducing equipment fouling. They help in ensuring the smooth operation of chemical reactors and other equipment.
Pharmacy: In pharmaceutical manufacturing, leaf disc filters are employed for clarifying liquid solutions, removing particulate contaminants, and ensuring the purity of active pharmaceutical ingredients (APIs). They are integral in processes such as solvent filtration, solution clarification, and final product polishing in pharmaceutical formulations.
Petroleum Industry: Leaf disc filters find applications. They find applications in the petroleum industry. They are used for filtering crude oil. They are used for removing impurities, water, and solid contaminants. This is done from oil and gas streams. They are utilized in refining processes, petrochemical production, and oilfield operations to ensure the quality and purity of petroleum products.
FAQ
Most frequent questions and answers
The leaf disc filter is made of stainless steel and can be single or multiple layers. If it is a multi-layer disc, the layers can be bonded using a metal plate frame or spot welding.
Used as a filter or screen element in the most diverse applications. Typical applications include filtration of extruded polymers and components used in solid-liquid or air filtration applications.
Die-cutting techniques can be used to mass-produce disc filters, and individual shapes can be made using laser systems specifically designed to produce wire mesh. Generally, all meshes can produce leaf disk filters, from the finest twill Dutch weave to highly rugged square meshes.
Cleaning the leaf disc filter is an important step. Remove all dirt in the final cleaning stage for frame or spot-welded disc filters.
We produce a variety of leaf disc filters. It is determined according to the customer’s requirements, such as material, wire diameter, mesh size, width, and length.
The leaf disc filter is processed by sintered wire cloth. Sintered wire cloth is made of stainless steel material and can also be provided according to the requirements of other alloy materials. It is very suitable for polymer filtration applications. These uniquely designed filters come in 60 micron to 5 micron absolute size and hub configurations to suit your requirements.
The disc structure of the filter maximizes the product’s filtration area while minimizing polymer residence time, ultimately reducing the overall risk of polymer degradation. The disc is designed for a smoother filtration process and longer service life.
When looking for the right leaf disc filter design and the right filter type for your enterprise, it is important to understand the type of filter options and the factors that determine the right filter. This includes the following designs and considerations:
First, there are three typical filter designs: horizontal, vertical, and fan. Getting the filter right will include the right blade design and other important considerations.
Some of the main factors determining which blade design and filter type include the type of process, the importance of filter cake or filtrate, particle type and level, and heat and pressure considerations.
The most critical part of the filter is the drain chamber. However, finding the right filter for your needs depends on other factors, such as the cleaning process, high heat resistance rating, and high capacity filter requirements.
Support high viscosity and large flow
Leaf disc filters can provide large filter area, high mechanical strength, and good rheological properties even under limited capacity.
Excellent cleaning features
Can reduce initial pressure drop, extend operating life and achieve easy cleaning in a variety of sizes, hub designs, filtration efficiency and porous metal filtration media types to meet a variety of requirements.
Strong and durable
Die-cutting techniques were used to mass-produce disc filters, and individual shapes were made using a laser system to produce wire mesh. Generally, all meshes can produce leaf disk filters, from the finest twill Dutch weave to highly rugged square meshes.
Easy to clean
Depending on their application, disk filters are produced as single – or multilayer disks. In the case of multilayer discs, sheet metal frames or spot welding may be used to bond the layers. For frame or spot-welded disc filters, all dirt can be removed in the final cleaning stage.
A leaf filter is a type of filtration system. It is used primarily in industrial processes. Its purpose is to remove solid particles. It removes these from a liquid stream. The function of a leaf filter is to capture solid particles. These particles include debris, contaminants, or sediment. It retains these particles. It allows the liquid to pass through.
The filter typically consists of vertically stacked, closely spaced metal or plastic plates called “leaves.” These leaves are usually made of a porous material. The porous material includes wire mesh or cloth. This allows the liquid to pass through. It traps the solid particles.
As the liquid flows through the filter, the solid particles are captured on the surface of the leaves. Periodically, the leaves need to be cleaned or replaced to maintain the efficiency of the filtration process. Leaf filters are commonly used in various industries, including chemical processing, oil and gas, pharmaceuticals, and food and beverage production, where removing solid contaminants from liquids is essential for product quality and process efficiency.