Sintered Powder Metal Filters v/s Sintered Wire Mesh Filters
All filters are designed differently and have different filtration capabilities. To know which filter gives maximum output, you must understand how different filters work and behave in challenging operating environments.
Regular wire mesh filters and sintered wire mesh filters; both have a short service life. Although the “sintered” wire mesh filters last longer than the regular ones, Both types of filters need frequent replacement either because
- + The metal mesh opens as it is made of wires laid out in warps and wefts to form a net-like structure.
- + Particles get entrapped / entangled in between the structures.
| Details | Sintered Metal Powder Filter | Sintered Wire Mesh Filter | Wire Mesh Filter |
| Type | Surface Filter | Depth filter | Surface Filter |
| Back Washable | Yes | Yes | Yes |
| (fragile and may break) | |||
| Service | Can be Continuous | Limited to Certain Period | Limited Period |
| In Situ Cleaning | Possible | Might be Possible but not Advisable | Not Possible |
| Valuable Solids and Catalyst Trapping | Efficiently Trapped and Recovered | Penetrate into the inner layers and cannot be recovered | Penetrate into the inner layers and cannot be recovered |
| Regeneration | Chemical cleaning and ultrasonic method reclaims nearly 100% . Other proprietary methods may recover these filters to nearly 100% capacity much after they are perceived useless. | Penetrates solids difficult to remove and hence cannot be fully regenerated | Cannot be Regenerated |
| Due to catalyst trapping capabilities | Has a long life (3 years and above) | Service lifecycle of only a few months | Service lifecycle less than Sintered mesh |
| Micron Rating | Wide Range from 0.2 to 50 µm | To achieve <5 µm is not consistent | To achieve <14 µm is difficult |
| Void – Volume | High | Low | Medium |
| Efficiency | High Due to Tortuous Path | High Due to Tortuous Path | Surface Filter |
If you deep dive, you will observe many factors that influence your choice of a filter.
Which Filter Materials are Used in Sintered Metal filter? Explain Advantages of Sintered Metal Filters
This process creates a porous structure that allows air to pass through while retaining particles larger than 0.3 microns. These filters are usually made out of bronze, stainless steel, titanium, or nickel based alloys. They are often used in industrial settings where dust levels are high.
Metal powder sintering is a process where powdered materials are compacted under pressure and heated to form solid products. This process is commonly used to make parts out of metal powders. In order to produce a metal part, the metal powder needs to be mixed with a binder and pressed into shape. After pressing, the powder is heated to remove any remaining liquid binder and bind together the particles. Once the powder is fully bonded, the part is removed from the mold and allowed to cool.
There are many types of sintered metal filters. Some of these include bronze, titanium, stainless steel fibers, and nickel based alloys. Each type of sintered metal filter has its own advantages and disadvantages.
Features of a Sintered Metal Filters
Some of the main features of sintered metal filtration systems include:
- + Good resistance to corrosion and highest quality durability.
- + Easily back washed hence making it possible to prolong the serviceable life.
- + High dirt holding capacity.
- + It is made of high-quality material.
- + High mechanical strength and pressure sufferance.
- + Filter Grade from 0.1 microns to 100 microns.
- + pore shapes Stable and guaranteeing high permeability.
- + Wide service temperature, which ranges from -200 degrees Celsius to 1000 degrees Celsius.
Which Shapes of Sintered Metal Filters are available?
- + They include square, tubes, elliptical, rectangle, triangle, circle, and polygon, among others.
- + It will be important to understand that they come available in these shapes with microns from 1 to 200.
How Sintered Metal Filters are Made?
- + It is made when the bonding of particles in powder form takes place.
- + This bonding takes place by diffusion in temperatures that are relatively below the melting point.
- + It is a process that involves three major steps.
- + The first step is about obtaining the powder form of your metal.
- + This can be done through grinding, atomization, or alternatively chemical decomposition.
- + At this stage, you can choose to combine this powder using another metal to form an alloy or use it as it is.
- + This process is somewhat simple and does not allow alteration of the element.
- + The second step is about injecting the powder into a die from where you can easily shape the actual design of your filter.
- + Formation of filter composition takes place under room temperature and high pressure.
- + Ordinarily, the amount of pressure that you need to apply is dependent on the specific type of metal you are using since metals have different malleable degrees.
- + Compacting of metal powder takes place to form a solid filter while in the die.
- + After this happens, you can choose to proceed and remove the screen, which is in a solid-state, and subject it to a furnace under high heat.
- + So the result is what is now referred to as sintering.
- + The metal particles fuse without melting during the sintering process hence forming a high strength, rigid and porous filter.
What are the Principal Specifications of Sintered Metal Filters?
- + Pressure Drop – Refers to the loss of pressure, which occurs as gases or liquids flow through the filter. It is always vital to determine what your specific application can allow and specify it to your filter manufacturer.
- Temperature Range – It refers to the level of hotness or coldness of the surrounding you are operating the filter.
- + Pressure Drop – it is important to ensure that you maintain the pressure of the fluid in your application and preventing any possibilities of pressure drop for the best results.
- + Fine Tolerance – it refers to the sintered metal filter’s ability to filter the fluid without necessarily reacting with it.
- + Hermal Shock – it is the variation in temperature, which ordinarily causes tension in the material.
Which Applications are used in Sintered Metal Filters?
- + Chemical processing – mostly common in nuclear manufacturing, given that it possesses some of the best properties, including high temperature and corrosion resistance.
- + Food and beverage – it is majorly used for the extraction of vital nutrients and juices in food processing. They do not react to food or beverage, thus making them ideal for this application.
- + Power generation – sintered metal filters help in ensuring efficiency and effectiveness in power generation by allowing filtration of water in turbines.
- + Petroleum Refining – Sintered metal filters enable you to filter different fuels effectively depending on the degree levels which you require.
- + Gas production – this element is suitable for gas production since they don’t react with gases and you can as well use them in different environments.