The determination of whether a ceramic filter plate needs to be replaced is mainly based on its comprehensive indicators such as physical damage, performance degradation, ineffective cleaning, and service life. When serious cracks occur, the filtration efficiency continues to decrease, or the flow rate recovers less than 50% after cleaning, it should be replaced immediately.
Ceramic filter plates, as core consumables, have a direct impact on filtration efficiency and production costs. Blindly using damaged or aged filter plates can not only cause turbidity in the filtrate and an increase in the moisture content of the filter cake, but may also lead to chain problems such as vacuum system overload and increased energy consumption. The following are replacement judgment criteria based on industry standards and on-site practice summary:
1、 Physical damage: a visible signal of 'hard injury'
When the filter plate experiences structural damage, it cannot be repaired by cleaning and must be replaced.
Cracks or broken edges on the board surface: Visible cracks, notches, or fractures, especially in the edge sealing area or around the central through-hole, can directly cause vacuum leakage.
Severe surface corrosion or deformation: The appearance of "age spots" - like corrosion spots, indentations, or bulges indicates that the material has undergone irreversible deterioration.
Large area blockage or sealing of micropores: Even after deep cleaning, there are still no bubbles or only local bubbles under air back blowing test, indicating loss of permeability.
Tip: If a single filter plate is damaged, it is recommended to replace the entire set to avoid uneven airflow distribution caused by the mixing of old and new.
2、 Performance degradation: the "sub-health" performance of system operation
Even if the appearance is intact, a continuous decline in performance means that the lifespan is coming to an end.
table
Possible reasons for the criteria for judging phenomena
The filtration flow rate has decreased, and after cleaning, the flow rate is still more than 50% lower than that of the new board. Deep blockage of micropores and aging of materials lead to a decrease in porosity
If the filtrate is turbid or has red suspended solids>0.08mg/L, or if the filtrate is red and the filter plate is broken, causing particle leakage, the machine should be stopped immediately
The moisture content of the filter cake increases by more than 10%, resulting in a wet and soft texture and reduced dewatering ability, which affects subsequent processing steps
It is difficult to maintain a vacuum degree of less than -0.08MPa, and the fluctuation is frequent. The micropores of the filter plate are blocked or damaged, resulting in uneven slurry suction
Industry experience: A certain beneficiation plant neglected the performance degradation of filter plates, resulting in a 3% increase in monthly filter cake moisture content and an annual increase in transportation and drying costs of over 120000 yuan.
3、 Cleaning ineffective: Maintenance methods are irreparable
Cleaning is the key to extending lifespan, but when cleaning is no longer effective, it indicates that the replacement node has been reached.
After conventional cleaning (nitric acid+ultrasound), there is no significant improvement in filtration efficiency;
Strengthening cleaning (extending pickling time, increasing concentration) still cannot restore permeability;
After deep cleaning with oxalic acid, the surface of the filter plate still has severe scaling or blocked micropores.
Suggestion: Establish a "pressure difference record table before and after cleaning". If the pressure difference rises by more than 80% after three consecutive cleaning cycles, replacement should be evaluated.