Project Background
A large unsaturated resin chemical plant produces exterior waterproof and epoxy floor liquid resin with 1100m³/h total raw material circulation flow. Raw material contains curing agent residue and colloidal particles. Original disposable melt-blown cartridge filters wear pump impellers, block reactor feeding pipes and cause uneven curing & particle defects on finished resin, reducing product selling price. Frequent cartridge replacement, high maintenance costs and repeated production shutdowns became severe issues amid full-load operation. Shortage of local maintenance staff and harsh high-temperature tropical working conditions pushed the client to adopt automatic metal screen self-cleaning filters with zero disposable cartridges, online non-stop filtration and remote intelligent control to cut labor and stabilize resin quality.
Core Pain Points
Cartridges fully clog every 8 hours; 5-hour full-line shutdown for replacement leads to over-polymerized waste semi-finished resin with heavy raw material losses.
Monthly cartridge procurement cost equals 140,000 RMB; resin-contaminated cartridges are hazardous waste with high disposal fees.
Two-shift manual cartridge replacement & tank cleaning under hot & humid tropical conditions; scarce skilled workers push labor costs up.
No online differential pressure monitoring; clogged cartridges trigger pipeline pressure surges, causing viscous resin leakage, floor corrosion and difficult cleaning.
Customized LEFILTER Solution
3 sets of LFZS series brush-type fully automatic self-cleaning filters are installed in parallel on raw material pipelines. 316L acid & alkali resistant stainless steel tank withstands long-term resin medium corrosion for tropical high-humidity outdoor workshops. Core 100μm integrated stamped wedge metal screen intercepts curing residue and colloids with high mechanical strength and differential pressure resistance. Built-in 360° stainless steel rotary brush self-cleaning unit activates at 0.14MPa differential pressure, completing 30-second brushing & blowdown without raw material supply interruption (other two units keep running). Bilingual English interface PLC with Modbus connects to overseas DCS central control for remote data viewing and parameter adjustment. Full equipment passed anti-resin immersion, anti-corrosion and hydraulic tests and finished sea delivery within 10 days.
Operating Effects
Stable operation for 14 months with 96% solid particle interception in resin raw material. Pump impeller wear and reactor pipe blockage reduced by 92%, cutting annual raw material waste loss by 760,000 RMB. Automatic rotary brush cleaning replaces manual cartridge replacement; maintenance staff reduced from 2 to 1, saving 430,000 RMB yearly on cartridges, hazardous waste disposal and labor. Reusable wedge screens eliminate continuous cartridge procurement with a 12-year service life. Stable raw material purity reduces surface particle defects and raises finished resin yield & overseas market recognition. This brush self-cleaning filter becomes a benchmark resin filtration renovation project for Southeast Asian chemical plants.
