Business sector: Manufacture of explosives (NAF Code 2008: 2051Z)
Company activity: Chemical synthesis & processing of energetic molecules
Company type: European company
Company creation period: 2009
Contact(s): Maintenance Engineer – Process Engineer – Investment/Maintenance Purchasing Team
Company context
The company designs, manufactures and supplies innovative, high value-added products and solutions for the pyrotechnics and chemical industries. With high-level expertise in energetic materials, the company is a key European player in explosives, propellants and military fuels. It also supplies explosives for the civilian sector (oil, gas and mining exploration). With over 900 employees, our client operates four production sites, all located in Europe.
Filtration challenge
The issue concerns final polishing filtration in a manufacturing workshop used to synthesize collodion, for the production of nitrofilm and ethylcellulose film. The collodion synthesis process includes several filtration steps to remove impurities, including the final filtration stage, which is the subject of this consultation.
Note
Collodion is a chemical product composed of nitrocellulose dissolved in a mixture of ether and ethanol, to which additives are added. This product is characterized by high viscosity.
The company’s issue covered five key points:
• Use of lead filter plates, whose manufacturing has been discontinued
• Deformation of the plates during dismantling due to collodion adhesion
• Overconsumption of filter media
• Long and labor-intensive filter cleaning (a 4 to 6-hour operation due to the highly viscous product that solidifies upon contact with air)
• Operator exposure to the product during dismantling
In addition, our client conducted tests with plastic plates, without conclusive results. The company therefore consulted us for the study and supply of an industrial filtration system to replace the existing installation.
Pemflow filtration solution
To ensure the technical and economic relevance of the final solution, we proposed industrial validation trials through the rental of a filter housing, equipped with filter cartridges specifically designed for the filtration of high-viscosity products.
The test conditions were as follows:
| Fluid type | ||||
|---|---|---|---|---|
| Collodion | Maximum flow rate: 1 m3/h | Temperature : 20 – 25 °C | Viscosity: 8000 à 10 000 cP | Density: 0,9 |
Filter cartridge
To address the challenges of high-viscosity fluid filtration, our partner AMAZON FILTERS has designed and developed a filter cartridge featuring a rigid structure, based on melt-blown manufacturing technology: the VisClear II cartridge.
Available in three media types, we selected a Nylon 6 media with a structure made from the same material.
For this project, the 30-inch VisClear II cartridge features a nominal filtration rating of 25 µm, EPDM seals, and Code A end caps (double O-ring + centering fin).
The graded density structure provides high dirt-holding capacity for consistent and reliable performance. In addition, the high mechanical strength of this cartridge is particularly well suited for viscous fluids.
Filter housing
Compte tenu du débit de 1 m3/h et d’une viscosité de 8000 à 10 000 cP à 20-25°C, nous avons dimensionné l’installation de filtFiltration with an AMAZON FILTERS Series 61 filter housing comprising five 30-inch VisClear II cartridges.
As collodion is highly loaded with ether, compliance with the ATEX regulation, Directive 2014/34/EU, level CE Ex II Gd cX, was imperative.
316L stainless steel
Electropolished finish
CE marking
At the end of one and a half months of trials under industrial operating conditions, our client confirmed and validated the VisClear II cartridges as a solution meeting its technical, quality and economic expectations.
Expert advice
Many companies handle hazardous materials and must protect operators and the environment. In addition, it is necessary to prevent cross-contamination in other activity sectors. Therefore, to address these challenges, it is advisable to enclose conventional cartridges in two sealed antistatic plastic bags. These are then contained within a filter housing that serves as the pressure vessel. The product and the filters are thus isolated.
Solution ergonomique & sécurisante
One of the operators’ key issues is prolonged exposure to contact with a product highly loaded with ether.
In addition, cleaning the plate filter is a very labor-intensive operation.
This solution enables:
• Protection of operators
• Improved productivity (operator gowning time significantly reduced)
• Very significant time savings for cartridge change-out compared with the plate system
• Fully satisfactory cartridge service life
Contact a filtration expert
We are at your service
Our experts place their knowledge and expertise at your disposal for liquid filtration, air and gas filtration, decontamination, and separation technologies.
