Filter Press Experiment - Fall 2016

Rowan University Department of Chemical Engineering

Introduction
Objectives

To obtain an understanding of filter press operation

To develop and implement a methodology to obtain the specific cake and filter medium
resistance in the system

Overview
The separation of solid particles from liquid is part of numerous chemical industry processes.
Many active pharmaceutical ingredient manufacturing processes, for example, involve crystallization
and subsequent separation of the crystals from the liquid phase. Plate-and-frame filtration is one method
widely used in the pharmaceutical and chemical process industries. Applications include the separations
of fermentation broths, cell culture media and pharmaceutical end-products in liquid solution. Plateand-frame filter presses are also used in the food and beverage industries. Beverages including beer,
wine and distilled spirits, soft drinks, fruit juices, and food products such as flavorings, baby foods, high
fructose corn syrup and gelatin are among the products produced using plate-and-frame filter presses.1
In a plate-and-frame filter press, the filter media are semi-permeable; the liquid phase can pass
through the media, while allowing for the collection of the solid phase. Solids build up and collect to
form a layer of semisolid block known as a filter cake. Plate-and-frame filter presses are operated in
semi-batch mode. Typically, the system is operated until the plates become full of solids resulting in
minimal filtrate flow.
The size of filter press units can vary significantly, and collection frames can range in size from
100 mm x 100 mm to 2.5 m x 2.5 m across and 10mm to 75 mm thick 1. The number of filters used also
varies depending on the size and scope of the operation. In the laboratory as few as six filters can be
used, whereas in industrial settings as many as hundreds can be employed. The larger number of filters
increases the surface area while minimizing the size of the plates and increasing the batch run-time.
Higher batch run-times mean the system is cleaned less often and productivity is increased.
Theory
A filter press utilizes a series of filters to separate solids from liquid slurries. The slurry flows through
the filters where solid particles are collected. In most cases, filters are placed perpendicular to the flow (parallel
to cross-section) in order to maximize the amount of solid gathered while maintaining an even flow throughout
the system. Solid particles collect on the filter surface and develop a wet solid cake. As filter cakes grow in size
the system pressure increases. This is due to an increased pressure drop through the thicker filter cake. The filters
are held in place by a series of alternating plates and frames. The purpose of this plate-and-frame set-up is to
allow spacing between each separate filter. The spacing of the filter media allows the media to effectively hold
the solid particles, while allocating the feed slurry to subsequent filters. Figures 1 a and b are schematics of this
set-up and process.

Figure 1a: Diagrams of plate-and-frame filter presses: (a) filtration of slurry with closed delivery, (b) through washing in a press
with open delivery2

Figure 2 shows the slurry flow and pressure profile in a filter press. The filtration process can be modeled by
taking the sum of the pressure drops across all of the filters and all of the filter cakes.

Figure 2: Pressure drop profile as a function of medium thickness and cake thickness in a filter press

The pressure drop equation (Carman-Kozeny) for laminar flow in a packed bed of particles (in this case,
the filter cake) is given by Geankoplis2 (Equation 1).

(1)
where: k1 = constant, 4.17 for random particles of definite size and shape
= filtrate viscosity (Pa*s)
= linear filtrate velocity based on filter area (m/s)
= void fraction or porosity of cake
L = thickness of cake (m)
S0 = specific surface area; particle area per particle volume (m2/m3)
pc = pressure drop across cake (N/m2)
A typical pressure profile is shown in Figure 1b.
The linear velocity of the filtrate flowing through the cake is given by Geankoplis2 as

(2)
2

where: A = filter area (m )

V = total volume (m3) of filtrate collected
t = time (s)

A system material balance can be used to relate the cake thickness to the volume of filtrate V collected as
shown by Equation 3.

(3)
where: cs = feed slurry concentration, (kg) solids per (m3) of filtrate
p = density of solid particles in the cake (kg/m3)
The term LA in Equation 3 can be neglected since it represents the volume of filtrate held within the
collected solid cake, which is relatively small compared to the volume of the total filtrate. Combining
Equations 1 and 2 with Equation 3, eliminates L and results in Equation 4.

(4)
where: = specific cake resistance (m/kg), and is defined as

(5)
The preceding equations modeled the pressure drop across the cake. Equation 6 (Geankoplis2) describes
the pressure drop across a filter and is analogous to Equation 4.

(6)
where: Rm = resistance of the filter medium to filtrate flow (m-1)
pf = pressure drop across filter medium
Since the filter press system contains cakes and filters in series, the resistances of the cake and the filter
material can be added. Summing the resistances from Equation 4 and Equation 6 yields

(7)
where:

= pc + pf
For constant pressure experiments, Equation 7 reduces to the following linear relationship.

(8)

(9)

(10)
6

where: Kp [=] (s/m )

B [=] (s/m3)
Under constant pressure conditions, along with constant (incompressible cake), V and t become the only
variables in Equation 8, which can be integrated to solve for filtration time

(11)

(12)

(13)
A plot of t/V vs. V yields a straight line and Kp/2 and B can be calculated from the slope and the
y-intercept respectively. Finally, solving Equations 9 and 10 with Kp/2 and B allows for the determination of
and Rm.

Experimental Equipment:
The experimental unit in the laboratory (model E102-4 Ertelalsop laboratory filter press) is a standard
plate and frame filter press and the number of plates, system pressure and type of filter can be varied. Figures 4 a
and b are pictures showing the system components. The filter press is equipped with a handwheel and 5 ton Jack
assist closing device.
A moisture balance (model IR-35 manufactured by Fisher Scientific) is also available for this experiment.
The moisture balance operating procedure is detailed in the Experimental Procedure Section.

The minimum and maximum operating pressures for the system are 3 - 4 psi and 100 psi, respectively.
The system can handle flow rates up to 1 gpm. The unit is equipped with

Bypass valve for P control

flow meters
Jack assist
by-pass

hydraulic release valve

collection tray
a

Figure 4 a) Ertelalsop filter press membrane system b) valve configuration

Figure 4 c) Plate and frame components showing ports and orientation.

four (4) filters. Figures 4 a and b also show the experimental equipment and the inlet/outlet valve configuration.
Figure 4 c shows the plate and frame components with port and assembly orientation. Each plate and frame is
marked with indicator numbers on the top right corner . Plates are numbered starting with zero (0). The fixed
head is numbered 00. All of the inlet frames have odd numbers and the outlets plates have even numbers. Outlet
plates should rest against the heads of the filter press. When viewed from the closure end, the inlet frames are
ported on the top left and the outlet plates are ported on the bottom right. Table 1 lists the filter press
specifications.
Table 1: Filter Press Specifications
Model EA102-4 specification
Liquid contact
Filter Area (ft)
Cake Volume (ft)
Inlets
Outlets
Discharge Porting
Maximum Pressure
Maximum Temperature

Specification Value
316LSS, Polypropylene
0.592
0.031
1
3
1B,3B Alternate
100psi
180F

Experimental Procedure
Safety:
Safety goggles must be worn at all times during the experiment.
o The filter press has a mixture of calcium carbonate and water under pressure which can spray if
not assembled correctly. Eye contact with the liquid slurry will result in irritation since the solid
is highly hygroscopic.
o Calcium carbonate can also cause irritation to the skin.
The filter press is under nominal pressure and pressure build up should not be a problem.

o
o

Fingers and clothing must be kept clear when the system is being tightened.
Damage to the equipment as a result of excessive compression is also a hazard. The hand-wheel
should not be turned excessively and the jack-assist should not be used excessively. Resistance
when turning the hand-wheel or operating the jack-assist indicates tightening completion.
The pump for this laboratory is very noisy and ear protection must be used
o Long exposure times to this noise level may cause discomfort and possible damage to the ears.
In the feed tank there is an exposed mixing shaft.
o Hands and hair should be kept clear of the rotating shaft
The pump can be an electrical hazard. Hands must be dry when plugging in electrical equipment and
equipment should be kept dry. Moisture may drip from the system onto the pump.
All hose connections should be checked for looseness and damage
o As previously stated, this system operates with a high flow rate and under pressure. The system
operation must be observed at all times to avoid unintended leaks from disconnected or ruptured
hoses.

System Assembly:

1) All hoses should be connected using fastener rings at the proper location.
2) Place the output of the hose running through the bypass in feed tank to allow recycle for
pressure control.
3) Place the output end hose exiting from the filter press unit in the feed tank to allow for filtrate
recycling and flow rate measurement.
4) The pump and agitator control should be plugged into a power outlet.
Loading the Filter Press
1. The filter press should be fully opened prior to installation of the filter media
2. Close the inlet valves and open the discharge valves and vent. The pressure gauge should read
zero.
3. Turn the hydraulic release valve counterclockwise at least one full turn
4. Open the filter by turning the handwheel counterclockwise
5. Outlet plate assemblies and inlet frames can now be moved by sliding against the moveable
head. Filter media can be removed as necessary.
6. The filter pads have two distinct surfaces. The inlet side of the pad is rough. The outlet side of
the pad is smoother and has a screen impression. The screened side must be installed against
the outlet place assembly. Sheets must be placed against either side of the outlet plate
assembly as single sheets.
Valves and Fittings:
Before turning on the pump, the inlet and outlet valves should be in the fully opened position to
ensure a clean start-up. Also the system should be visually inspected for kinks and leaks prior to start
up.

Operating Limits:
The maximum operating pressure for the system is 100 psi. Potentially dangerous leaking
from the gaskets can occur for pressures exceeding this maximum pressure.
Operation:
The feed tank should be agitated for at least five (5) minutes before turning on the pump. This
allows for consistent feed concentration. When the pump is turned on, the system can be set to a
specific pressure using the bypass valve. The experiment should start when the pressure desired is
steady.
It is necessary to keep track of the time and the flow rate (flow meter). The flow rate and time
should be recorded every twenty to thirty seconds. A typical experiment at one set of conditions lasts
approximately 10 minutes for each pressure run. Once the experiment is completed, the system should
be shut off according to the shut-off procedure.
General Operating Procedure Recycle Mode
Operating Procedure
Open inlet and outlet valves
The line exiting the filter press should be drained
into the feed tank.
Both recycle lines connected to the feed line should
also be drained back into the feed tank. These are
used for system pressure control.
Check for disconnected or loose fitting hoses
Make sure that the flow meter on the filtrate line is
fully opened by turning the black knob on the
bottom of flow meter all of the way to the left. This
allows for constant calibration flow meter
measurements.
Zero the stopwatch
Start mixer by pressing green switch on agitator
control to the ON position, set rotation speed to half
of maximum, and allow it to run for 5 minutes
Turn on pump using the power strip next to the tank.
Start stopwatch
Use the bypass valve to adjust pressure , maintain
pressure, and record data from the flow meter vs.
time for a specified period
Once the specified pressure is reached start
recording the filtrate flow rate every 20 - 30
seconds.
After 10 15 minutes, turn OFF the pump via
switch and stop the stopwatch
Turn the agitator control to the OFF position by
pressing the green switch
Open bypass valve

Safety Considerations / Process Comments

This could cause a major leak if a hose is not

connected properly

This allows time for the slurry to reach a

homogenous state in the feed tank.
Water on hands could lead to electrical shock, be
sure to have dry hands.

Wet hands are an electrical shock hazard

Resetting between Runs

Operating Procedure
Open all valves
Turn the hydraulic release valve clockwise and
Turn the handwheel clockwise until the assembly is
fully opened.
Separate the plates from the frames (a substantial
amount of cake should be collected), remove the
filter paper from the plates.

Scrape the remaining cake back into the feed tank

with the spatula and the brush
Rinse the filter papers in the sink with water
Fill up the feed tank with the house water line back
up to the marked fill line
Place the filter papers back on the plates in the
correct orientation
Close and tighten the filter press as listed in the
Loading the Filter Press Section above.

Safety Considerations / Process Comments

The hydraulic release valve must be open

Using the scraper, take a sample of the cake and

place it in an aluminum dish. This sample will be
used to obtain the moisture content of the cake
(refer to procedure below on how to use the
moisture balance)

See Step 6 in the Loading the Filter Press Section

above.
Do not tighten the filter press excessively

Cleanup after Final Run

Operating Procedure
Open all valves
Carefully open the filter press
Remove all filters
Scrape the remaining cake back into the feed tank
Rinse the filter papers in the sink with water
Fill up the feed tank with the house water line to
about half a foot from the top of the tank
Place the filters on the tray provided
Rinse the plate and frames from the filter press, dry
with towels, and place back on the press when
finished

Safety Considerations / Process Comments

If opened too quickly the system will spill over the
sides
Do not disturb the built up cake

Moisture Balance Operation

Operating Procedure

Safety Considerations

Obtain a sample of filter cake and place in

aluminum tray

Turn on the moisture balance with the I/O button

Allow the system to go through normal startup

procedure.

Place an empty aluminum dish onto scale and press

ENTER to Tare the balance

Be careful not to bend the aluminum dish

Switch the aluminum dish with the one that has the
CaCO3 sample in it, then close the lid, this will
automatically start the drying process.
Let the moisture balance run, taking note of the
time taken to reach the end point
Use the up and down arrows to scroll between %M,
%S, %MS, and g

%M is the percent moisture in the cake, %S is the

percent dry weight, %MS is the ratio of moisture to
dry material left, and g is the residual weight in
grams
Open up the moisture balance, throw away the
aluminum dish and press the I/O button again to
turn off the moisture balance

The end point is reached when the moisture balance

displays END on the bottom of the screen.

Take the g reading and using the scale obtain the

weight of a dry filter paper to collect just the
amount of CaCO3 present in the sample dish. This
is the [CaCO3].

References
[1] Coulson, Richardon, Harker, Backhurst. Chemical Engineering. Butterworth-Heinemann. 5th ed. 2002. pp.
390-399.
[2] Geankoplis, Christie John. Transport Processes and Separation Process Principles. Prentice Hall. 4th ed. 2003.
pp. 908-913.