In industrial production, the stable operation of the circulating water system is crucial for equipment life and production efficiency, and a high - quality pretreatment process is the key to ensuring the quality of circulating water. The shallow sand filters produced by [Company Name], with their efficient filtration and stable performance, have become the ideal choice for the pretreatment of circulating water in many industrial enterprises. The following takes the actual project of a large - scale steel enterprise as an example to introduce the application of our company's shallow sand filters in detail.
I. Project Background
The industrial circulating water system of a large - scale steel enterprise is mainly used to cool production equipment such as steelmaking and steel rolling, with a circulating water volume of 5,000 cubic meters per hour. The original pretreatment equipment adopted traditional gratings and simple sedimentation tanks, resulting in poor treatment effects. According to tests, the turbidity of the raw circulating water was as high as 40NTU, containing a large amount of suspended rust, sediment, and metal debris generated during the rolling process. These impurities caused many problems in the circulating water system:
Serious Equipment Blockage
Impurities accumulated in heat exchangers and pipelines, narrowing the water flow channels, reducing heat exchange efficiency, and significantly increasing equipment failure rates. The annual downtime for maintenance due to equipment blockage totaled 200 hours.
Water Quality Deterioration
The microorganisms and organic substances carried by suspended impurities accelerated the corruption and deterioration of the circulating water. After the water quality deteriorated, chemical agents needed to be added frequently for treatment, with an annual chemical agent cost of up to 3 million yuan.
Increased Energy Consumption
To maintain the normal operation of the circulating water system, the water pump needed to consume more energy to overcome pipeline resistance, resulting in an increase in electricity costs. The annual electricity expenditure increased by about 1.5 million yuan.
In order to improve the quality of circulating water and reduce operating costs, the steel enterprise decided to upgrade the pretreatment equipment of the circulating water system. After comprehensive evaluation, it chose the shallow sand filters of our company.
II. Application and Implementation of Our Company's Shallow Sand Filters
(I) Equipment Selection and Customization
The technical team of our company customized a pretreatment system composed of 12 parallel shallow sand filters according to the circulating water volume, water quality characteristics, and production conditions of the steel enterprise. Each single filter has a diameter of 3 meters and a height of 2.5 meters, with a designed treatment flow rate of 450 cubic meters per hour. The filter media selected are refined quartz sand with a particle size of 0.5 - 1.2mm, which has the characteristics of high hardness, good chemical stability, and strong dirt - intercepting ability, ensuring efficient filtration.
(II) System Installation and Debugging
Equipment Installation
The shallow sand filters were installed in the pretreatment workshop of the circulating water system and connected to the raw water inlet and circulating water pump through pipelines. Each filter is equipped with independent inlet and outlet valves, backwash valves, and sewage discharge valves, facilitating individual operation and maintenance.
Configuration of Backwash System
An automatic backwash control system was adopted. When the pressure difference between the inlet and outlet of the filter reaches the set value (0.05MPa) or the operation time reaches the set duration (8 hours), the system automatically starts the backwash program. The backwash water source is taken from the clear water tank of the circulating water system, and the siphon principle is used to achieve efficient backwashing. The backwash time is about 3 - 5 minutes, which can quickly remove the impurities intercepted by the filter media.
Debugging and Optimization
The professional technicians of our company conducted a one - week debugging of the system, adjusting the time and flow parameters of backwashing to ensure the best backwash effect; monitoring parameters such as the turbidity and pressure of the inlet and outlet water during the filter operation, and fine - tuning the height and filling density of the filter media layer according to the actual situation to ensure the stable and efficient operation of the equipment. At the same time, comprehensive operation training and maintenance guidance were provided for the enterprise's operators.
III. Application Effects
Effect Category | Specific Performance |
Significant Improvement in Water Quality | - The inlet turbidity was reduced from 40NTU to below 5NTU, effectively removing more than 90% of suspended impurities, and the clarity of the circulating water was significantly improved- Particle substances such as rust and metal debris were basically intercepted, reducing the wear and tear on the equipment of the circulating water system |
Reduction in Operating Costs | - The frequency of equipment blockage decreased significantly, and the annual downtime for maintenance was reduced to less than 50 hours, significantly improving production efficiency- The usage of chemical agents was reduced by 40%, saving about 1.2 million yuan in chemical agent costs annually- The energy consumption of the water pump decreased, saving about 800,000 yuan in electricity costs annually |
Extended Equipment Life | - Due to the improvement of water quality, the corrosion and scaling of equipment such as heat exchangers and pipelines were effectively alleviated, and the service life of the equipment was extended by 3 - 5 years, reducing equipment replacement costs |
IV. Summary of Application Experience
Accurate Selection is the Prerequisite
The circulating water volume and water quality of different industrial enterprises vary greatly. Our company customizes equipment solutions based on on - site inspections and data analysis, combined with the needs of enterprises, to ensure that the treatment capacity of shallow sand filters matches the actual working conditions.
Efficient Backwashing is the Key
The automatic backwash system can promptly remove impurities in the filter media and maintain the high filtration efficiency of the filter. Reasonably setting the triggering conditions and parameters of backwashing is the core to ensure the stable operation of the equipment.
Complete Service is the Guarantee
Our company provides comprehensive after - sales services for customers, including equipment installation and debugging, personnel training, regular inspections, and technical support, promptly solving problems during the use process to ensure the long - term stable operation of the equipment.
The successful application of our company's shallow sand filters in this steel enterprise fully demonstrates the reliability and advancement of the products. In the future, [Company Name] will continue to optimize the technology of shallow sand filters, providing more efficient and economical pretreatment solutions for circulating water in more industrial enterprises.
