In this guide, you will find all information you’re looking for about sintered screen basket.
From design, properties, sizes, working principle to cleaning options among other fundamental aspects – you will learn everything about sintered screen basket.
- What is a Sintered Screen Basket?
- What are the Benefits of Sintering a Screen Basket?
- What are the Available Sizes for a Sintered Screen Basket?
- What Factors Influence the Design of Sintered Screen Basket?
- What are the Materials that can Make a Sintered Screen Basket?
- What are the Applications of a Sintered Screen Basket?
- What Patterns are Available for a Sintered Screen Basket?
- What are the Properties of Layered Sintered Screen Baskets?
- How Does a Woven Wire Mesh Screen Basket and Sintered Mesh Screen Basket Compare?
- What is Sintering?
- What Tests should you Conduct on a Sintered Screen Basket?
- What are Sintered Mesh Laminates?
- Why is it Important to Laminate a Sintered Screen Basket?
- How Do you Clean a Sintered Screen Basket?
- How Does a Sintered Screen Basket Work?
- How Do you Maintain a Sintered Screen Basket?
- What is the Filtration Principle of a Sintered Screen Basket?
- Why is Porous Metal Suitable in a Sintered Screen Basket?
- What should you Consider When Selecting a Sintered Screen Basket Filter Element?
- What is the Benefit of Using Stainless Steel to make a Sintered Screen Basket?
- What Filtration Grades of Sintered Screen Baskets are Available?
- Which are the Structural Parts of Sintered screen baskets?
- Can a Sintered Screen Basket Come in Several Layers?
- What Features can you find in a Sintered Screen Basket?
- When should you Replace a Sintered Screen Basket?
- How Does a Sintered Screen Basket and Traditional Wire Cloth Compare?
What is a Sintered Screen Basket?
Sintered Screen Basket
What are the Benefits of Sintering a Screen Basket?
Here are the advantages of sintering a screen basket:
When you sinter a screen basket, you can produce complex shapes from the tool that compacts the materials.
This is possible with no machining operations such as splines, profiles, teeth, frontal geometries, etc.
High Dimensional Accuracy
The tolerances you can achieve in perpendicular compacting are usually IT 8 to 9.
On the other hand, sintering will improve this to IT of between 5 and 7 after sizing.
An IT of between 10 and 13 is possible in length depending on the geometry of the components.
Also, if you add machining operations, this can enhance this precision.
Repeatability in Mass Production
The technical advancement of the production equipment and the tool stability will offer high reliability and repeatability.
Also, the SPC control systems assist in achieving this high level of repeatability in the mass production of sintered screen baskets.
The properties of sintered screen baskets are isotropic since the materials are homogeneous in their microstructure.
Besides, the diffusion mechanisms for the solid-state that you apply will create micro-structures.
These micro-structures will assist in achieving compositions and materials that are hard to obtain when you apply a melting mechanism.
The manufacturing of sintered screen baskets is considered as being ecological.
This is because the waste of the materials is minimal.
Also, one can recycle the products and it is energy efficient as the materials are not in a molten state.
Good Surface Finish
The surface of a sintered screen basket has the availability of flat areas that have low levels of roughness.
These parts infuse with the dips that correspond to the porosity.
Also, this surface is suitable than one of the wrought materials that undergo machining.
This is because they have alternating series of troughs and peaks.
The availability of the lower peaks will allow the reduction of the run-in time of these parts.
The internal tiny porosity will produce a damping response to the vibrating propagation.
When you sinter a screen basket, the overall weight will reduce by between 5% and 25%.
This is in comparison to the same material with no sintering since it has no porosity.
What are the Available Sizes for a Sintered Screen Basket?
A sintered screen basket can be as tiny as the size of the head of a pin.
Depending on the application, one can get large or small sintered screen baskets that will fit in the production line.
The standard sizes are 500mm by 1000mm, 600mm by 1200mm, 1000mm by 1000mm, and 1200mm by 1200mm.
What Factors Influence the Design of Sintered Screen Basket?
The sintered screen basket design depends on the following factors:
Sintered Filtration Screen Basket
Pore Size or Micron Rating
The micron rating will indicate the type of contaminants it can eliminate.
Ensure the micron rating matches the fluid and contaminants in your application.
For instance, an absolute micron rating of 5 means it will eliminate 99% of contaminants over 5 microns.
Also, a nominal micron rating of 5 means it will remove 60% of contaminants.
It will also allow a large number of particles with a micron rating of 5 to pass through the sintered screen basket.
This is the loss in pressure that happens when the fluids or gasses flow through the sintered screen basket.
Ensure you determine this by your application before designing a sintered screen basket.
The range of temperature in the operating environment is a vital factor to consider when designing sintered screen basket.
It will determine the kind of sintered screen basket you will be using in your application.
A sintered screen basket is a suitable choice when you require high strength.
Also, they offer the same strength in both forward and reverse flow.
Resistance to Corrosion
Ensure the sintered screen basket can withstand fluids with high chemical content when designing.
Particle Holding Capability
Depending on your usage, ensure it can hold a large number of contaminants before becoming ineffective.
What are the Materials that can Make a Sintered Screen Basket?
There are two materials that you can use to construct a sintered screen basket.
These are variations of stainless steel, bronze, and other types of alloys.
Bronze is the most common material as they are affordable to purchase.
The downside of using bronze to make a sintered screen basket is that it has poor mechanical and tensile strength.
This makes it weak and prone to breakages and corrosion from different substances.
Stainless steel is by far the most suitable material that you can use to construct a sintered screen basket.
Stainless steel has low quantities of carbon and adding chromium will increase its corrosion resistance.
Depending on the amount of alloy you add, stainless steel comes in different grades depending on the amount of alloy you add.
The different stainless steel grades used in sintered screen baskets include:
- 304 stainless steel
- 316 stainless steel
- Martensitic stainless steel
- Ferritic stainless steel
- Austenitic stainless steel
Stainless Steel Sintered Screen Basket
Other materials you can use to make sintered screen mesh basket that is costly since they are hard to work with include:
- Nickel alloy
What are the Applications of a Sintered Screen Basket?
Several industries use sintered screen basket include:
Food and Beverage Industries
Sintered screen baskets will assist in the extraction of important nutrients and squeezes.
Filtration will assist in preventing these supplements from washing away in the processing phase.
Also, it will assist in eliminating impurities that will affect the quality of foods and beverages.
Hydroelectric Power Plants
A sintered screen basket will clean water that will turn turbines in this industry.
It helps in maintaining suitable electric power cycle production with minimal interruptions.
Sintered screen mesh allows filtration of gases to eliminate contaminants which would affect its performance.
Also, it has tiny pores that will capture small contaminants in the gas.
It can apply a depth or a surface filtration technique.
Sintered screen baskets will filter out harmful contaminants and improve the efficiency of chemical products.
They also shield equipment from damage, repair, and costly downtime.
This device will enhance the purity of various petroleum products by eliminating contaminants.
It makes the petroleum products pure thus will not affect the operations of machines.
Sintered screen baskets will remove impurities from pharmaceutical products.
This makes them suitable for human consumption and enhances their effectiveness at providing medicinal value.
What Patterns are Available for a Sintered Screen Basket?
Some of the sintered screen basket patterns include:
Plain Woven Square Sintered Screen Basket
This pattern offers good permeability and low resistance to the flow of fluids.
It can come with varying number and square combinations to achieve specific flow and filtration traits.
Also, it has a filter rating that ranges from 1 um to 200 um and the plate size has a maximum size of up to 1200 mm by 1500 mm.
Dutch Woven Sintered Screen Basket
The pattern has openings that are even and offer a constant permeability to airflow.
Besides, it offers great mechanical strength.
The common application is in powder transportation, fluid beds in laboratories, coolers, and other solid and dry substances.
Perforated Sintered Screen Basket
This has perforated metal acts as a reinforcement layer to provide support to the sintered screen basket.
Besides, it offers great mechanical strength and impressive compressive strength.
They are suitable for oil wells in which you need to filter out fine contaminants in high-pressure working conditions.
What are the Properties of Layered Sintered Screen Baskets?
Multilayer Sintered Screen Basket Cross-Section
A sintered screen basket can have one or multiple layers.
For multi-layered screen baskets, the number of layers will influence the properties of the basket.
Here are some of the properties you will find in a sintered screen basket:
One can manufacture a sintered screen basket using different materials.
The type of material you decide to select will depend on the application.
One of the most common materials is stainless-steel and it can come as SS30 or SS306.
This is because it has high mechanical strength and it is resistant to many forms of corrosion.
Besides, one can use monel, nickel, aluminum, hastelloy, or inconel.
Thickness of the Material
Sintered screen baskets come in varying thickness levels.
The thicker the screen basket, the sturdier it is and this means it can handle extreme environments with ease.
Some of the standard thickness can be 3.5 mm, 2.5 mm, and 1.7 mm.
Type of Weaving
The different weave options available will assist in enhancing a wide range of filtration specifications.
Every kind of weave will offer unique features and benefits for your application.
Some of the weaves you can find are plain, twilled, dutch, dutch twilled, or a reverse weave.
A sintered screen basket can come with a number of layers.
One can find a basket with three, five, or several layers which you can customize for your application.
Besides, multiple layers means you achieve a higher filtration efficacy.
Accuracy of Filtration
These baskets have a high filtration accuracy since they come with varying micron ratings.
This makes them able to filter out both large and tiny particles and contaminants.
For instance, it can come in a micron rating ranging from 1 to 200.
A sintered screen basket can comfortably operate on a temperature that ranges from -200°C to 800°C.
This makes it suitable for operation in different applications in which you will conduct filtration at varying temperatures.
How Does a Woven Wire Mesh Screen Basket and Sintered Mesh Screen Basket Compare?
Both woven wire mesh screen basket and a sintered mesh screen basket play a filtration role in varying applications.
They are both stable and offer a suitable pore structure.
A woven wire mesh screen basket has wires that run in two vertical directions: shute and warp.
On the other hand, Sintered mesh screen baskets bind metal surfaces with no filler or bonding agents.
What is Sintering?
It is the process that involves the forming and compacting of solid materials by heating or applying pressure without melting them.
What Tests should you Conduct on a Sintered Screen Basket?
Testing a sintered screen basket determines if it meets the specific quality standards, and the consist of:
- Air permeability test
- Product porosity test
- Bubble point pressure test
- Filtration efficiency test
What are Sintered Mesh Laminates?
This is a fine woven wire mesh that has undergone lamination.
It occurs when you weave single or multi-layers using a special diffusion-bond technique.
Also, sintered mesh laminates have more mechanical strength and stability than traditional wire mesh.
Why is it Important to Laminate a Sintered Screen Basket?
The fine wire meshes are normally thin and can damage easily despite having a micron pore rating.
It is important to laminate them to increase the strength, support, and protection against damages.
How Do you Clean a Sintered Screen Basket?
There are various techniques you can use to clean a sintered screen basket.
These include chemical and physical methods.
When using physical methods, you will use a piece of ultrasonic cleaning equipment to backflush.
Backflushing uses cleaning gases or cleaning fluid recoil.
Chemically cleaning a sintered screen basket involves diluting an acid, alkali, oxidizers, or surfactant.
Besides, one can apply both physical and chemical cleaning methods interchangeably to achieve a suitable product regeneration level.
The cleaning method you will select depends on the following factors:
- Nature of the contaminants.
- Physio-chemical features of the material construction.
- Chemical properties of the contaminants.
How Does a Sintered Screen Basket Work?
This basket works by filtering fluid that enters via inlet port, undergoes filtration, and exits system.
The fluid will flow in the system at a high pressure level.
Once in the sintered screen basket, the basket will allow the fluid to pass through as the contaminants remain behind.
The micron rating of the basket will allow it to eliminate a certain amount of contaminants.
After the filtration process, the clean fluid will exit the system via the outlet port.
Besides, dirt will continually accumulate on the basket and after a while, it is important to clean it.
This will eliminate the chances of compromising the filtration process.
How Do you Maintain a Sintered Screen Basket?
Maintaining a sintered screen basket ensures that the filtration process is accurate and reliable.
Always inspect the basket to ensure no damages occur in the core of the basket.
Eliminate impurities timely when you notice a pressure drop so that the flow rate will not decrease.
Do not damage the stainless steel body when cleaning otherwise it will decrease the filtration efficiency.
Replace the device when you notice deformations and damages on the surface.
What is the Filtration Principle of a Sintered Screen Basket?
Filtration operation relies on constant flow, increasing the pressure drop until you reach the terminal pressure.
It reaches terminal condition when the thickness of the catalyst cake increases until the fluid flow pressure drop is maximum.
One will backwash the sintered screen basket by pressurizing with gas then opening the discharge valve.
Backwashing generates high reverse pressure which eliminates solid contaminants from the surface of the media.
A reverse flow of a clean filtrate will assist in removing solids out of the basket.
A uniform rise in pressure drop illustrates that the particle size of the feed slurry remains constant just as the slurry concentration.
Inside-out basket configuration will utilize the basket with a uniform porosity to build cakes inside the surface.
These will enhance the particle removal and the backwash efficacy.
The recovery pressure following backwashing will slightly increase after you condition the media.
Also, it should be within 2 to 3 PSI of the clean flow’s pressure drop.
The recovery pressure drop has to be stable to enable a consistent performance.
Also, following a good backwash process will ensure suitable media cleaning.
A change in the temperature will influence viscosity and the pressure drop will rise in the media.
It is therefore important to maintain design-operating temperatures in the entire filtration procedure.
Why is Porous Metal Suitable in a Sintered Screen Basket?
It offers a consistent method of eliminating contaminants, is easy to clean, and is durable.
What should you Consider When Selecting a Sintered Screen Basket Filter Element?
Sintered Screen Basket Filter Element
Temperature and Corrosion Resistance
Ensure the basket can withstand high temperatures and chemicals from varying fluids without damaging it.
The micron rating will determine the kind of contaminants it can eliminate.
Besides, you have the choice of nominal and absolute micron ratings.
It should maintain the pressure drop of fluids in the filtration process.
This means you will filter all the fluid in the system.
Select a sintered screen basket with high-quality material, such as stainless steel as it ensures durability.
Dirt Holding Capacity
A high dirt holding capacity means you will continually operate the basket without stopping the filtration process.
Large usages require high dirt holding capacity and vice versa.
This is the measurement of the pressure drop of fluids in a specific flow within the filtration area.
High permeability allows the basket to have a high-pressure drop thus efficient filtration.
What is the Benefit of Using Stainless Steel to make a Sintered Screen Basket?
Some of the advantages of stainless steel sintered screen basket include:
- Can handle high pressure and low flow rates.
- Stainless steel is easy to clean and it also provides a stylistic appeal.
- Resistant to high temperatures levels and can withstand corrosion from several kinds of fluids.
- It will not bend at high-temperature levels.
What Filtration Grades of Sintered Screen Baskets are Available?
Filtration grades vary from one sintered screen basket to another.
They can vary from 0.1 microns to 100 microns depending on your application needs.
Which are the Structural Parts of Sintered screen baskets?
The structural parts have a certain arrangement to them when using a sintered screen basket.
Also, they depend on the layers available within the sintered screen basket.
The five structural parts that form these layers are:
- Protection layer
- Filtration layer
- Dispersion layer
- Reinforcement layer
- Second reinforcement layer
Can a Sintered Screen Basket Come in Several Layers?
Yes, they can have several layers.
What Features can you find in a Sintered Screen Basket?
Some of the features of sintered screen basket include:
- Resistance to Temperature, corrosion, oxidation, abrasion, and pressure.
- Robust and economical structure.
- Varying filtration ratings.
- Ease of cleaning and using.
- Excellent mechanical strength.
When should you Replace a Sintered Screen Basket?
Replacement depends on the grade, working conditions, material construction, and quality of the sintered screen basket.
It is possible to use it for more than 5 years before replacing it.
Selecting the wrong basket will need frequent replacements as they are not resistant to many elements.
How Does a Sintered Screen Basket and Traditional Wire Cloth Compare?
Sintered screen baskets are hard and rigid than traditional wire cloth.
Traditional wire cloth has poor permeability than sintered screen baskets.
Sintered screen baskets can eliminate specific contaminants depending on the micron rating.
However, traditional wire cloth has unstable pores and is not reliable at eliminating contaminants of a specific micron rating.
Sintered screen baskets have a long lifespan than traditional wire cloth as they can withstand several backwashes.
Moreover, it is possible to have a sintered screen basket in multiple layers.
Traditional wire cloth has a loose setting thus can lose shape easily than the sturdy sintered screen basket.
Depending on your specific needs and requirements, FilSon Filters offers perfect sintered screen basket for your unique application requirements.
Contact us now for custom sintered screen baskets.