Precision Sintered Powder Filters for Micro-Particle Removal - China Suppliers and Factory Solutions
Product Description
Corrosion resistance covering PH2-12, temperature resistance 500 ℃, suitable for petrochemical, food processing and other scenes.
Corrosion resistance to aqua regia and seawater, temperature resistance to 600°C in dry state, preferred in pharmaceutical and seawater desalination fields.
High temperature resistance to 980 ℃, chlorine corrosion resistance, dedicated to high temperature catalytic reaction systems (Inconel, Hastelloy).
Porosity 35-45%, thermal conductivity of 380W/(m-K), suitable for explosion-proof environments.
Monel alloy (Ni-Cu), ferro-aluminum alloy, etc. to meet the needs of special working conditions.
How is our sintered powder filter structure?
Through gradient sintering technology to realize the precise distribution of pores (pore size 0.22-200μm), porosity range 28-50%:
- Tubular cartridge: Outer diameter Φ5-200mm (can be customized to Φ1000mm), length 1-15m welded molding, axial flow channel design to reduce pressure drop.
- Composite structure: Five-layer sintered mesh (protective layer + precision control layer + dispersion layer + double-layer reinforcement layer) to achieve compressive strength ≥ 8MPa.
What is the application of our sintered powder filter?
- PTA mother liquor recovery: 316L material filter element intercepts ≥0.5μm catalyst particles.
- Crude oil pre-filtration: Monel alloy is resistant to hydrogen sulfide corrosion.
- Aseptic air purification: Titanium filter element is FDA approved, with a surface roughness Ra≤0.8μm.
- Terminal filtration of pharmaceutical solution: 0.22μm precision PTFE cartridge realizes bacterial retention rate >99.99%.
- Ultrapure water preparation: gradient pore titanium cartridge removes ≥0.1μm particles.
- High-purity gas filtration: the nickel-based alloy cartridge is resistant to corrosion of electronic special gas.
- Beer clarification: five-layer sintered mesh to achieve turbidity <0.5EBC.
- Fruit juice filtration: 316L cartridge passes 3A sanitary certification.
How is our Sintered Powder filter Production Process?
- The metal powder is selected from 316L stainless steel, titanium alloy or copper-based alloy with 20-100 mesh (particle size of about 150-840μm), and the particle size distribution is optimized by ball mill or screening machine.
- Add 5-10% volatile agent (e.g. paraffin) or molding agent (e.g. polymer binder), mix in the mixing equipment for 1-3 hours to achieve uniform dispersion and ensure the stability of the pore structure.
- Special process requirements: gradient cartridge needs to be layered with coarse particles (≤100 mesh), medium particles (200-300 mesh), fine particles (≥300 mesh) powder, which is stacked layer by layer to form 1-3mm raw embryo sheet through casting machine.
- Cold isostatic pressing molding: the mixed powder is pressed into the high-speed steel mold under 500MPa pressure to form a hollow cylindrical/tubular structure with a compactness of more than 92%.
- Gradient structure manufacturing: 3D printing technology or casting method is used to realize the gradient change of porosity (e.g. 30% outer layer → 50% inner layer), which improves the dirt holding capacity by 30%.
- Drying treatment is required after molding, and the temperature is controlled at 80-120°C to remove volatile agents and prevent the billet from cracking.
- Vacuum sintering furnace for high temperature treatment: stainless steel cartridge 800-900 ℃, titanium alloy 1250 ℃, nickel-based alloys 1350 ℃, sintering time 2-6 hours.
- Key control points: oxygen content <50ppm (argon protection), temperature uniformity ± 5 ℃, cooling rate <5 ℃ / min.
- Special structural treatment: multi-layer composite cartridges need to be coiled and welded, with low-precision security cartridges (e.g. 0.5μm) embedded inside to form a double protection.
- Mechanical processing: laser cut the end face to Ra≤0.8μm, welded M20/DOE standard interface, precision error＜0.05mm.
- Surface treatment: Electrochemical polishing to enhance corrosion resistance, or spray PTFE coating to enhance hydrophobicity.
- Performance testing: ISO 2941 permeability test, ASTM F838 bacterial retention verification, burst pressure ≥ 8MPa test.
What are the Advantages of our sintered Powder filter?
- Resistant to extreme environment: 316L stainless steel is resistant to 500℃ high temperature/PH2-12 corrosion, titanium alloy is resistant to aqua regia/seawater erosion (600℃ dry state).
- Excellent mechanical strength: compressive strength of 0.8-3MPa, nickel-based alloy burst pressure up to 8MPa, alternating load withstand > 10,000 cycles.
- Outstanding regeneration ability: ultrasonic cleaning efficiency >95%, high temperature burning regeneration >50 times, life expectancy is 3-5 times longer than traditional cartridges.
- Gradient pore design: the outer layer has 5μm precision to intercept large particles, the middle layer has 2μm control precision, and the inner layer has 0.22μm to realize terminal filtration, with a pressure drop of 0.08ΔP.
- Composite function integration: five-layer sintered mesh structure (protective layer + precision layer + dispersion layer + double-layer reinforcement layer) improves the dirt holding capacity to 3-5 times.
- Intelligent pore size adjustment: Memory alloy cartridge can realize ±5μm dynamic pore size adjustment to adapt to flow fluctuation.
- Raw material utilization rate ＞98%, energy saving 40% than traditional casting process.
- Rapid prototyping technology shortens the production cycle by 50%, and 3D printing realizes single-piece customization of complex structures.
- Modular design supports online replacement, reducing maintenance costs by 60%.
Typical application scenarios
- PTA mother liquor recovery: 316L filter element intercepts ≥0.5μm catalyst and is resistant to 20MPa high pressure.
- Crude oil desulfurization: gradient nickel-based cartridge is resistant to H₂S corrosion, with a precision of 1μm.
- Aseptic air filtration: titanium cartridge passed FDA certification, surface roughness Ra≤0.8μm.
- Vaccine terminal filtration: 0.22μm precision PTFE composite cartridge with bacterial retention rate >99.99%.
- Semiconductor ultrapure water: gradient titanium cartridge removes ≥0.1μm particles, resistivity >18MΩ-cm.
- Aviation hydraulic system: multi-layer sintered mesh cartridge is resistant to -196℃ liquid nitrogen environment.