Finding vacuum leaks on a carousel vacuum filter
Inspection of a working filter in a fertilizer production plant: detection of air leaks on a corrugated hose and along a pressure bar using NAC-PU.
What causes vacuum leaks?
Hypothetical scenario for a single filter from the case study: 55 kW pump, 8,000 operating hours per year, and a dry product capacity of 50 t/h. Assumed prices: electricity — 6 ₽/kWh, gas — 7.5 ₽/m³. The final drying cost estimate is based on the original model. This does not represent actual losses or confirmed savings at the facility. With a hypothetical product price of 5,000 ₽/t, the shortfall corresponds to 240 million ₽ in annual revenue; the impact on profit depends on costs and the ability to offset the output.
About the project
- Client
- Fertilizer production
- Industry
- Chemical Industry
- Object
- Carousel vacuum filter
- The task
- Finding air leaks on operating equipment
- Equipment
- NAC-PU
- Software
- Aura SVS
Task: Find leaks in a vacuum filter
A fertilizer production facility needed to identify air leaks in a rotary vacuum filter. The inspection included connections, pipes, manifolds, rotary joints, valves, cell joints, and filter fabric fasteners.
Loss of vacuum impairs sludge filtration and washing: productivity decreases, cake moisture increases, and subsequent drying costs increase. For continuous production, it's important to detect leaks during plant operation.
It was necessary to localize specific locations of suction leaks on large equipment in conditions of workshop noise and record them for subsequent repair.
Solution: Search by acoustic map
The NAC-PU visual-acoustic leak detector and Aura SVS software were used for the inspection. The camera recorded ultrasound from turbulent airflow through the leak and displayed the source on an image of the filter.
The non-contact method allowed testing of the operating system without applying liquids or introducing tracer gas. Spatial signal processing helped isolate sources from the background noise of the equipment.
How was the examination conducted?
Inspection of the working filter
The operator inspected the rotary joint between the carousel and the collector, the cell joints and the vacuum system connections.
Search for sources of suction cups
Using the acoustic map, we identified the locations of leaks, including the corrugated hose and the area along the pressure bar.
Notes with notes
The materials were stored in container files, noting the location of the sources and the features of the surveyed areas.
Processing in Aura SVS
The saved records were used for automated report generation and compilation of a list of areas to be tested.
Result: Air leaks detected
The inspection revealed vacuum leaks in the corrugated hose and along the pressure plate of the rotary vacuum filter. An acoustic map allowed us to pinpoint the sources to specific areas of the equipment.
The operator's notes and recordings formed the basis for reporting and planning the inspection of seals and connections. A repeat inspection after repair allows for verification of the source of the problem.
Where applicable
A similar approach can be used to detect air leaks in vacuum filters in other industries.
Mining and mineral processing industry
Dewatering of ore concentrates and tailings on disc, carousel and belt filters.
Chemical and mineral industry
Production of fertilizers and phosphoric acid, filtration of salts, pigments and mineral fillers.
Metallurgy
Filtration of aluminum hydroxide, washing of sediments and dewatering of sludge.
Coal and fuel industry
Dewatering of coal sludge and preparation of raw materials for briquetting.
Pulp and paper industry
Filtration of process suspensions and sediments, separation of fillers.
Food industry
Separation and washing of starch, filtration of sediments and food suspensions.
Pharmaceuticals and biotechnology
Isolation of crystalline products, separation of biomass and sediments after fermentation.
Construction industry and production of building materials
Filtration of gypsum, kaolin and clays before drying and further processing.
Ecology and water treatment
Dewatering of wastewater treatment plant sludge and separation of impurities from industrial wastewater.
Laboratories and pilot plants
Checking the tightness of vacuum systems when testing filtration modes.
Equipment and Software
A camera for detecting air leaks and software for analyzing recordings and preparing reports.
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