What is the Advantage and Disadvantage of Dashang wire mesh

In the extrusion industry, exruder screens are key components used to remove impurities (such as unmelted particles, carbides, metal debris, etc.) in molten plastics or rubber, protect equipment and improve product quality. Different types of extruder screens have their own advantages and disadvantages due to their different structures, filtration efficiencies and applicable scenarios. The following is an analysis of the characteristics and usage scenarios of common filter types:

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1. Round Extruder ScreensFeatures:- Round in shape, usually composed of multiple layers of metal mesh with different mesh sizes (such as a combination of 20 mesh coarse mesh + 40 mesh fine mesh).- Simple structure, easy installation and low cost.Usage scenarios:- Suitable for raw materials with low impurity content or ordinary extrusion processes with low requirements for filtration accuracy.- Commonly used in the production of conventional products such as PVC pipes and profiles.Advantages:- Low cost, easy to replace, and suitable for most standard extruder filter plates.Disadvantages:- Small filtration area, easy to clog, and requires frequent replacement; multi-layer stacking may increase melt resistance.

2. Oval Extruder ScreensFeatures:- Oval design, larger area than circular filter, can accommodate more impurities.- Usually adopts single-layer or multi-layer metal mesh composite structure.Application scenarios:- Suitable for raw materials with medium to high impurity content (such as recycled or reclaimed materials) or production scenarios that require a longer filtration cycle.- Commonly used in the processing of products such as films and sheets that are sensitive to impurities.Advantages:- Increase the effective filtration area and extend the replacement cycle; reduce melt pressure fluctuations.Disadvantages:- Installation requires a special screen plate, which has low compatibility; the initial cost is higher than the circular filter.

3. Cylindrical Screen FilterFeatures:- Cylindrical shape, because the filter medium wraps the entire device, it can provide a huge filtering surface area, and the amount of filtered material is 4 times that of ordinary circular filter screens.- Deep filtration is achieved by increasing the surface area.Application scenarios:- High-precision filtration requirements (such as medical catheters, optical-grade plastics) or high-viscosity melts (such as TPU, PC).- Suitable for high-pressure extruders or twin-screw extrusion systems.Advantages:- High filtration accuracy (up to 5-10 microns), high pressure resistance, and long service life.Disadvantages:- Complex structure, difficult to clean; high initial investment and maintenance costs.

4. Multi-layer Cylindrical FilterFeatures:- It is composed of multiple concentric cylindrical filter screens nested, and the mesh size of each layer increases step by step (such as outer layer coarse filtration, inner layer fine filtration).- Combined with graded filtration and deep filtration, impurities are more evenly distributed.Application scenarios:- Raw materials with high impurity content (such as recycled plastics) or complex processes requiring multi-stage filtration.- Suitable for the production of high-strength products such as cable sheaths and automotive accessories.Advantages:- Strong anti-clogging ability, extended continuous operation time; strong adaptability.Disadvantages:- Large volume, customized design required; time-consuming replacement and cleaning.

5. Screen Belt/Continuous Filter BeltFeatures:- Belt-shaped metal mesh, continuously moved by hydraulic or mechanical drive to achieve dynamic filtration.- Combined with an automatic scraper system to remove surface impurities without stopping for replacement.Application scenarios:- Ultra-high-yield continuous production lines (such as large-scale film blowing machines, sheet extrusion lines).- Processing of highly polluted raw materials (such as recycled agricultural films, masterbatches containing a large amount of fillers).Advantages:- No need to stop for screen replacement, extremely high production efficiency; suitable for high impurity loads.Disadvantages:- Complex equipment, huge initial investment; high maintenance technology requirements.

Comprehensive comparison and selection recommendations

Type

Filtration accuracy

Anti-clogging

Cost

Applicable scenarios

 Round filter

 Low-medium

Low

Low

Ordinary products, low-impurity raw materials

Oval filter

Medium

 Medium

Medium

Recycled material processing, medium output

Cylindrical filter barrel

 High

High

 High

High precision, high viscosity melt

Multi-layer cylindrical filter

Medium-high

High

High

High impurity raw materials, multi-stage filtration requirements

 Filter belt

Medium

Very high

Very high

Ultra-high production line, continuous production cannot be interrupted

Now, as the application of filter screens is becoming more and more uniform around the world, their sizes and specifications will also tend to be unified. Dashang Wire Mesh can customize the appropriate filter type according to the actual needs of customers, significantly improving production efficiency and product quality, while reducing energy consumption and scrap rate.

Sintered Mesh Filter Element

Stainless steel mesh sintered filter element is a high-performance metal porous filter element. It uses a special manufacturing process to firmly combine multiple layers of stainless steel wire mesh with different pore sizes to form an overall structure with specific filtering accuracy, high strength and excellent performance.

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The stainless steel mesh sintering process is usually composed of multiple layers (such as protective layer, control filter layer, dispersion layer, support layer) of stainless steel wire mesh with different mesh sizes (i.e. pore sizes) stacked together. The core lies in sintering. These stacked metal meshes are heated under high temperature, high pressure and protective atmosphere (such as vacuum or inert gas). In this process, the contact points of the metal mesh melt and diffuse, and finally fuse and bond together firmly to form an integral, rigid three-dimensional mesh porous structure. Austenitic stainless steel is mainly used, the most common ones are 304, 304L, 316, 316L. These materials have excellent corrosion resistance, high temperature resistance, high strength and good processing performance, and are suitable for various harsh environments.

The core working principle of the stainless steel mesh sintered filter element: By selecting a combination of wire meshes with different mesh sizes and the sintering process, the absolute filtration accuracy of the filter element (usually between 1 micron and 300 microns) can be precisely controlled to ensure that impurities above a certain size are intercepted. The internal support layer and dispersion layer provide strong mechanical support, allowing the filter element to withstand high pressure differences, while also helping to evenly distribute the fluid and reduce local blockages.

       Sintered Mesh Filter Element                                                     Sintered Mesh Filter Element                                          Sintered Mesh Filter Element

Key performance advantages of stainless steel mesh sintered filter element :

1. High strength and rigidity: The overall structure after sintering has extremely high mechanical strength and rigidity, can withstand high pressure, high flow rate and frequent backwashing, and is not easily deformed or damaged.

2. High filtration accuracy and stability: The pore size is uniform and stable, the filtration accuracy is reliable, and it can effectively intercept tiny particles.

3. Excellent temperature resistance: Stainless steel material enables it to work stably in high temperature (usually up to 400°C or above, 316L or even higher) and low temperature environments.

4. Excellent corrosion resistance: Stainless steel (especially 316/316L) can withstand a variety of acids, alkalis, salts and organic solvents, and is suitable for corrosive media.

5. Cleanability/Regenerability: This is one of its biggest advantages. Filter cake or blockages intercepted on the surface can be effectively removed by high-pressure gas backwashing, high-pressure liquid backwashing, ultrasonic cleaning, chemical cleaning, etc., with good performance recovery and extremely long service life (much longer than disposable filter elements).

6. No medium falling off: The sintered structure is firm, the metal fiber will not fall off, and there is no pollution to the filter medium. It is especially suitable for occasions with extremely high requirements for cleanliness (such as food, pharmaceuticals, and electronics).

7. Good permeability: The porosity is high and regular, and the resistance to fluid passage is relatively small.

8. Non-magnetic (austenitic stainless steel): Suitable for applications where magnetic contamination is not permitted.

9. Weldability: Easy to connect to metal pipes or equipment by welding and other means, with good sealing.

Stainless steel mesh sintered filter elements and stainless steel pleated filter elements are both important metal filter elements, but they have significant differences in structure, performance characteristics and application scenarios. Understanding these differences is crucial for correct selection. The following is a detailed comparison of the two:

               Sintered Mesh Filter Element                                              Sintered Mesh Filter Element                                         Sintered Mesh Filter Element

1. For ultimate performance, long life, and resistance to harsh environments: choose sintered filter elements.

High and stable absolute filtration accuracy is required.

The working conditions involve high temperature, high pressure and highly corrosive media.

The filter element is required to be able to be repeatedly and thoroughly cleaned and regenerated to reduce long-term replacement costs and downtime.

The cleanliness requirements for the filtration products are extremely high (such as no fiber shedding).

The budget allows for a higher initial investment.

2. Focus on initial flow rate, dirt holding capacity, cost, and relatively mild working conditions: select pleated filter element.

Handles large flow rates and is sensitive to initial pressure drop.

The filtering accuracy requirement is acceptable with a medium nominal accuracy.

The operating pressure and temperature are in the medium range.

The media is relatively clean or used as a pre-filter with low contaminant load.

The budget is limited and regular replacement of filter elements is accepted as consumables.

Space is limited and high filtration area per unit volume is required.

Simply put: sintered filter element is a solution for "high performance, long life, high investment and high return"; pleated filter element is a common choice for "economical and practical, large flow, easy to replace".

The main application areas of stainless steel mesh sintered filter element :

Petrochemical: catalyst recovery, crude oil filtration, gas purification, tail gas recovery, acid/alkali/solvent filtration.

Pharmaceuticals and bioengineering: liquid medicine filtration, air sterilization filtration, fermentation liquid filtration, pure water/water for injection (WFI) system.

Food and Beverage: Precision filtration of alcohol, beverages, edible oil, syrup, milk and purified water.

Water treatment: industrial circulating water, wastewater treatment, seawater desalination pretreatment, ultrapure water system security filtration.

Environmental protection: flue gas dust removal, dust recovery, and wastewater precision filtration.

Machinery and Metallurgy: Hydraulic oil, lubricating oil, cutting fluid, coolant filtration, metal melt filtration (such as aluminum liquid).

Energy: Nuclear industry, fuel cell gas purification.

Aerospace: Fuel and hydraulic system filtration.

Electronics: High-purity gas and high-purity chemical transmission and filtration.

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