Alpenfalke Horizontal Filter: A Critical Tool in Nitrocellulose Processing

Nitrocellulose production is a meticulous and highly specialized process. Ensuring the purity and quality of nitrocellulose involves advanced filtration systems capable of handling complex industrial needs. Among these systems, the Alpenfalke Horizontal Filter for Nitrocellulose Processing stands out as a critical component. Designed for efficiency and durability, this device plays an essential role in separating fibers and liquids during the manufacturing process.

What is a Alpenfalke Horizontal Filter for Nitrocellulose Processing?

The Alpenfalke Horizontal Filter is a cylindrical filtration system designed specifically for the rigorous demands of nitrocellulose production. Its primary function is to separate filtered liquids from the fibers and impurities, ensuring high-quality output while maintaining operational efficiency.

Key features of this horizontal filtration system include:

  • A robust cylindrical design for continuous and reliable filtration.
  • Advanced sealing systems to prevent leaks and contamination.
  • Interchangeable filter mesh for adaptability and ease of maintenance.

How Does the Alpenfalke Horizontal Filter Work?

The Alpenfalke Horizontal Filter operates through a combination of centrifugal and filtration mechanisms. Here is how the process unfolds:

  1. Material Input:
    • The suspension containing nitrocellulose fibers is introduced into the system through the filling pipe (XX01-N11), connected via a DN 80 PN 16 flange.
  2. Filtration Process:
    • The cylindrical drum rotates, forcing the liquid through the filter mesh while retaining fibers and impurities.
    • Six filtration sieves, attached externally to the drum, ensure efficient separation.
  3. Collection of Filtered Liquids:
    • Filtered liquids are drained through the bottom outlet (XX01-N21) using a DN 80 PN 16 flange, while overflow liquids exit through a separate outlet (XX01-N22) with a DN 50 PN 16 flange.
  4. Removal of Trapped Fibers:
    • Trapped nitrocellulose fibers are collected and discharged through a dumper system (XX01-N31), equipped with a DN 100 PN 16 flange for efficient handling.
  5. Cleaning and Maintenance:
    • The filter is designed for easy cleaning and maintenance, with a removable hatch for replacing filter segments and a flushing system to prevent residue buildup.

Technical Features of the Alpenfalke Horizontal Filter

The Alpenfalke Horizontal Filter is engineered with precision and durability to meet the stringent demands of nitrocellulose production. Key technical components include:

  1. Cylindrical Stator:
    • The filter stator is a horizontal cylindrical container with a base, providing connection points for the rotor and drive. The stator includes:
      • A front bolted flange for easy access.
      • Drain outlets for filtered and overflow liquids, designed to EN 1092-1 standards.
  2. Filter Drum:
    • The cylindrical drum features a solid back wall, a front ring cover, and six interchangeable filtration sieves for flexibility and efficiency.
  3. Sealing and Bearings:
    • Equipped with a lip seal in the stator shaft’s back wall to prevent leaks.
    • Rolling bearings with lifelong grease filling for durability and maintenance-free operation.
  4. Drive System:
    • The rotor is powered by an oil-filled gearbox connected to an asynchronous electric motor (XX01AM10), designed for use with a frequency converter. This ensures consistent and energy-efficient operation.
  5. Additional Features:
    • Ventilation neck (XX01-N61) with a DN 100 PN 16 flange for safe air exhaust.
    • Integrated connection points for compressed air nozzles (XX01-N71, XX01-N72) for effective cleaning.

Applications of the Alpenfalke Horizontal Filter in Nitrocellulose Production

The Alpenfalke Horizontal Filter is indispensable in the production of nitrocellulose due to its ability to efficiently handle the separation of fibers and liquids. Key applications include:

  1. Filtration of Nitrocellulose Suspensions:
    • Ensures that fibers are separated effectively, providing a purified liquid for further processing.
  2. Fiber Recovery:
    • Recovers trapped nitrocellulose fibers, reducing waste and improving overall yield.
  3. Product Quality Assurance:
    • Maintains the quality of nitrocellulose by eliminating impurities and ensuring uniform filtration.
  4. Operational Efficiency:
    • Supports continuous operation with minimal downtime due to its easy maintenance features.

Advantages of the Alpenfalke Horizontal Filter

Investing in a Alpenfalke Horizontal Filter for nitrocellulose processing provides several benefits, including:

  1. Enhanced Durability:
    • Constructed with high-quality materials like stainless steel (DIN – WSt.-Nr. 1.4571, AISI 316Ti) for wet parts and structural steel for dry components with chemical-resistant paint.
  2. Easy Maintenance:
    • Features a removable stator cover, accessible hatches, and interchangeable filter meshes for quick and hassle-free maintenance.
  3. Energy Efficiency:
    • Powered by an asynchronous motor with a frequency converter, ensuring optimized energy consumption.
  4. Compliance with Industry Standards:
    • Designed to meet CE conformity and regulations such as 2006/42/EG and 2014/34/EU for explosive environments.

Why Choose the Alpenfalke Horizontal Filter for Nitrocellulose Processing?

  1. Precision Filtration:
    • Achieves precise separation of liquids and fibers, critical for high-quality nitrocellulose production.
  2. Reduced Waste:
    • Effectively recovers fibers, minimizing material loss and maximizing yield.
  3. Operational Safety:
    • Built to handle the demands of potentially explosive environments, ensuring safety and reliability.
  4. Sustainability:
    • Designed for long-term use with minimal environmental impact due to durable and recyclable materials.

Conclusion

The Alpenfalke Horizontal Filter for Nitrocellulose Processing is a cornerstone of modern nitrocellulose production. Its robust design, advanced features, and compliance with industry standards make it an essential tool for achieving high efficiency and quality in the manufacturing process. By investing in this cutting-edge technology, manufacturers can ensure superior product quality, operational safety, and long-term sustainability.

For more information about integrating the Alpenfalke Horizontal Filter into your production line, contact Alpenfalke today and discover how we can optimize your nitrocellulose processing workflow!