1. Introduction
According to the “2024 Municipal Wastewater Treatment Technology Report of the National Wastewater Treatment Technology Research Institute”, after the 2023 renovation project of the XX City Wastewater Treatment Plant adopted a high-pressure chamber diaphragm filter press, the moisture content of the filter cake dropped from 70% to 45% based on the daily sludge processing of 50 tons and the unit electricity price of 1 yuan/kWh, saving 100,000 kWh of electricity annually and saving about 120,000 yuan in electricity bills.
2. Equipment principle and system composition
2.1 Diaphragm Principle and Technical Barriers
The chamber diaphragm filter press uses a controllable expansion diaphragm to maintain pressure for 2-3 minutes in the initial filtration stage to ensure solid-liquid separation; then a second squeezing force of 0.3-0.5 MPa is applied, and the moisture content of the filter cake can be reduced by an additional 20%. Compared with traditional mechanical filter presses, diaphragm technology breaks through the dual bottlenecks of pressure uniformity and filter cake hardness, becoming a core technical barrier.
2.2 Main components and industry significance
– **Diaphragm filter plate**: 304 food grade stainless steel, plum blossom-shaped plate increases pressure bearing capacity by 20%;
– **Hydraulic system**: German imported cylinder + PLC control, pressure gradient 0.5-1.0 MPa/min, adaptive adjustment;
– **Control system**: touch screen + remote monitoring, real-time diagnosis and alarm.
3. Optimize operating procedures
The following processes ensure efficient collaboration of the system:
3.1 Operation steps
1) **Feeding** → 2) **Pre-dehydration** (16 MPa, 2-3 minutes) → 3) **Diaphragm composite extrusion** (0.3-0.5 MPa, 1.5-2 minutes) → 4) **Cake unloading and cleaning** (backwashing twice, high-pressure water jet cleaning).
3.2 Parameter Optimization Suggestions
– The first pressurization phase lasts for 2-3 minutes to ensure solid phase aggregation;
– The second squeeze lasts for 1.5-2 minutes to maximize dehydration efficiency;
– Backwash twice to reduce filter cloth residue and extend the service life to 1500 hours.
4. Energy saving and consumption reduction and case analysis
Before explaining the core cases, it is necessary to emphasize the significance of coordinated optimization of equipment and systems: by coordinating variable frequency feeding and online monitoring, the overall energy efficiency is further improved.
4.1 Municipal Project Cases
XX City Wastewater Treatment Plant (treatment capacity 50 tons/day) project: Annual average power consumption decreased by 40% (compared with traditional units), filter cake moisture content 53%→45%, annual power saving 100,000 kWh, electricity bill savings of 120,000 yuan.
4.2 Printing and dyeing factory case
After the transformation of a printing and dyeing factory (30 tons/day benchmark), the dosage of chemicals was reduced by 20% from the benchmark 4 kg/ton, the annual cost was reduced by 80,000 yuan, and the transmittance of the filtrate was increased to 99.5%.
5. Maintenance and monitoring warning
To ensure continuous and efficient operation, it is recommended to formulate the following periodic maintenance plan:
5.1 Filter cloth maintenance
The filter cloth is replaced every 600 hours and cleaned with a high-pressure water jet to maintain water permeability; tension monitoring can provide timely warning of wear.
5.2 Hydraulic and system inspection
– Hydraulic oil should be replaced every six months, and the oil viscosity and impurity content should be tested;
– Pressure fluctuations should be monitored (±0.2 MPa threshold), and leakage or tripping should be repaired immediately;
– Log analysis: Fault trend prediction should be carried out based on PLC data.
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