SUMMARY

TECHNICAL COMPETENCIES
Competency in X – Filter and Dregs Handling
at Recausticizing area

Teguh Widodo
07-0611

APRIL ACADEMY 8
RECAUST, KILN & EFFLUENT DEPARTMENT
2007
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X – FILTER (472-E-001 AND 472-E-002)

A. Function
X – Filter is to clarify the green liquor from the impurities or dregs which is
coming from the Recovery Boiler with the filtration system with pressurized
filtration. There are two X-Filter (472-E-001 AND 472-E-002), servicing only
line 2.

Figure 01. X-Filter

B. Basic Theory
The separation of solids from a suspension in a liquid by means of a porous
medium or screen which retains the solids and allows the liquid to pass is termed
filtration.
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In general, the pores of the medium are larger than the particles which are to be
removed, and the filter works efficiently only after an initial deposit has been
trapped in the medium.

In most industrial applications it is the solids that are required and their physical
size and properties are of paramount importance. Thus, the main factors to be
considered when selecting equipment and operating conditions are:
(a) The properties of the fluid, particularly its viscosity, density and corrosive
properties.
(b) The nature of the solid—its particle size and shape, size distribution, and
packing characteristics.
(c) The concentration of solids in suspension.
(d) The quantity of material to be handled, and its value.
(e) Whether the valuable product is the solid, the fluid, or both.
(f) Whether it is necessary to wash the filtered solids.
(g) Whether very slight contamination caused by contact of the suspension or
filtrate with the various components of the equipment is detrimental to the
product.
(h) Whether the feed liquor may be heated.
(i) Whether any form of pretreatment might be helpful.

Filtration is essentially a mechanical operation and is less demanding in energy

than evaporation or drying where the high latent heat of the liquid, which is
usually water, has to be provided. In the typical operation shown in Figure 01, the
cake gradually builds up on the medium and the resistance to flow progressively
increases. During the initial period of flow, particles are deposited in the surface
layers of the cloth to form the true filtering medium. This initial deposit may be
formed from a special initial flow of precoat material which is discussed later. The
most important factors on which the rate of filtration then depends will be:
(a) The drop in pressure from the feed to the far side of the filter medium
(b) The area of the filtering surface
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(c) The viscosity of the filtrate

(d) The resistance of the filter cake
(e) The resistance of the filter medium and initial layers of cake

Figure 02. Principle of filtration

The mechanical details of the equipment, particularly of the flow channel and the
support for the medium, influence the way the cake is built up and the ease with
which it may be removed. A uniform structure is very desirable for good washing
and cakes formed from particles of very mixed sizes and shapes present special
problems. Although filter cakes are complex in their structure and cannot truly be
regarded as composed of rigid non-deformable particles, the method of relating
the flow parameters developed in

It may be noted that there are two quite different methods of operating a batch
filter. If the pressure is kept constant then the rate of flow progressively
diminishes, whereas if the flowrate is kept constant then the pressure must be
gradually increased. Because the particles forming the cake are small and the flow
through the bed is slow, streamline conditions are almost invariably obtained, and,
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at any instant, the flowrate of the filtrate may be represented by the following
form :

(1)

where is the volume of filtrate which has passed in time t ,

A is the total cross sectional area of the filter cake,
uc is the superficial velocity of the filtrate,
l is the cake thickness,
S is the specific surface of the particles,
e is the voidage,
μ is the viscosity of the filtrate,
and -∆P is the applied pressure difference.
In deriving this equation it is assumed that the cake is uniform and that the
voidage is constant throughout. In the deposition of a filter cake this is unlikely to
be the case and the voidage, e will depend on the nature of the support, including
its geometry and surface structure, and on the rate of deposition. The initial stages
in the formation of the cake are therefore of special importance for the following
reasons:
(a) For any filtration pressure, the rate of flow is greatest at the beginning of
the process since the resistance is then a minimum.
(b) High initial rates of filtration may result in plugging of the pores of the
filter cloth and cause a very high resistance to flow.
(c) The orientation of the particle in the initial layers may appreciably
influence the structure of the whole filter cake.

Filter cakes may be divided into two classes—incompressible cakes and

compressible cakes. In the case of an incompressible cake, the resistance to flow
of a given volume of cake is not appreciably affected either by the pressure
difference across the cake or by the rate of deposition of material. On the other
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hand, with a compressible cake, increase of the pressure difference or of the rate
of flow causes the formation of a denser cake with a higher resistance. For
incompressible cakes e in equation 1 may be taken as constant and the quantity e3/
[5(1 − e)2S2] is then a property of the particles forming the cake and should be
constant for a given material.
Thus:

(2)
where:

(3)

It may be noted that, when there is a hydrostatic pressure component such as with
a horizontal filter surface, this should be included in the calculation of −∆P.

Equation 2 is the basic filtration equation and r is termed the specific resistance
which is seen to depend on e and S. For incompressible cakes, r is taken as
constant, although it depends on rate of deposition, the nature of the particles, and
on the forces between the particles. r has the dimensions of L−2 and the units m−2
in the SI system.

Relation between thickness of cake and volume of filtrate

In equation 2, the variables l and V are connected, and the relation between them
may be obtained by making a material balance between the solids in both the
slurry and the cake as follows.

Mass of solids in filter cake = (1 − e)Alρs, where ρs is the density of the

solids
Mass of liquid retained in the filter cake = eAlρ, where ρ is the density of
the filtrate.
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If J is the mass fraction of solids in the original suspension then:

or:

so that: l =

(4)
and:

(5)

If v is the volume of cake deposited by unit volume of filtrate then:

(6)

and from equation 5:

(7)

Substituting for l in equation 2:

(8)
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Equation 8 may be regarded as the basic relation between −∆P, V, and t. Two
important types of operation are: (i) where the pressure difference is maintained
constant and (ii) where the rate of filtration is maintained constant.

For a filtration at constant rate

so that:

(9)
or:

(10)

and −∆P is directly proportional to V .

For a filtration at constant pressure difference

(11)
or:

(12)

Thus for a constant pressure filtration, there is a linear relation between V2 and t or
between t/V and V.

Filtration at constant pressure is more frequently adopted in practice, although the

pressure difference is normally gradually built up to its ultimate value.
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If this takes a time t1 during which a volume V1 of filtrate passes, then integration
of equation 12 gives:

(13)
or:

(14)

Thus, there where is a linear relation between V2 and t and between (t−t1)/(V − V1)
and (V − V1), where (t − t1) represents the time of the constant pressure filtration
and (V − V1) the corresponding volume of filtrate obtained.

Measurements on the flow in a filter cake concluded that the resistance is

somewhat greater than that indicated by equation 1. It was assumed that part of
the pore space is rendered ineffective for the flow of filtrate because of the
adsorption of ions on the surface of the particles.
Typical values of the specific resistance r of filter cakes are given in Table 01. In
the absence of details of the physical properties of the particles and of the
conditions under which they had been formed, these values are approximate
although they do provide an indication of the orders of magnitude.
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Table 01. Typical Values of Specific Resistance, r

Flow of liquid through the cloth

Experimental work on the flow of the liquid under streamline conditions has
shown that the flowrate is directly proportional to the pressure difference. It is the
resistance of the cloth plus initial layers of deposited particles that is important
since the latter, not only form the true medium, but also tend to block the pores of
the cloth thus increasing its resistance. Cloths may have to be discarded because
of high resistance well before they are mechanically worn. No true analysis of the
buildup of resistance is possible because the resistance will depend on the way in
which the pressure is developed and small variations in support geometry can
have an important influence. It is therefore usual to combine the resistance of the
cloth with that of the first few layers of particles and suppose that this corresponds
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to a thickness L of cake as deposited at a later stage. The resistance to flow

through the cake and cloth combined is now considered.

Flow of filtrate through the cloth and cake combined

If the filter cloth and the initial layers of cake are together equivalent to a
thickness L of cake as deposited at a later stage in the process, and if −P is the
pressure drop across the cake and cloth combined, then:

(15)

which may be compared with equation 2.

Thus:

(16)

This equation may be integrated between the limits t = 0, V = 0 and t = t1, V = V1

for constant rate filtration, and t = t1, V = V1 and t = t , V = V for a subsequent
constant pressure filtration.

For the period of constant rate filtration:

or:

or:
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(17)

For a subsequent constant pressure filtration:

(18)
or:

or:

(19)

Thus there is a linear relation between (t − t1)/(V − V1) and V − V1, as shown in
Figure 03, and the slope is proportional to the specific resistance, as in the case of
the flow of the filtrate through the filter cake alone given by equation 7.14,
although the line does not now go through the origin.
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Figure 03. A typical filtration curve

The intercept on the (t − t1)/(V − V1) axis should enable L, the equivalent thickness
of the cloth, to be calculated although reproducible results are not obtained
because this resistance is critically dependent on the exact manner in which the
operation is commenced. The time at which measurement of V and t is
commenced does not affect the slope of the curve, only the intercept. It may be
noted that a linear relation between t and V2 is no longer obtained when the cloth
resistance is appreciable.

Compressible filter cakes

Nearly all filter cakes are compressible to at least some extent although in many
cases the degree of compressibility is so small that the cake may, for practical
purposes, be regarded as incompressible. The evidence for compressibility is that
the specific resistance is a function of the pressure difference across the cake.
Compressibility may be a reversible or an irreversible process. Most filter cakes
are inelastic and the greater resistance offered to flow at high pressure differences
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are caused by the more compact packing of the particles forming the filter cake.
Thus the specific resistance of the cake corresponds to that for the highest
pressure difference to which the cake is subjected, even though this maximum
pressure difference may be maintained for only a short time. It is therefore
important that the filtration pressure should not be allowed to exceed the normal
operating pressure at any stage. In elastic filter cakes the elasticity is attributable
to compression of the particles themselves. This is less usual, although some
forms of carbon can give rise to elastic cakes.

As the filtrate flows through the filter cake, it exerts a drag force on the particles
and this force is transmitted through successive layers of particles right up to the
filter cloth. The magnitude of this force increases progressively from the surface
of the filter cake to the filter cloth since at any point it is equal to the summation
of the forces on all the particles up to that point. If the cake is compressible, then
its voidage will decrease progressively in the direction of flow of the filtrate,
giving rise to a corresponding increase in the local value of the specific resistance,
rz, of the filter cake. The structure of the cake is, however, complex and may
change during the course of the filtration process. If the feed suspension is
flocculated, the flocs may become deformed within the cake, and this may give
rise to a change in the effective value of the specific surface, S. In addition, the
particles themselves may show a degree of compressibility. Whenever possible,
experimental measurements should be made to determine how the specific
resistance varies over the range of conditions which will be employed in practice.

It is usually possible to express the voidage ez at a depth z as a function of the

difference between the pressure at the free surface of the cake P1 and the pressure
Pz at that depth, that is ez as a function of (P1 − Pz). The nomenclature is as defined
in Figure 04.
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Figure 04. Flow through a compressible filter cake

For a compressible cake, equation 1 may be written as:

(20)

where ez is now a function of depth z from the surface of the cake.

In a compressible cake, the volume v of cake deposited per unit area as a result of
the flow of unit volume of filtrate will not be constant, but will vary during the
filtration cycle. If the particles themselves are not compressible, however, the
volume of particles (v’) will be almost independent of the conditions under which
the cake is formed assuming a dilute feed suspension. Any small variations in v’
arise because the volume of filtrate retained in the cake is a function of its
voidage, although the effect will be very small, except possibly for the filtration of
very highly concentrated suspensions. The increase in cake thickness, dz resulting
from the flow of a volume of filtrate dV is given by:
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(21)

By comparison with equation 6, it may seen that:

(22)
Substituting from equation 21 into equation 20 gives:

Thus:

(23)

(25)

Comparing equations 8 and 24 shows that for an incompressible cake:

At any instant in a constant pressure filtration, integration of equation 24 through

the whole depth of the cake gives:

(26)

At any time t, dV/dt is approximately constant throughout the cake, unless the rate
of change of holdup of liquid within the cake is comparable with the filtration rate
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dV/dt , such as is the case with very highly compressible cakes and concentrated
slurries, and therefore:

(27)

rz has been shown to be a function of the pressure difference (P1 − Pz) although it
is independent of the absolute value of the pressure. Experimental studies
frequently show that the relation between rz and (P1 − Pz) is of the form:

(28)

where r’ is independent of Pz and 0 < n_ < 1.

Thus:

(29)
Thus:

(30)

where r”= (1 − n’)r’

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and:

(31)

where is the mean resistance defined by:

(32)

As the pressure is increased above atmospheric, the porosity decreases in

proportion to some power of the excess pressure.

The filter medium

The function of the filter medium is generally to act as a support for the filter
cake, and the initial layers of cake provide the true filter. The filter medium
should be mechanically strong, resistant to the corrosive action of the fluid, and
offer as little resistance as possible to the flow of filtrate. Woven materials are
commonly used, though granular materials and porous solids are useful for
filtration of corrosive liquids in batch units. An important feature in the selection
of a woven material is the ease of cake removal, since this is a key factor in the
operation of modern automatic units.

Washing of the filter cake

When the wash liquid is miscible with the filtrate and has similar physical
properties, the rate of washing at the same pressure difference will be about the
same as the final rate of filtration. If the viscosity of the wash liquid is less, a
somewhat greater rate will be obtained. Channelling sometimes occurs, however,
with the result that much of the cake is incompletely washed and the fluid passes
preferentially through the channels, which are gradually enlarged by its continued
passage. This does not occur during filtration because channels are self-sealing by
virtue of deposition of solids from the slurry. Channelling is most marked with
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compressible filter cakes and can be minimised by using a smaller pressure

difference for washing than for filtration.

Washing may be regarded as taking place in two stages. First, filtrate is displaced
from the filter cake by wash liquid during the period of displacement washing and
in this way up to 90% of the filtrate may be removed. During the second stage,
diffusional washing, solvent diffuses into the wash liquid from the less accessible
voids and the following relation applies:

(35)

Although an immiscible liquid is seldom used for washing, air is often used to
effect partial drying of the filter cake. The rate of flow of air must normally be
determined experimentally.

Vacuum filters
If in a horizontal filter both sides are open to atmosphere then, as slurry is
introduced above the filter medium, filtration will occur at an adequate rate as
long as the hydrostatic head of slurry above the filter medium is sufficient. The
unit then operates as a gravity filter. If, however, the top of the vessel is enclosed
and the slurry is introduced under pressure, then the unit operates as a pressure
filter and the driving force is the amount by which the applied pressure exceeds
atmospheric pressure below the filter medium. Greatly enhanced filtration rates
may then be achieved. Similarly, if the pressure beneath the filter is reduced
below atmospheric, the unit operates as a vacuum filter and the driving force may
again be appreciably greater than that available with a gravity filter. The
maximum theoretical driving force is then 101 kN/m 2 less the vapour pressure of
the filtrate, and much higher flowrates may be obtained than with gravity
filtration. With, for example, a head of liquor of 0.3 m in a gravity filter, the
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maximum driving force is about 3 kN/m 2, whereas in theory the driving force of a
vacuum filter could be some thirty times greater.

Vacuum filtration has many advantages, not the least being the fact that the feed
slurry, often containing abrasive solids in a corrosive liquid, can be delivered by
gravity flow or by low pressure pumps which need only to overcome the
resistance in the feed pipework. In addition, vacuum filtration equipment does not
have to withstand high pressures and can therefore be manufactured in a wider
range of materials. When, because of corrosive conditions or the need to prevent
product contamination, expensive materials of construction are required, the low
pressures involved allow considerable economy in manufacturing costs. A further
advantage is that, after the bulk of the mother liquor has been filtered from the
solids, the cake is accessible to mechanical dewatering, flood washing and
sampling, and cake removal can be carried out quickly as it is easily automated.
Because of the ease of solids removal, a vacuum filter may be operated with very
short cycle times of around 60 s, and the resulting thin filter cakes give very high
flowrates per unit area, typically six times as great as those obtained with a
pressure filter operating at the same differential pressure. Where delicate solids
are handled, very low differential pressures may be used and, since the feed and
the filtrate are not handled under positive pressure, there is no possibility of liquor
leakage from the system as might be the case with high pressure differentials. This
is an important advantage especially where corrosive or hazardous materials are
involved.

Rotary drum filters

Because of its versatility and simplicity, one of the most widely used vacuum
filters is the rotary drum filter and a filter of this type was patented in England in
1872 by William and James Hart. The basic design varies with different
manufacturers, although essentially all drum type vacuum filters may be divided
into two categories:
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(a) Those where vacuum is created within compartments formed on the

periphery of the drum, and
(b) Those where vacuum is applied to the whole of the interior of the drum.

The most frequently used continuous drum type filters fall into the first category.
These give maximum versatility, low cost per unit area, and also allow a wide
variation of the respective time periods devoted to filtration, washing and drying.

Essentially, a multi-compartment drum type vacuum filter consists of a drum

rotating about a horizontal axis, arranged so that the drum is partially submerged
in the trough into which the material to be filtered is fed. The periphery of the
drum is divided into compartments, each of which is provided with a number of
drain lines. These pass through the inside of the drum and terminate as a ring of
ports covered by a rotary valve, through which vacuum is applied. The surface of
the drum is covered with a filter fabric, and the drum is arranged to rotate at low
speed, usually in the range 0.0016–0.004 Hz (0.1–0.25 rpm) or up to 0.05 Hz (3
rpm) for very free filtering materials.

As the drum rotates, each compartment undergoes the same cycle of operations
and the duration of each of these is determined by the drum speed, the
submergence of the drum and the arrangement of the valve. The normal cycle of
operations consists of filtration, drying and discharge. It is also possible, however,
to introduce other operations into the basic cycle, including:
(a) Separation of initial dirty filtrate—which may be an advantage if a
relatively open filter fabric is used.
(b) Washing of the filter cake.
(c) Mechanical dewatering of the filter cake.
(d) Cloth cleaning.
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Figure 05.a shows a typical layout of a rotary drum installation and Figure 05.b
shows the sequence of cake formation, washing and dewatering. A large rotary
drum vacuum filter is shown in Figure 06.

In order to achieve consistent performance of a continuous filter, it is necessary to

maintain the filter medium in a clean condition. With a drum type vacuum filter
this requires the complete and continuous removal of the filter cake from the drum
surface, and the operating conditions are often influenced by the need to form a
fully dischargeable cake. Again, in order to achieve high capacity and good cake
washing and/or drying, it is very often desirable to operate with very thin cakes.
Therefore, the cake discharge system of most drum type vacuum filters must be
arranged so as to ensure the complete and continuous removal of extremely thin
filter cakes. The most effective way of achieving this is determined to a large
extent by the physical nature of the solids being handled.
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Figure 05. Typical layout of rotary drum filter installation

Figure 06. Rotary vacuum drum filter

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Continuous Precoat Filters

These filters may be operated as either pressure or vacuum filters, although
vacuum operation is the prevailing one. The filters are really not continuous but
have an extremely long batch cycle (1 to 10 days). Applications are for continuous
clarification of liquids from slurries containing 50 to 5000 ppm of solids when
only very thin unacceptable cakes would form on other filters and where “perfect”
clarity is required.

Construction is similar to that of other drum filters, except that vacuum is applied
to the entire rotation. Before feeding slurry a precoat layer of filter aid or other
suitable solids, 75 to 125 mm (3 to 5 in) thick, is applied. The feed slurry is
introduced and trapped in the outer surface of the precoat, where it is removed by
a progressively advancing doctor knife which trims a thin layer of solids plus
precoat. The blade advances 0.05 to 0.2 mm (0.002 to 0.008 in) per revolution of
the drum. When the precoat has been cut to a predefined minimum thickness, the
filter is taken out of service, washed, and freshly precoated. This turnaround time
may be 1 to 3 h.

Disk Filters
A disk filter is a vacuum filter consisting of a number of vertical disks attached at
intervals on a continuously rotating horizontal hollow central shaft (Fig. 18-127).
Rotation is by a gear drive. Each disk consists of 10 to 30 sectors of metal, plastic,
or wood, ribbed on both sides to support a filter cloth and provide drainage via an
outlet nipple into the central shaft. Each sector may be replaced individually. The
filter medium is usually a cloth bag slipped over the sectors and sealed to the
discharge nipple. For some heavy-duty applications on ores, stainless-steel
screens may be used.

The disks are typically 30 to 50 percent submerged in a troughlike vessel

containing the slurry. Another horizontal shaft running beneath the disks may
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contain agitator paddles to maintain suspension of the solids. In some designs,

feed is distributed through nozzles below each disk. Vacuum is supplied to the
sectors as they rotate into the liquid to allow cake formation. Vacuum is
maintained as the sectors emerge from the liquid and are exposed to air. Wash
may be applied with sprays, but most applications are for dewatering only. As the
sectors rotate to the discharge point, the vacuum is cut off, and a slight air blast is
used to loosen the cake. This allows scraper blades to direct the cake into
discharge chutes positioned between the disks. Vacuum and air blowback is
controlled by an automatic valve as in rotary-drum filters.

Of all continuous filters, the vacuum disk is the lowest in cost per unit area of
filter when mild steel, cast iron, or similar materials of construction may be used.
It provides a large filtering area with minimum floor space, and it is used mostly
in high-tonnage dewatering applications in sizes up to about 300 m2 (3300 ft2) of
filter area.

The main disadvantages are the inadaptability to have effective wash and the
difficulty of totally enclosing the filter for hazardous material operations.

Figure 07. Rotary Disk Filter

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Maintaining a pressure difference through a filter media drives green liquor in the
filtrations. The media can be a filter cloth, a lime mud cake, a dregs cake, or a
mixture of lime mud and dregs. In the cake filtration, the dregs that separate from
the green liquor are collected in the cake. In cross-flow filtration, the dregs are
collected in circulating liquor sludge outside the filter cloth.

Compared with the clarification of green liquor, filtration ensures better liquor
clarity since incoming liquor properties do not have any substantial effect on the
filtrate quality. Liquor quality and variations can influence the filtration capacity.
Plugging and wearing of filter cloths is impossible to avoid as they age.
Occasionally, they will require washing by acid or complete replacement.

In cross-flow filtration, a strong tangential flow on the surface of the filter media
prevents cake formation during pressure filtration. Green liquor cross-flow filter
has an arrangement that makes a thin film of green liquor fall onto filter cloth.
Some falling liquor is forced through the vertical filter cloth while most of the
liquor with dregs continues in the film to the bottom for recirculation to the top of
the filter to maintain the film. Filtration continues and the sludge thickens in the
circulation until reaching the desired sludge density. The filtration resistance
increase simultaneously, but increasing filter pressure maintains the filtration rate.
Thickened sludge is discarded from the filter by the pressure inside the filter. This
method does not require lime mud as filter aid. The final density in the dregs is
high, but a separate dregs washing and drying stage is still necessary.

C. Input, Output and Capacity

Feed to X-Filter #1 and #2 are from stabilization tank #2, pumped with 472-P-006
for X-Filter #1 and 472-P-009 for X-Filter #2. Flow to each X-filter designed to
be 75 l/s raw green liquor with TSS ≤ 1500 ppm.
 26

The filter has filtration capacity by design of 3500 m 3, with filtration pressure of
4 bar. The expected output TSS shall be 50 ppm

The Filtrate output of X-Filter goes X Filter filtrate tank (472-T-002 for X filter
#1 and 472-T-003 for X filter #3) before it enter to pumping tank of green liquor
clarifier #2 and #3 (472-T-007), and dregs product from the bottom side X Filter
goes to X filter dregs tank, then goes to dregs removal system.

D. Equipment
 X Filter 1, 472-E-001 and X Filter 2, 472-E-002
 X Filter level controller, LIC-1201 for X filter 1 and LIC-1301 for X filter 2
 X filter gas space pressure PI-1203 for X filter 1 and PI-1303 for X filter 2
 X filter filtrate space pressure PI-1221 ; PI-1321
 Pressure difference control PDIC-1222; PDIC-1322
 Filtrate valve HIC-1207; HIC-1307
 Filtrate valve HIC-1206; HIC-1306
 Green liquor flow control FIC-1211; FIC-1311
 Green liquor flow control FIC-1226; FIC-1326
 Pressure control PFIC-1204; PFIC-1304
 Compressed air valve HS-1223; HS-1323
 Gas outlet valve HS-1209 ; HS-1309
 Pressure balancing valve HS-1205 ; HS-1305
 X filter operation selector switch HS-1224 ; HS-1324
 X filter timer controls KC-1227 ; KC-1327
 Circulation pump 472-P-007 for X filter 1; 472 P-010 for X filter 2
 Circulation pipe level meter LI-1217; LI-1317
 Green liquor feed pump 472-P-006; 472-P-010
 Pump speed control SIC-1230; SIC-1330
 Green liquor pump slave valve OS-1225; OS-1325
 Green liquor line pressure measurement PI-1218; PI-1318
 Green liquor valve HS-1212; HS-1312
 27

 Dregs valve HS1213; HS-1313

 Hot water valve HS-1214; HS-1314
 Dregs return valve HS-1216; HS-1316
 Hot water return valve HS-1220; HS-1320
 Hot water tank 472-T-004 (for both X filter)
 Hot water tank level control LIC-1402
 Hot water tank temperature control TIC-1401
 X-Filter dregs tank 472-T-005 (for both X filter)
 Dregs tank level LI-1404
 Filtrate tank 472-T-002; 472-T-003
 Filtrate tank level control LICA-1208; LICA-1308
 Filtrate pump 472-P-008; 472-P-011
 Green liquor line closing valve HS-1209; HS-1309
 Weak wash line closing valve HS-1210; HS-1310

E. Design
- X-Filter #1(472-E-001) and X-Filter #2 (472-E-002)
Dimension :
- Diameter : 3400 mm
- Height : 10500 mm
- Operation pressure : 0 – 5.5 bar
The filter comprises:
- pressure vessel with convex bottom
- design value p = 6 / -1 bar, t = 120oC
- removable convex top
- dividing box
- supporting structures for elements
- 4 filtering elements, 19 lamella/element, 76 filtering
bags
- inner pipes for filtrate and vapors
- manholes and necessary connections
 28

- support structures for filter unit

- insulated
Material :
- SS 2343/HII
- Filter bags polypropylene
- Supporting structures of mild steel

- Filtrate Tank #1 and #2 (472-T-002 and 472-T-003)

Dimension :
- Diameter : 1500 mm
- Height : 4000 mm
- Volume : 160 m3
The tank comprises :
- flat bottom and conical top
- necessary connections and manholes
- insulated
Material :
- tank SS 2333
- manholes, connections SS 2333

- X-Filter dregs tank (472-T-005)

Dimension:
- Diameter : 5700 mm
- Height : 6500 mm
- Volume : 166 m3
The tank comprises:
- flat bottom and top
- baffles
- necessary connections and manholes
- mechanism support beams
- insulated
 29

Material:
- tank of SS 2333
- mechanism support beam of mild steel
- covering plate of checkered mild steel
- connections of SS 2333/mild steel
X-Filter Dregs Tank Agitator (472-A-002)
The agitator comprises:
- shaft
- propeller
- drive gear
Material : SS 2333
Motor : 7.5 kW, 25 r/s

- Trap #1 and #2 (472-E-003 and 472-E-003)

For separating coarse impurities from the green liquor feed to the X-Filters.
Material SS2343.
Dimension :
- Diameter : 406 mm
- Length : 2115 mm
- Weight : 137 kg
- insulated

Technical Description
1. Construction
X Filter Green liquor comprises:
 Pressure vessel
 Four filter cartridge
 Distribution box with perforated plates and screen plates
 Circulation pipe
 Circulation pump
 30

1. Pressure vessel
The pressure vessel acts as the filter frame. Attach the filter cartridge to
the upper part of the vessel, the lower part of the vessel provides storage
for dregs and slurry.
2. Filter cartridge
The filter cartridge comprises:
1. a cartridge frame
2. Lower frame
3. Filter elements (19 pieces per each)
There are altogether four cartridges in the filter.
The filter element is a rectangle covered with a supporting wire and filter
cloth (dimensions 0.75 x 4 x 0.02 m) made of perforated, acid-proof steel
and on the other narrow and there are two pipes for filtrate and one of
pressure balancing.
The lower frame acts as an installation stand for the filter elements and as
a filtrate collector. The collection header of the lower frame is connected
to the connection in the pressure vessel. It can be switched off from the
operation with the hand valve of the connection.
The cartridge frame forms a steel frame which combines the lower frame
and the filter elements together.
3. Distribution box
The distribution box is located above the filter cartridges under the
diffuser. The distribution box distributes the green liquor to be filtrated
evenly to all filter elements.
4. Diffusor
The diffuser is located at the end of the circulation pipe on the pressure
vessel cover. The diffuser balances the flow pressure in the circulation
pipe and evenly spreads the liquid flow to the whole distribution box.

5. Circulation pipe
 31

In the circulation pipe the green liquor to be filtrated is circulated from the
lower part of the pressure vessel to the distribution box, where it forms a
film on the filter elements.
6. Circulation pump
The circulation lifts the green liquor to be filtrated from the lower part of
the pressure vessel to the distribution box by circulation pipe.

Technical Data
Filtration capacity : 3500 m3
Filtration pressure : max. 4 bar
Filtration tank : 7 m3 (1 pcs)
Filter cartridge : 4887 mm x 1078mm x 860 mm (4 pcs)
Filter element : 750 mm x 4000 mm (76 pcs)
Filtration area : 456 m2

F. Process Description
Operation Principle

X-Filter filters out the dregs from green liquor. Filter comprises of the pressurized
filter body, filtering elements, flow distribution box and the circulation pump.

Filtering is based on falling film on the surface the filter element. Pressure
difference across the element forces some of the liquid through the element. Cake
formation is prevented by the circulation flow from the bottom to the top of the
filter. Capacity of the X-Filter is controlled by the pressure difference across the
filtering element.
 32

Figure 07. Filtration Principle

Concentrated dregs are discharged periodically.

X-Filter Operation
Process has sequence controlled step which follow automatically each other.
These steps are programmed to DCS.
In the following is description of steps:
- Filtration
Raw green liquor is pumped from the stabilization tank to X-Filter by the
frequency controlled pump. Pump speed is controlled by the level in the X-
Filter. Green liquor feed valve is open. When the level in X-Filter has reached
the set value (30%), the circulation pump starts. Pressure difference is kept
zero until the level reaches a new set point (40 - 50 %). When the level has
reached the set point, the pressure difference increases and green liquor
clarification starts. Clarified green liquor from the X-Filter filtrate tank is
pumped to the green liquor pumping tank.
During filtration the pressure balancing is needed time to time. Start of the
pressure balancing is controlled by the timer.
When filtration timer has expired, the concentration starts.
 33

- Pressure balancing
Pressure balancing is made during the filtration if selected. Filtration is
stopped and the pressure difference across the filtering element to zero. After
pressure balancing the process continues according to selected program.
Purpose of the pressure balancing is to recover the filtration without washing
the cloth.
- Concentration
When filtration time has expired, raw green liquor feed to the X-Filter is
stopped and dregs from the X-Filter dregs tank is fed into the X-Filter and
dregs is concentrated by filtering green liquor. When level in X-Filter dregs
tank has dropped to the set point, filtering stop and concentrated dregs is
emptied to the X-Filter dregs tank.
- Emptying
When concentration is finished the dregs is drained from the X-Filter.
Emptying is made with pressure in the X-Filter. At the end of filtration,
pressure is normally 3 -4 bar. Draining is easy with this pressure. If vessel
must be drained when pressure is low, emptying happens with pressurized air.
Dregs slurry is led to the X-Filter dregs tank. From the X-Filter dregs tank is
pumped continuously to the dregs filter feed tank.
- Cloth Washing
Filtering cloths are washed when filtration counter reaches the set number of
filtrations, normally after two filtrations. First the elements are washed with
hot condensate while pressure difference is kept zero. When X-Filter level
reaches the set value (40-50%) pressure difference is generated. Washing is
continued until washing time has expired. Pressure balancing is made and hot
water from the X-Filter is discharged to the hot water tank. From the hot water
tank about 30% of water is pumped to the weak wash line.

- Acid Washing
Acid washing is needed every now and then to clean the filter clothes
thoroughly. Acid washing starts with acid preparation. Proper amount of acid
 34

is manually filled to the acid tank and the same time hot water is fed into the
acid tank. Acid concentration is controlled with acid and water amount. When
X-Filter is emptied and washed with water, X-Filter is filled with water for
correct level and acid is fed into the X-Filter. Acid is circulated in X-Filter for
the time controlled by timer. When circulation time has expired, acid is
filtered and pumped from the filtrate tank back to the X-Filter. Filtration
continues until the filtration time has expired.

Acid is neutralized in X-Filter by feeding NaOH into the suction side of the X-
Filter circulation pump. When pH has reached 6, NaOH feed is stopped and
the neutralized acid is drained through the weak wash line to the stabilization
tank.

Figure 08. X-Filter Operation Sequences

 35

DREGS FILTER (471-E-003, 472-E-007, 473-E-00X)

A. Function
The main functions of dregs filter are:
1. To remove the dregs solid from green liquor dregs for disposal to the
landfill.
2. To minimize the soda loss, carried out by dregs solid drawn to the landfill,
by washing it using hot water spray.
The original liquor, slightly diluted, is returned to process
There are 3 dregs filter existing. Dregs filter #1 (471-E-003) for line 1, dregs filter
#2 (472-E-007) and dregs filter #3 (473-E-00X) for line 2.

B. Input, Output and Capacity

The input coming from dregs tank (472-T-006), pumped by dregs pump. The
input dregs to the dregs filter designed to 12 l/s for dregs filter #1, 14 l/s for dregs
#2 and 16 l/s for dregs #3. However, in the actual condition, the actual capacities
are less than designed capacity.

The cake scrapped from dregs filter is carried with the dregs conveyor to the
waste container for subsequent disposal. The actual dregs solid dispose to the
landfill for given input of liquor, shall be average 900 m 3. The filtrate, which is
slightly diluted liquor, returned to the stabilization tank.

C. Equipment
List of the equipment for Dregs Filter #1 and #2
 Filter drum and drive 471-E-003; 472-E-007, speed control SIH 1018; SIH-
1712
 Dregs filter vacuum tank 471-E-005 ; 472-E-009
 Dregs filter jet condenser 471-E-006 ; 472-E-010
 Filter vat agitator and drive 471-A-002; 472-A-004
 Dregs pump 472-P-018; 472-P-019
 36

 Filtrate pump 471-P-007; 472-P-021

 Vacuum pump 471-P-008; 472-P-081
 Dregs and gritz conveyor 3 472-C-002
 Zero speed switch for conveyor 3 SA-2013
 Speed control for conveyor 3 SIC-2019
 Dregs and gritz conveyor 4 472-C-003
 Zero speed switch for conveyor 4 SA-2017
 Speed control for conveyor 4 SIC-2020
 Conveyor 4 operating direction switch HS-2014
 Filter scrapper and drive 471-E-004; 471-E-008
 Speed control for scrapper drive 471-E-004, SIC-1820 ; 472-E-008, SIC-
1719
 Scrapper inner limit switch ZI-1028.1 ; ZI-1713
 Scrapper outer limit switch ZI-1028.2 ; ZI-1714
 Lime mud isolating valve HS-1019 (for both dregs filter)
 Lime mud valve HS-1017 (for both dregs filter)
 Flushing valve DV-1100 (for both dregs filter)
 Lime mud dnsity control DIC-1100 (for both dregs filter)
 Lime mud valve HS-1818
 Lime mud valve HS-1819
 Compressed air valve HS-1025
 Vacuum valve HS-1026 ; HS-1708
 Vat washing valve HS-1024 ; HS-1711
 Vat drain valve HS-1023 ; HS-1703
 Drain line washing valve HS-1030 ; HS-1704
 Vacuum tank isolating valve HS-1029 ; HS-1705
 Filter cloth washing valve HS-1027 ; HS-1710
 Filter function switch HS-1716 (for dregs filter #2)
 Filter and scrapper control KJ-1021 (for dregs filter #1)
 Precoat blowing start-up switch HS-1122 (for dregs filter #1)
 Precoat feed start HS-1123 (for dregs filter #1)
 37

 Precoat feed pump 471-P-024 (for dregs filter #1)

 Dregs filter level control LIC-1020 ; LIC-1701 (upper limit alarm +
interlocking function)
 Vacuum separator level control LIC-1022 ; LIC-1706 (upper limit alarm +
interlocking function)
 Dregs quantity control FIC-1816 ; FIC-1702
 Timer
Dregs filter #1 Description Dregs filter #2
T1801 Flushing time for precoat lime mud T1701
T1804 Blowing air valve open T1704
T1805 Blowing air valve closed T1705
T1806 Duration of periodical blowing T1706
T1807 Continuous blowing T1707
T1808 Precoat lime mud feeding T1708
T1809 Vat drain time T1709

D. Design
- Dregs filter feed tank (472-T-006)
Diameter : 5730 mm
Height : 6000 mm
Volume : 154 m3
The tank comprises flat bottom and top with baffle.

- Dregs Filter #1 (471-E-003)

Dimension:
- Diameter : 3000 mm
- Length : 3500 mm
The filter comprises:
- vat
- hood
- drum
 38

- drum bearings
- drum drive gear
- agitator
- agitator drive gear
- scraper with drive gear and motor
- flat suction head
- cake wash pipes
- lubricator for suction head
- filter cloth
- necessary connections and inspection doors
- supporting structures
Material:
- wetted parts of vat, drum and agitator of SS 2333.
- Inner pipes of drum and cake wash pipes of SS 2333
- Grids and filter cloth of polypropylene
- Hood of reinforced plastics
- Doctor blades of sintered hard metal
- Supporting structure of mild steel
Motors:
- drum 7.5 kW, 16.7 r/s
- agitator 4.0 kW, 25 r/s
- scraper 0.55 kW, 25 r/s
Vacuum tank dregs filter #1 (471-E-005)
Dimension :
- Diameter : 1900 mm
- Height : 3500 mm
The tank comprises:
- convex top
- concave bottom
- necessary connections
- sight glasses
 39

Material:
- SS 2333
Jet condenser dregs filter #1 (471-E-006)
Dimension :
- Diameter : 1580 mm
- Height : 2400 mm
The tank comprises:
- conical bottom and top
- necessary connections
Material:
- SS 2333

- Dregs Filter #2 (472-E-007)

Dimension :
- Diameter : 4000 mm
- Length : 8000 mm
The filter comprises:
- Vat
- Hood
- Drum with bearings and drive gear
- Scraper with drive gear and motor
- Suction head
- Cake wash pipes
- Lubricator for suction head
- Filter cloth
- Necessary connections and inspection doors
- Supporting structure
Material:
- vat and agitator SS2333
- drum SS2333
- inner pipes of drum and cake wash pipes of SS 2333
 40

- grids and filter cloth of polypropylene

- hood of reinforced plastics
- doctor blades of sintered hard metal
- supporting structures of mild steel
Motors:
- drum 15.0 kW; 16.7 r/s
- agitator 7.5 kW; 25 r/s
- scraper 0.75 kW; 25 r/s

Vacuum tank dregs filter #2 (472-E-009)

Dimension :
- Diameter : 1900 mm
- Height : 3500 mm
The tank comprises:
- convex top
- conical bottom
- necessary connections
Material:
- SS 2333
Jet Condenser dregs filter #2 (472-E-010)
Dimensio :
- Diameter : 1580 mm
- Height : 2400 mm
The tank comprises:
- convex top
- conical bottom
- necessary connections
Material:
- SS 2333
 41

E. Process Description
The amount of solids or dregs in green liquor varies considerably from one mill to
another, but it is often 600 – 2000 mg/L. The chemical composition of the dregs
also varies depending on such items as closure of mill cycles, delignifying
processes, and pulping raw materials. Other processes can also significantly
influence the composition of the dregs. Improper operation of the recovery boiler
can be result in fine carbon particles in smelt and green liquor. Difficulties in lime
mud washing in recausticizing may also cause high mud carryover via weak wash
to the dissolver.

The underflow from the clarifier is about 90% green liquor and only 8—10%
dregs. This valuable chemical is to be recovered before the dregs are discharged
and so it is necessary to wash the dregs. The purpose of green liquor dregs
washing is to replace the liquor in which the dregs are suspended with alkali free
liquid, water. The original liquid, slightly diluted, is returned to the process.

Dregs washing should be continuous. Insufficient dregs removal from the clarifier
interferes with the efficient operation of the clarifier and causes problems in the
whole processes. Insufficient dregs removal causes an increase torque of green
liquor clarifier rakes. An unnecessary large dregs discharge results in some waste
energy and a waste of lime mud.

Dregs slurry is most commonly filtered with a vacuum precoat drum filter. With
this type of filter, the cake becomes relatively dry. The process can be automatic,
and the filter requires very little maintenance. Typical lime mud consumption with
precoat filtration is about 1.2 times the separated dregs amount. The cake dryness
is 30% - 50% depending on the dregs quality. Alkali loss is usually 4% - 5% as
Na2O in the discharged cake.
 42

Figure 09. Dregs Filter Plant

Lime mud is a common filtering aid either mixed with dregs or as precoat on a
precoat filter, since filtering green liquor dregs as such is difficult. Lime mud can
also be used as a filtering aid in belt filtration. Belt filtration can also be done
without extra mud, but then the filtered dregs are removed by water showers and
discarded as slurry.

The precoat filter has an automatic advance on the scrapper (doctor blade) so that
the precoat layer is gradually removed along with dregs. A precoat thickness of 75
—100 mm is normally sufficient to last for 8—24 hours, depending on the rate of
scrapper advance. A new precoat is applied by pumping mud slurry to the filter
vat and after the proper thickness is obtained, dregs are readmitted and the cycle
starts again. It is important that all of dregs material in the vat be sluiced out and
drained prior to pumping lime mud to the vat for the next precoat. If dregs are left
in the vat, they will incorporate in the precoat which can increase the filtration
resistance considerably. The scrapper knife advance rate must be enough to
 43

remove the total dregs layer and penetrate slightly into the precoat layer.
Otherwise, some of the dregs will be rubbed into the precoat and tend to blind it.

SUMMARY
TECHNICAL COMPETENCY
Competency in X – Filter and Dregs Handling at Recausticizing area

Approved by Mentor Prepared by,

Tolong Butar Butar Teguh Widodo