Optimization For Existing Tilting Pan Filters Metalcraft

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Metalcraft – Located in Tampa Florida 3

Metalcraft Metalcraft Manufacturing 4

Metalcraft Services Filter Pans 5

Metalcraft Car Frame 6

Metalcraft Bearing Pedestals 7

Level Track 8

Metalcraft Services Installation of New Filter Components 9

Metalcraft Services 10

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Optimization for Existing Tilting Pan Filters 13

Reliability / Mission Time RELIABILITY speaks of intended function over time. MISSION TIME is critical to maximize acid production 14

Filter Mission Times Maintenance turnaround to turnaround Down day to down day (PM the filter) Scheduled wash cycle to wash cycle Scheduled cloth change out to cloth change out 15

Wash Cycle to Wash Cycle Mission Times Acid production is critical Interval times are critical 16

Cloth Change Mission Times Acid production is critical Intervals - Most Critical 17

Filter Performance Optimization This is mechanical approach for existing tilting pan filters, offering increased mechanical reliability and increased recovery of P₂O₅. Results are, a reduction in maintenance costs and increased production dollars. 18

Objectives for Filter Optimization Increase acid production Minimize dilution Increase P₂O₅ recovery Lower maintenance costs / Increase mission times Improve cloth cleaning efficiencies 19

Filter Optimization Step 1 Initial operational and maintenance benchmarks established. A detailed study and mapping of the filter is completed. 20

All aspects of the filter and its parts are measured 21

Filter Optimization Step 2 Measured data is integrated into the modeling software. Study of the filter in the “as found” condition begins. 22

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Filter Optimization Step 3 The filter is accurately modeled in its optimized condition. Demonstrates the recommended changes 24

Filter Optimization Step 4 Client report submittal, steps planned in harmony with client goals Report includes optimized proposal package. (How can Metalcraft best support changes the client would like to see?) 25

Filter Software Modeling – Design – Mapping Process 26

Components for Optimizing Existing Tilting Pan Filters Cloth spray headers Cam roller turnovers Enlargement of filtration area (pans) Filter valve timing 27

Cloth Spray Headers 28

Metalcraft Services Nozzle Placement and Spray Patterns are Critical for Cloth Spray Header Efficiencies 29

Cloth Spray Header Optimization Nozzle Design and Efficiency Conflicting Sprays Delivered Flow and Pressure to Header Loop Design with Cleanout 30

Nozzle Design and Geometry Vee Jet Flat Jet 31

s Address cleaning for all areas of the pan - Corners 32

Typical Cloth Spray Header Installation 33

Metalcraft Services Cam Turnover Sections 34

Cam Turnover Designed for accurate and simple field adjustment Assures proper operation 35

Metalcraft Services uses modeling software for both detailed design work and problem solving. 36

3 D Modeling Cloth Spray Evaluation 3 D Modeling 37

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Increased Filtration Area 51

Increased Filtration Area Considering new pans for an existing filter? Build them with additional filtration area! 52

Filtration Area Increased to s/m Filtration Area Increased.46 s/m Per Pan 53

Optimization for the Central Valve Is the valve timed correctly? Is dilution being addressed? Are wash and feed boxes located correctly to maximize filter efficiency 54

Central Valve 55

Optimization of Central Valve Adjustment / Repair of compartment baffles Replace Seal and Wear Plates Machining of Poly Ring and Timing Crown surfaces in place 56

Metalcraft Services 57

MCS 4/2010Metalcraft Services of Tampa MCS 4/22/2010 Filter Performance Optimization Results 58

Tilting Pan Filter Project Success – Example 1 Production and Down Time Cost Savings Savings of $0.9 Million per Year Recovery of 3500 Tons of Phosphoric Acid Per Year Reduced Cloth Usage and Overtime Cloth Changes 59

Tilting PanFilter Project Success – Example 2 Production and Down Time Cost Savings Reduction of Filter Down Time Per Month Increase P₂O₅ Recovery Overall Filter Improvement Annual Savings - $2.2 Million Per Year 60

Other Filter Components for Optimization Car Frames Bearing Pedestals Level Tracks 61

Car Frames Heavy Duty T316L Stainless Steel Design integrated Wear Track – Minimal wear to bottom flange of the frame 62

Improved Joint Design For Car Frames 63

Car Frame Bull Gears Integral Bull Gear bolts directly to the frame 64

Filter Pans in Progress 65

Objectives for Filter Optimization Increased acid production Minimize dilution Increase P₂O₅ recovery Lower maintenance costs / Increased Mission Times Improved cloth cleaning efficiencies 66

METALCRAFT Leading with Vision 67