YINGCAI Ceramic Filter Plate Cleaner Applied in a Jiangxi Iron Concentrate Project, Improving Filtration Efficiency and Reducing Acid Cleaning Risks

YINGCAI Ceramic Filter Plate Cleaner Applied in a Jiangxi Iron Concentrate Project, Improving Filtration Efficiency and Reducing Acid Cleaning Risks

A copper environmental protection company in Jiangxi, mainly engaged in non-ferrous metal solid waste recycling, iron concentrate recovery, and environmental treatment, had long faced ceramic filter plate blockage, frequent cleaning, unstable dehydration performance, and high maintenance costs in its iron concentrate production line.

To improve production stability and reduce environmental and safety risks, the company introduced YINGCAI ceramic filter plate cleaner. Through on-site application and continuous process optimization, the solution achieved significant improvements in filtration performance, equipment operation, cleaning safety, and overall cost control.

Industry Challenge

Before using YINGCAI’s cleaner, the iron concentrate production line faced several operational challenges.

Iron concentrate particles are fine and sticky, making ceramic filter plate micropores easy to block. As blockage accumulated, vacuum stability decreased, dehydration performance became unstable, and the production line required frequent shutdowns for cleaning.

The traditional cleaning process mainly relied on nitric acid and other strong acid cleaners. Although strong acid cleaning could temporarily relieve blockage, it also damaged the microporous structure of ceramic filter plates. This increased the risk of cracking, leakage, performance decay, and shortened service life, resulting in high replacement and maintenance costs.

At the same time, nitric acid is a hazardous chemical. Its storage, transportation, handling, and on-site use require strict management and create safety risks for operators. Waste acid liquid after cleaning is also difficult and costly to treat, increasing environmental compliance pressure.

Technical Highlights

YINGCAI ceramic filter plate cleaner is developed for different mineral processing conditions, including iron concentrate, copper tailings, non-ferrous metal solid waste recycling, and non-metallic mineral filtration systems.

The product features strong penetration, high dispersion, low corrosion risk, easy operation, and easier wastewater treatment. It provides a safer and more environmentally responsible alternative to traditional strong acid cleaning.

In the Jiangxi iron concentrate application, the cleaner showed the following advantages:

Efficient Deep-Pore Cleaning

The special composite formulation can penetrate deeply into the micropores of ceramic filter plates and help remove iron mud, oxide scale, colloidal matter, and fine particle deposits attached to the pore walls. After cleaning, filtration flux and vacuum performance recovered quickly, and the dehydration effect approached the level of new filter plates.

Milder Formulation and Better Filter Plate Protection

Compared with strong acid cleaning, the cleaner is milder and helps reduce damage to the ceramic microporous structure. It lowers the risk of corrosion, cracking, leakage, and performance decline, helping extend the replacement cycle of ceramic filter plates and reduce equipment investment.

Easy Operation and Existing System Compatibility

The product can be integrated into the existing online or offline cleaning process without large-scale equipment modification. The dosing method is simple, and the cleaner can be used in a circulating cleaning process, helping shorten downtime and improve production line availability.

Lower Safety and Environmental Risks

By reducing the use of nitric acid and other hazardous chemicals, the solution improves the on-site working environment. It helps reduce strong odor, corrosion risks, and operational safety pressure. The cleaning wastewater is more stable and can be treated through precipitation, neutralization, and standard wastewater treatment processes, helping reduce environmental disposal costs.

Application Results

After continuous on-site operation, YINGCAI ceramic filter plate cleaner delivered clear results in the customer’s iron concentrate production line.

Filtration efficiency improved significantly. Filter plate blockage slowed down, vacuum performance became more stable, and filter cake moisture control became more consistent, supporting better iron concentrate dehydration quality and production efficiency.

The cleaning cycle was extended, and equipment downtime was reduced. A longer-lasting cleaning effect increased the continuous operating time of the ceramic filters and improved overall production line efficiency.

Filter plate service life was extended, and maintenance costs decreased. Corrosion-related damage was reduced, replacement frequency declined, and the customer achieved lower chemical costs, labor costs, hazardous waste treatment costs, and equipment maintenance costs.

Safety and environmental management also improved. The reduced dependence on strong acid cleaning helped the customer achieve safer on-site operation, easier environmental compliance, and more standardized production management.

ROI and Cleaning Process Comparison

During the cleaning replacement process, the customer compared different cleaning methods under actual operating conditions.

Traditional Nitric Acid Cleaning:

Nitric acid cleaning liquid was injected into the internal cavity of the filter plate during the backwashing process. The cleaning time was approximately 1.5 hours, and the positive pressure permeability recovery reached about 75%. However, nitric acid procurement and transportation were inconvenient due to hazardous chemical control requirements. Nitric acid storage also created safety risks, and the discharge of nitric acid cleaning wastewater brought environmental compliance challenges.

Combined Cleaning Process:

The customer also tested a combined process using YINGCAI cleaner and nitric acid in different shifts. The cleaning time remained approximately 1.5 hours, while the positive pressure permeability recovery increased to about 83%. This process helped reduce safety risks for outsourced night-shift operators and provided a transition path for replacing high-risk acid cleaning.

The comparison showed that professional ceramic filter plate cleaning technology can help customers improve cleaning performance while reducing hazardous chemical risks, environmental treatment pressure, and long-term maintenance costs.

Industry Significance

The application of YINGCAI ceramic filter plate cleaner in the Jiangxi iron concentrate production line shows that eco-friendly specialized cleaners can effectively replace or reduce traditional strong acid cleaning in iron concentrate, copper tailings, non-ferrous metal solid waste recycling, and mineral dehydration applications.

This case provides a practical and replicable equipment maintenance upgrade solution for non-ferrous metal processing, solid waste recycling, iron concentrate dehydration, and ceramic filtration systems.

YINGCAI New Materials will continue to focus on industrial filtration and eco-friendly cleaning technologies. By optimizing formulations for different minerals, water qualities, equipment structures, and operating conditions, YINGCAI provides safer, more efficient, and more economical ceramic filter plate cleaning solutions for mining, environmental protection, and mineral processing enterprises.