Proceedings

Novel 3D designed filter and innovative manufacturing process delivers a decrease in pumping energy requirements

Burns, N., Geekie, L., Travis, D. and Burns, M., Croft Filters Ltd, UK

(free)

Abstract Filtration through conventional filters not only induces an increase in the pressure drop but also increases turbulence of fluid flow so increased pumping energy is required. Using aerodynamic principles, Croft has developed an innovative filter that has holes inline with fluid flow. This novel 3D design was produced by Selective Laser Melting Additive Manufacturing (AM). When increasing flow rates were applied to the AM filter the resultant pressure drop across the filter was found to be significantly lower than that of a conventional filter of identical pore size. The decrease in pressure drop with rising flow rates reflects a decreased level of pumping energy used and so reduces carbon footprint. The freedom of filter design, using AM, allows for increased functionality of filters as well as decreased flow disruption. The application of the novel filter design in downstream processes may form part of a capital solution in waste water management.

Keywords Additive manufacturing, design, filter, pressure drop, metal 3D printing, pumping energy

Introduction Water is essential for all life on earth and its management is essential for delivery to the population and agricultural areas in a clean non-contaminated state. Effective waste water treatment not only removes sewage solids, pathogens, nutrients, toxic chemicals and metals which are potential health risks to humans and could damage ecosystems through oxygen depletion as well as eutrophication but also returns a higher proportion of clean water to the environment.

Globally, clean water and effective sanitation levels vary greatly, with less developed countries having less clean water and sanitation and greater levels of water borne diseases as a result, some fatal (De Albuquerque, 2012). In more developed countries strategic planning for waste water management has been driven by national governments and for Europe, by the EU through the European Union Urban Waste Water Treatment Directive -91/2714/EEC. This directive seeks to improve the quality of clean water being returned to the environment, to decrease the impact of waste water on the environment and to increase the levels of recovered water. In the UK implementation of this directive has resulted in major changes in sewage sludge disposal with none being discharged to surface waters rather it is recycled mainly as a soil enhancer and fertiliser on agricultural land. In addition the introduction of nutrient stripping at particular water treatment plants eg Ashford plant, UK, has reduced algal growth and led to an increase in biodiversity (Defra 2012).

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