I. Process Core Challenges and Requirements Analysis

In the chemical and related industries, the dehydration of gypsum (such as phosphogypsum, desulfurization gypsum) and non-metallic minerals (such as calcium carbonate, kaolin, bentonite) is a key step in achieving resource utilization, reducing transportation costs, or meeting downstream product requirements. This process faces the following unique challenges:

1. Large processing capacity, requiring continuous operation: Whether it is desulfurization gypsum produced by power plant flue gas desulfurization, phosphogypsum produced as a by-product of phosphorus chemical industry, or large-scale production of calcium carbonate, dehydration equipment is required to operate continuously, stably, and efficiently for 24 hours..

2. There are significant differences in material characteristics and high adaptability requirements:

   • Gypsum: The crystal morphology of primary gypsum is unstable, and its dewatering performance fluctuates greatly; Phosphogypsum contains many impurities, strong acidity, and strong corrosiveness.

   • Calcium carbonate/kaolin: Fine particles, high viscosity of slurry, high filtration resistance, and high requirements for product whiteness and purity, requiring efficient washing.

   • Bentonite: It has extremely strong water absorption and forms a gel like structure. Traditional methods are extremely difficult to dehydrate, and the moisture content requirement for the filter cake is loose but the processing difficulty is high..

3. Urgent washing demand:

   • Phosphogypsum: It needs to be thoroughly washed to remove soluble impurities such as phosphorus and fluorine in order to achieve resource utilization.

   • Kaolin/Calcium Carbonate: Impurities such as iron and sulfur need to be removed by washing to improve product whiteness and purity..

4. Operating cost control pressure: Energy consumption, filter cloth consumption, and maintenance labor costs are key indicators for measuring equipment economy..

5. Environmental Protection and Site Restrictions: Open equipment is prone to leakage and pollution of the workshop environment..

II. Core Value of Zhejiang Hexu Machinery DU Rubber Belt Vacuum Filter Solution

The DU type rubber belt vacuum filter machine from Zhejiang Hexu Machinery is an ideal choice for solving the above challenges due to its continuous operation, excellent washing function, strong material adaptability, and low operating costs.

Core Value Proposition:

“ Provide stable, efficient, and economical dehydration solutions for large-scale and continuous production, turn waste into treasure, improve quality and reduce costs. ”

III.Zhejiang Hexu Machinery DU Rubber Belt Vacuum FilterSolution Technical Explanation

1. Core technical mechanism of Zhejiang Hexu Machinery DU type rubber belt vacuum filter:

• Horizontal vacuum filtration: The filter slurry is evenly distributed on the horizontally advancing filter cloth through a cloth feeder, and solid-liquid separation is achieved under vacuum suction. The filter cake structure is stable and not easy to crack.

• Circular rubber belt drive: The filter cloth runs synchronously with the wear-resistant and corrosion-resistant circular rubber belt. The rubber belt is not only the supporting body, but also the longitudinal groove at its bottom forms the vacuum chamber, achieving a large area of vacuum operation surface.

• Mobile Vacuum Box Technology: The unique mobile vacuum box slides in contact with the bottom of the circular tape, greatly reducing frictional resistance and tape wear while maintaining high vacuum, and significantly reducing energy consumption compared to fixed vacuum box designs..

• Multi stage countercurrent washing: According to process requirements, 2 to 4 washing spray devices can be installed on the path of the filter cake, using the principle of countercurrent washing to achieve the best washing effect with the least amount of washing solution.

2. Zhejiang Hexu Machinery DU type rubber belt vacuum filterTargeted process adaptation:

For gypsum dehydration:

• Desulfurized gypsum: The slurry with a concentration of about 10-20% discharged from the absorption tower can be dehydrated by a DU filter once, and the moisture content of the filter cake can be reduced to10% -15%, which can be directly used for gypsum board production..

• Phosphogypsum: Through the efficient washing function of the DU machine, while dehydrating, the filter cake is repeatedly sprayed and vacuum sucked with clean water or process water, effectively removing soluble P ₂ O ₅ and F ⁻, providing qualified raw materials for the production of building gypsum powder and cement retarders.

For non-metallic mineral dehydration:

• Calcium carbonate/kaolin:

  1. Pre hanging layer technology (optional): For ultrafine particles, a pre hanging layer can be formed to prevent the filter cloth from clogging..

  2. Efficient washing: Multi stage washing thoroughly removes chloride ions, iron, etc., ensuring product purity and whiteness..

  3. High vacuum dehydration: Obtain a dry, sheet-like filter cake, which is convenient for subsequent drying and packaging..

• Bentonite: Although the moisture content of the filter cake is still relatively high (~40-50%), the DU machine can achieve continuous discharge and large processing capacity, meeting the preliminary dehydration needs before modification or landfill, and has significant economic benefits.

3. Zhejiang Hexu Machinery DU Rubber Belt Vacuum FilterSystem Process Flow Diagram:

[Slurry from concentration tank or reactor]→ [Buffer Mixing Tank]→ [Uniform feeding of DU filter]→ [Filter cake formation zone]→ [Multi stage countercurrent washing zone]→ [Dehydration and Drying Zone]→ [Filter cake discharge]→ [Dry material conveying] ↓ ↓ ↓ [Filtrate enters the circulation system or treatment] [Washing solution is graded and reused] [Automatic cleaning and regeneration of filter cloth]

Fourth, the core advantages of the DU type rubber belt vacuum filter solution of Zhejiang Hexu Machinery are highlighted

• Excellent dehydration and washing effect

  • Horizontal filtration ensures uniformity of the filter cake, stable vacuum suction force, and low moisture content of the filter cake.

  • The efficiency of countercurrent washing is 30% -50% higher than traditional equipment, and water consumption is saved by 20% -40%, significantly improving product quality.

• Extremely high operational reliability and low maintenance

  • The rubber band design has a long lifespan, and the mobile vacuum box technology minimizes friction losses.

  • The filter cloth automatic correction and online flushing system ensures continuous and stable operation, reducing unplanned downtime.

  • The equipment has a sturdy structure, few main power components, low failure rate, and easy maintenance.

• Significant economic benefits

  • Low energy consumption: Compared to plate and frame filter presses (high-pressure pumps) and traditional fixed vacuum box filters, energy consumption is reduced by 15% -30%.

  • Low labor cost: Fully automatic continuous operation, without the need for multiple disassembly and cleaning per shift like plate and frame filter presses.

  • Recycling Value: By efficiently washing and improving product grade, high-value utilization of by-product gypsum and minerals can be achieved..

• Good environmental friendliness and site adaptability

  • The liquid is circulating within the system, and the site is clean and dry.

  • The equipment has a modular structure, compact layout, and low requirements for the height of the factory building.

V. Typical Application Scenarios and Value Comparison of Zhejiang Hexu Machinery DU Rubber Belt Vacuum Filter

Application Scenarios	Pain points of traditional devices	Value of DU solution
Dehydration of desulfurization gypsum	Intermittent operation of board and frame, low production capacity; The vacuum disc filter cake is prone to detachment.	Continuous and stable production of gypsum with a moisture content of 10-15%, directly meeting building material standards and having a large production capacity.
Purification and dehydration of phosphogypsum	Incomplete washing and high soluble phosphorus content restrict resource utilization.	Efficient washingis key, significantly reducing impurity content,connecting the“ resource utilization; The Last Mile; 。
Dehydration of slurry calcium carbonate	Severe filtration of fine particles results in low product yield; Poor washing effect.	High precision filter cloth+pre hanging layerPrevent filter penetration; Multi level washing ensures high whiteness and strong product competitiveness.
Preliminary dehydration of bentonite	Using centrifuges or filter presses, which have high energy consumption or cannot be continuous.	Economically and continuously reduce the moisture content from above 90% to below 50%, achieving large-scale stable treatment.

VI. Investment Return Analysis

Taking a DU-20 filter machine for processing desulfurization gypsum as an example:

• Equipment investment: Based on the material and degree of automation, the investment amount is at the level of XXX million yuan..

• Cost savings in operation:

  • Electricity consumption: Compared to a plate and frame filter press with the same processing capacity, it saves about X million kWh of electricity per year..

  • Labor: Reduce the number of operators by 1-2 per shift..

  • Maintenance: The filter cloth has a long service life and low spare parts consumption..

• Benefit creation:

  • The qualified gypsum cake produced can be sold as a commodity, creating direct economic benefits.

  • Avoid environmental and land costs associated with gypsum storage.

• Investment payback period: usually between1.5 to 3 years, depending on the processing scale and local policies..

7. Our Service Commitment

Zhejiang Hexu Machinery DU type rubber belt vacuum filterWe provide...; “ Material Testing - Scheme Design - Equipment Customization - Installation and Debugging - Training Delivery - Spare Parts Support;   Full process service. We have a professional laboratory that can provide you with free material filtration tests to obtain key process parameters and ensure that the solution is foolproof.

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Summary

Zhejiang Hexu Machinery DU type rubber belt vacuum filter is a classic, mature, and efficient solution for large-scale dehydration of gypsum and non-metallic minerals in the chemical industry. It perfectly balances technical performance, operating costs, and investment returns, providing a reliable guarantee for achieving clean production, resource recycling, and cost reduction and efficiency improvement. Choosing DU means choosing a trustworthy long-term partner in the field of chemical dehydration.