Past Filter Press Projects & Field Experience

USA – Aggregate

Filter Press | Site Service
Sub-sector: Aggregate

Four large filter presses used in an aggregate fines-recovery application initially functioned well but eventually encountered issues with plates opening and closing unevenly. A field study identified residual slurry in the feed eye, insufficient plate cleaning, and difficulty synchronizing the plate-opening mechanisms as the root causes. Solutions were developed and implemented to restore consistent operation.

USA – Aggregate

Filter Press | Site Service
Sub-sector: Aggregate

An inspection and comprehensive filter-operation training were provided. Shifters and drip trays were adjusted, slurry-pump operations were reviewed, and options for process improvement were discussed. The two-stage centrifugal and piston-diaphragm pumping systems required frequent rebuilds, and parts acquisition was coordinated for the next improvement phase.

USA – Aggregate

Filter Press | Site Service
Sub-sector: Aggregate

At this new sand-and-gravel recycling plant in Maryland, the filter presses achieved substantial progress. Mechanical assembly was largely completed and I/O testing began before full commissioning. Ten slurry cycles were successfully run. Although upstream equipment operated at roughly 50% capacity—causing schedule delays—the filtration system performed reliably. The team continued addressing tie-ins, conveyors, and wiring, and collaborated with the end user on operations and maintenance planning.

USA – Aggregate

Filter Press | Site Service
Sub-sector: Aggregate

The wash-plant filter press, operating since 2019 with roughly 4,200 cycles, was inspected and found in excellent condition with minimal corrosion. The main challenge had been plate shifting during cloth washing due to limited clearance between plates. The issue, reported since installation, was resolved by optimizing timers, set-points, and wash speeds—resulting in a smoother, more reliable cloth-wash operation.

USA – Aggregate

Pumps and Shredders | Site Service
Sub-sector: Frac Sand

At a frac-sand mine where equipment had been idle for nearly two months, a systematic troubleshooting process identified crossed hoses and wiring as the root cause. After corrections, operations resumed successfully. Preventive-maintenance practices, housekeeping measures, and design improvements were recommended to enhance long-term reliability.

INDONESIA – Chemical

Filter Press | Site Service
Sub-sector: Precious Metals Recovery

Ten new filter presses were installed as part of a precious metals recovery project. This visit focused on supporting installation and commissioning activities, including verification of mechanical assembly, hydraulic function, and PLC/HMI logic. Dry and water cycle testing were performed to confirm motion sequences, pressure setpoints, and communication between the filter control panels and the plant DCS. Operator training and functional handover were completed, marking a key milestone toward full production readiness.

USA – Chemical

Filter Press | Site Service
Sub-sector: Titanium Dioxide

The site struggled to keep up with all filters running constantly, limiting maintenance and reducing reliability. Key issues and solutions included upgrading plate opening links to prevent operational issues, improving cake release with thicker, drier cakes, containing cloth wash water to prevent leakage, and enhancing the historian system for real-time operations. Additional recommendations included having more equipment, personnel, and improved facilities, understanding slurry variability, investigating filterability improvements, considering a thickener, targeting thicker cakes, drying cakes while squeezing, moving feed pumps, avoiding long slurry suction lines, adding slurry recirculation lines, rerouting wash and sump water, removing trash from slurry, avoiding unnecessary mechanical complications, improving hose management, using custom parts, improving cake containment, conducting more predictive maintenance, updating sequence logic, reducing cloth failures, updating feed inserts, using high-performance cloths, improving the squeeze system, tuning the mechanics, protecting the air control valve, expanding for more capacity, updating valve sequencing, polishing membrane retainers, maintaining frame alignment, upgrading slurry pumps, developing training procedures, finding root causes of failures, adjusting locking bars, improving cake quality, replacing corroded sidebar bolts, updating valve sequences, and planning for routine rebuilds.

MEXICO – Chemical

Filter Press | Site Service
Sub-sector: Sulphur

The new filter presses initially faced issues with the air-over-oil hydraulic system, with air getting into the oil and preventing full hydraulic pressure. Also the Movable Head to lift off the Sidebars. We focused on press #2, flushing the air lines and replacing the air regulator on the booster pump. While Filter #2 became operational, the main ram was bypassing, causing air from the rod side to flow into the cap end, indicating piston seal failure. We replaced the cylinders on both filters and the air regulators on the booster pumps, ensuring the filters ran correctly.

USA – Chemical

Filter Press | Site Service
Sub-sector: Sulfuric Acid

A filter press had been in operation for 20 years in a corrosive sulfuric acid application, and the OEM of the equipment had since gone out of business. The sidebars/rails had corroded so much that they were at risk of structural failure. 3D CAD drawings were created from field measurements and site photos. By creating accurate drawings and working closely with fabricators, a new set of stainless steel clad filter press sidebars were produced and efficiently installed. Press is running with clad sidebars that are expected to outlast the original frame.

ARGENTINA – Chemical

Leaf (Polishing) Filter | Site Service
Sub-sector: Lithium

The new pressure leaf filter was installed at the lithium plant expansion in Argentina. During the visit, we completed the mechanical and electrical portions of the commissioning, with the next step being the installation and testing of the automation logic (provided by the customer). We completed medical exams and site safety training, walked down P&ID, completed I/O checks, discussed filter operation and DCS controls for upcoming programming, created a programming and training guide, opened the filter, adjusted hydraulic speeds, installed leaves, repaired a damaged leaf bag, filled the filter with water, adjusted the high-level switch, and provided operator training.

USA – Chemical

Tower (Vertical) Filter Press | Site Service
Sub-sector: Acid

Serial #1 of this new, high-tech filter for a highly corrosive application was held up in the shop after failing customer acceptance testing due to numerous mechanical design issues. A critical understanding was established by engaging with the designers, fabricators, assemblers, and testers of the equipment. Redesign concepts were collaboratively created, and detailed solutions were developed by running both physical tests and virtual finite element analysis (FEA). These solutions were implemented and successfully tested, allowing the customer to accept the equipment and ship the filter.

INDIA – Chemical

Tower (Vertical) Filter Press | Site Service
Sub-sector: Fertilizer

The tower filter with stainless steel cladding was installed at a new fertilizer plant in India. This large, greenfield project was on a fast-track schedule. The main structure of the filter was assembled, with many small parts and the electrical system still to install. The main goal of the first visit was to assist with assembly of the smaller parts. Future visits focused on completing the mechanical assembly, wiring the filter, installing and testing the PLC logic, running dry cycles, water cycles, and final commissioning the equipment with slurry.

USA – Chemical

Filter Press | Site Service
Sub-sector: Industrial Wastewater

The filter presses had been running at a wastewater treatment plant since the mid-80s. While the filters were functional and the main structure appeared sound, the controls, hydraulics, and other components were unreliable, with some parts being completely obsolete. During this visit, we reviewed the installation, discussed typical issues with operators and maintenance, and discussed potential options for replacing, rebuilding, and upgrading. Potential paths forward were identified and presented in a detailed report.

COLUMBIA – Chemical

Leaf (Polishing) Filter | Site Service
Sub-sector: Industrial Glue

Two new pressure leaf filters were installed on an existing circuit. During this visit, we addressed mechanical and electrical issues and ran process fluid through both filters. Tasks completed included mechanical/electrical checkout and greasing ring/wedges on both filters, troubleshooting the pressure switch on Filter-B, resolving a shell sticking issue on Filter-A, conducting pressure tests with water, updating wiring to stop shell opening with the switch, testing pre-coating and running product through both filters, and providing general training for mechanical and operational procedures.

USA – Chemical

Filter Press | Site Service
Sub-sector: Industrial Wastewater

The filter press had been running on a waste stream for over 20 years. After many years without a cylinder issue, the original cylinder and a spare cylinder were changed out and rebuilt numerous times due to leaks around the barrel (both rod end and cap end heads). The rebuild procedure was identified as a potential issue, a new cylinder was installed during the visit and appeared to be working well.

JAPAN – Chemical

Filter Press | Site Service
Sub-sector: Lithium

The filter press was installed at a new plant to extract lithium for car batteries. The filter was removing contaminants (suspended calcium carbonate) from a brine stream containing dissolved lithium, with the cake being waste and the filtrate containing the product. Work included commissioning, training and upgrading the hydraulic system to better protect the plates from the high-temperature slurry. 30mm cake was successfully made to test the equipment/logic.

USA – Chemical

Filter Press | Site Service
Sub-sector: Plastics

The filter press was installed on a waste stream at the new ethane cracker project in Texas. The greenfield installation completed the mechanical handoff and moved into full operation. During these visits, we focused on controls and communication between the filter press PLC and other plant systems, adjusting PLC logic and touchscreens for user-friendliness, including PLC/HMI programming, and updating IP addresses. We also established communication between the filter press PLC and plant systems (though some plant permissives between the filter PLC and feed pumps remained an issue), completed a dry cycle using the filter’s PLC, and addressed open issues from previous visits. While the overall filter was in good shape, some mechanical assembly and wiring issues remained. More work was required to establish necessary communication and complete testing so the equipment would be ready for commissioning with water and slurry.

MEXICO – Chemical

Leaf (Polishing) Filter | Site Service
Sub-sector: Sulphur

The new pressure leaf filters were installed on the molten Sulphur filtration circuit. Recent visits focused on pushing sulfur through Filter-2 and getting Filters 1 & 3 closer to commissioning. Issues were encountered such as the drain safety pressure switch, flow meter, flange gaskets, small sulfur fires, and the steam pressure regulator while flowing steam through Filter-2. Filtering sulfur through Filters 1 & 3 led to freezing lines and pipe leaks, while running sulfur through Filter-2 involved further trouble with freezing lines, pump control, and rupture discs. A preliminary inspection reviewed mechanical/electrical portions of the installation and identified potential issues. Considerable mechanical/electrical work was then required to fully commission all filters.

USA – Chemical

Filter Press | Site Service
Sub-sector: Toxic Waste

Two new filter presses ran for a short time on a waste stream at a toxic waste facility. This was believed to be the first ever technical visit to the site. During the visit, minor programming issues were noted (unable to run a complete cycle) and some unused features were discussed (no air connected for cake/core blow). We also addressed hydraulic issues with the booster pumps and overall settings were fine-tuned.

USA – Chemical

Filter Press | Site Service
Sub-sector: Industrial Wastewater

Numerous filters at this facility were running on the same product, but one of the newest filters had been reported to discharge wetter cakes from day one. It was found that some of the plates had not been completely drilled for the membrane squeeze. These plates were drilled on-site and appeared to be functioning properly. Cake moisture then dropped to match the other filter presses.

USA – Chemical

Pumps and Shredders | Site Service
Sub-sector: Municipal Waste

The headworks equipment was installed at the WWTP as part of their new expansion. Initially, we encountered electrical issues but addressed them with locally supplied parts and some temporary wiring. We identified potential issues, including HMI screen protection, door safety switches with PLC notification, and blower motor voltage/frequency (400V/50Hz). Potential paths forward were identified and presented in a detailed report.

CHINA – Food and Beverage

Tower (Vertical) Filter Press | Project Management
Sub-sector: Starch

A Chinese customer required Chinese manufacturing for their new corn starch filter on a tight delivery schedule, even though this equipment had never been made in China. With the short delivery time, multiple new manufacturers within numerous industrial areas of China had to be brought up to speed quickly. Success was achieved by working closely with engineering, procurement, and manufacturing personnel. We met the customer’s needs and shipped a quality filter within their deadline.

USA – Food and Beverage

Tower (Vertical) Filter Press | Site Service
Sub-sector: Starch

The first filter was rebuilt with a completely new frame. The filter plates were retrofitted with added stiffeners, creating a hybrid design incorporating a newer structure within the original design. Crews worked around the clock and had the press rebuilt and ready to run in four days. Despite this, there were minor issues that needed addressing to improve filter performance. Additionally, the second filter at the same facility experienced hydraulic hammering when opening and closing. We managed to stop the hammering with a new SOV.

IRELAND – Food and Beverage

Leaf (Polishing) Filter | Site Service
Sub-sector: Soft Drink Syrup

Two new pressure leaf filters were installed on two different circuits to remove oils and contaminants from beverage concentrates. During the visit, we reviewed the installation, completed the start-up checklist, adjusted speeds/pressures, and installed the leaves. The 36” filter ran well on one concentrate, but the 48” filter had trouble filtering the other concentrate due to difficulty building a complete DE precoat, resulting in DE and slurry bypassing through the filter. Multiple tests were run, potential issues identified, and next steps advised. The Sluicer was also rebuilt (separate issue).

USA – Food and Beverage

Tower (Vertical) Filter Press | Site Service
Sub-sector: Starch

The first tower filter experienced hydraulic hammering when opening and closing the press. We were able to stop the hammering intermittently when the SOV was working but needed a new SOV to permanently fix the issue. The second filter had hydraulic problems, and the HPU was pulling excessive amperage. We adjusted the low-pressure pump pressure setting and the bypass pressure (PLC logic) to lower the amps into the normal range. Additionally, we eliminated intermittent belt “failure to run” problems and reduced the amp draw for that step too.

CHINA – Food and Beverage

Tower (Vertical) Filter Press | Site Service
Sub-sector: Starch

The main goal of this visit was to review the assembly, assist with the Factory Acceptance Test (FAT), complete controls testing, and facilitate customer shop visit, disassembly, and shipping.

USA – Food and Beverage

Filter Press | Site Service
Sub-sector: Starch

Upon arrival, the filter press would not close. The air booster pump had recently been replaced, but that did not solve the problem. It was found that the main air directional valve was not releasing pilot pressure when it shifted into the close position. The trapped air pressure on the open side of the valve was holding the PO Check and Dump valves open, causing the pump to recirculate oil back to the tank instead of sending flow to the cylinder to close the press. Replacing this valve solved the problem.

USA – Food and Beverage

Tower (Vertical) Filter Press | Site Service
Sub-sector: Beer

The five pressure leaf filters had been running at a brewery for many years. The filters were running well but were due for a routine inspection, including overall mechanical and wedge condition. During the visit, we inspected all five filters and identified any open concerns.

USA – Food and Beverage

Tower (Vertical) Filter Press | Site Service
Sub-sector: Beer

The four pressure leaf filters had been running at a brewery in Jacksonville, FL for many years. The filters were running well but were overdue for a lug/wedge inspection. During this visit, we inspected all four filters.

USA – Food and Beverage

Filter Press | Site Service
Sub-sector: Wine

We conducted a thorough general inspection of the filter press to understand and document the current issues affecting its performance. The inspection focused on identifying the causes of bowing sidebars and holes in the cloths. We meticulously examined each component, noting any signs of wear, misalignment, or damage that could contribute to these problems. Our findings provided valuable insights into the mechanical integrity of the press and highlighted areas needing immediate attention. Recommendations for corrective actions were also developed to address these issues and improve the overall reliability and efficiency of the filter press.

USA – Food and Beverage

Leaf (Polishing) Filter | Site Service
Sub-sector: Food Oils

Two new pressure leaf filters were installed on the tallow filtration circuit, replacing two homemade pressure leaf filters from the 1950s. During the visit, we commissioned the first filter, while the second filter was not yet piped in.

USA – Food and Beverage

Leaf (Polishing) Filter | Site Service
Sub-sector: Food Oils

The pressure leaf filter had been running on fats and oils and was leaking, requiring gasket replacement every two weeks. During this visit, we inspected the equipment, opened the filters, installed the leaves, and ran precoat and sluice cycles. Potential paths forward were identified and presented in a detailed report.

BRAZIL – Mining and Metals

Tower (Vertical) Filter Press | Site Service
Sub-sector: Iron Ore

These new, largest of their kind tower filters were installed at a remote iron ore mine in Brazil. Numerous problems arose with this new product, including significant mechanical, process, and political/personnel challenges. The best progress was made by spending time on-site, working hands-on with field-service engineers and plant maintenance and operations personnel. Valuable information was then brought back to the OEM engineering group, and together, solutions were devised and implemented in the field.

USA – Mining and Metals

Filter Press | Site Service
Sub-sector: Zinc Recycling

Ten filter presses of various sizes and OEM manufacturers operated throughout this zinc recycling plant. Equipment and process issues required ongoing assistance, both on-site and remote. Design upgrades and major overhauls were required. Consequently, filter press reliability and performance steadily improved, allowing the plant to increase production. Work included troubleshooting, commissioning, and optimization of the filter presses.

MEXICO – Mining and Metals

Tower (Vertical) Filter Press | Project Management
Sub-sector: Lead & Zinc

An emergency expansion of multiple filtration systems was required for a lead and zinc circuit at this gold mine. The customer was losing a lot of money because the filtration system had become the bottleneck for the entire lead and zinc circuits. Success was achieved by working closely with engineering, procurement, and manufacturing personnel. Together, we were able to adapt the design and significantly cut the delivery time for parts from the originally estimated six months to having the system up and running in just under three months. The upgrade was successful, and the filtration system is no longer the mine’s bottleneck.

UNITED ARAB EMIRATES – Mining and Metals

Filter Press | Site Service
Sub-sector: Aluminum Oxide

The red mud filter press dewatering circuit for dry stack tailings was the bottleneck for the entire alumina refinery. Work was done to improve the reliability and efficiency of the red mud filtration system. The filters were not meeting the design throughput demand and cake moisture, due to both utilization and performance problems. Additionally, plate strength was an issue. Potential paths forward were identified and presented in a detailed report.

USA – Mining and Metals

Filter Press | Site Service
Sub-sector: Lithium

An approximately 40-year-old filter press structurally failed and was replaced. Given the constraints of the existing building, the new filter had to be carefully disassembled prior to being rebuilt on-site. This intricate process involved meticulous planning and coordination to ensure each component was properly handled and reassembled. The project demanded precision to ensure the new filter was installed correctly and safely, meeting all operational requirements.

BRAZIL – Mining and Metals

Tower (Vertical) Filter Press | Site Service
Sub-sector: Iron Ore

Specialized iron ore filtration equipment in the field needed support with documentation and instructions for subcontractors to bid from and perform a major product retrofit. The job was located in southern Brazil and was too large and time-consuming for on-site, word-of-mouth communication. A valuable instruction manual was produced by working closely with engineering, field-service, and technical writing personnel. The final product was delivered in multiple languages and included step-by-step instructions supplemented with invaluable photos, drawings, and CAD images.

USA – Mining and Metals

Filter Press | Site Service
Sub-sector: Copper Concentrate

A fast-acting minerals filter press was only a few years old and faced reliability issues, including leaking filter plates and damaged filter cloths, causing a bottleneck for the entire copper mine. Troubleshooting required close collaboration with maintenance and operations personnel to repair the equipment and restore performance. Delivered necessary filter press field service, diagnosing cases where the filter press was not reaching pressure due to booster valve sequencing. A preventative maintenance plan was implemented, operator training was conducted (while serving as the commissioning engineer for the overall filtration system) to validate operational readiness.

PERU – Mining and Metals

Filter Press | Site Service
Sub-sector: Copper Concentrate

Three filter presses ran on the Merrill Crowe process, operating in parallel. Two filters ran for about three years, while the third ran for only a few months. Typical cycles lasted 7–10 days. There were issues with corrosion of shifter components and the filter frame, but overall, the filters ran well. The installation benefited from a hydraulic rebuild on the two older filters. Considerations included a cloth washing mechanism, valve automation, spare parts (hydraulic components, valves, and plates), and an acid wash recirculation system for cloth cleaning, as well as a standalone hydraulic unit as a backup.

USA – Mining and Metals

Filter Press | Site Service
Sub-sector: Copper Concentrate

The new moly circuit had been running for a few months with intermittent problems. This visit focused on the feed system, which recently experienced low flow and low pressure. Upon first arriving onsite, the press was only building 20–30 psi during the feed step, and cake moistures were around 12–14 % with 1800–2000 lbs/drop. We believed the slurry was over-flocculated and difficult for the pump to move. By temporarily plumbing a spare pump into the suction of the main pump, we were able to reach 130-psi feed, 9–10 % moisture, and 3400–3900 lbs/drop.

PAPUA NEW GUINEA – Mining and Metals

Tower (Vertical) Filter Press | Site Service
Sub-sector: Gold

Assembly of the new concentrate dewatering plant was almost complete, with most remaining work focused around the tower filter. The peripheral pumps, valves/piping, and controls were mostly tested and ready to go. Damage to the filter press during shipping caused significant delays for that portion of the project. Most of the repaired components were on-site and being installed. There were still a few outstanding parts to be delivered, as well as minor mechanical assembly, wiring, and hydraulics/piping to be completed. Potential paths forward were identified and presented in a detailed report.

USA – Mining and Metals

Filter Press | Site Service
Sub-sector: Copper Concentrate

The filter plant was running in a solid, steady state of operation with experienced personnel (operating for 16 years). While much of the equipment was aged and well-used, it continued to produce as designed. There were a few concerns that needed to be resolved: failing rubber barrel necks lasting only days instead of months; shrinking backer cloth pulling up into the chamber and covering the lower filtrate ports; and mixed plate chamber sizes creating sealing issues. Potential paths forward were identified and presented in a detailed report.

PERU – Mining and Metals

Filter Press | Site Service
Sub-sector: Gold

The filter presses running on the Merrill Crowe process operated in parallel, with the pre-coat step done in series, and typical cycles lasted 7–10 days. There were issues with the hydraulic system, corrosion, and bending/distortion of the filter frame, posing significant safety concerns that needed to be addressed. Spare parts, including hydraulic components, valves, and plates, were strongly recommended.

USA – Mining and Metals

Filter Press | Site Service
Sub-sector: Gold Tailings

The new high-grade mill neared readiness to run product, with recent visits focusing on the filter presses. Key points addressed included improperly assembled driptrays on the 2×2 filter presses, dislodged center bearings, hydraulic system problems, cloth shakers, PLC program issues, and cake-discharge malfunctions. Smaller presses ran similar cycles at 140 psi with 15 % cake moisture. The overall plant was operating at ~50 % capacity. Potential paths forward were identified and presented in a detailed report.

MEXICO – Mining and Metals

Filter Press | Site Service
Sub-sector: Gold Tailings

Seven large filter presses were not performing in a gold tailings application. There were numerous problems, including significant mechanical, process, and reliability issues. Success was achieved by spending time on-site, working hands-on with plant maintenance and operations personnel. Valuable information was brought back to management, and together, solutions were devised and implemented. The equipment is now performing at the “nameplate” production rate.

USA – Mining and Metals

Filter Press | Site Service
Sub-sector: Copper Concentrate

Several issues were addressed during the visit: the 50-hp electric motor for the HPU was tripping overloads due to a malfunctioning piston-pump horsepower adjustment. The pump was replaced but initially wouldn't build pressure due to an incorrect unloading valve, which was replaced. The shaker lift had a faulty pressure-reducing valve, replaced during service. Additional PLC and valve issues were noted for correction.

MEXICO – Mining and Metals

Filter Press | Site Service
Sub-sector: Gold Tailings

The filter press dewatering circuit for dry stack tailings was the mill's bottleneck due to its closed-loop design, which required filtrate for upstream processes. The challenges included insufficient capacity for routine cloth washing and downtime and long cycle times due to manual cake scraping. Progress included reduced cycle times through mechanical improvements and better operational practices, leading to fewer leaks and drier cakes. Optimization steps and additional filters were recommended to achieve sustainable production.

USA – Mining and Metals

Tower (Vertical) Filter Press | Site Service
Sub-sector: Geothermal

Several issues were identified and addressed on the tower filter. A pressure transmitter connection failed and the manifold was removed and sent for inspection and pressure testing. The hydraulic system was refurbished, including pumps, cylinder, and manifold rebuild. Post-refurbishment, the main pump failed to build pressure, likely due to a damaged seat for the pilot relief valve. The compensator on the high-pressure pump was also not functioning. Recommendations were provided in a detailed report.

CANADA – Mining and Metals

Filter Press | Site Service
Sub-sector: Copper Concentrate

Conducted a comprehensive audit of the filter press, encompassing mechanical, electrical, and process aspects, focusing on production and reliability. A detailed report was supplied after the visit.

USA – Mining and Metals

Filter Press | Site Service
Sub-sector: Gold Tailings

The filter press faced reliability and parts-availability issues. HP wash was frequently skipped due to reliability concerns. Acting as a sludge-dewatering consultant, we tuned the HP cloth wash and replaced two damaged plates, running one slurry cycle. Recommendations included addressing corrosion and abrasion issues, revising hydraulic schematics to prevent recurring hydraulic problems, and restoring normal wash sequences to improve cloth life and cake quality.

NICARAGUA – Mining and Metals

Stripping Boiler | Site Service
Sub-sector: Gold

A closed-loop boiler circuit delivered heat to the main stripping circuit through the primary heat exchanger. The old boiler was not hot enough, resulting in slow stripping due to the low temperature of the barren solution. A new boiler was installed, reaching higher temperatures, resulting in faster stripping.

USA – Mining and Metals

Filter Press | Site Service
Sub-sector: Copper Concentrate

The filter-press installation was relatively clean and well-run, but the slurry-pumping system had limitations, resulting in production inefficiencies and pump damage. Variations in slurry makeup made it difficult to run the filter consistently day-to-day. Key issues included holding tanks for thickener underflow at a lower elevation than the filter, small elevation pumps, and an undersized slurry tank requiring careful operation to avoid pump damage. Regular maintenance and optimization were crucial for consistent performance.

CANADA – Mining and Metals

Tower (Vertical) Filter Press | Site Service
Sub-sector: Copper Concentrate

Two tower filters have been running on copper concentrate since 2009. They consistently ran but faced ongoing reliability and operational challenges, including plate-seal failures, valve seat/sleeve failures, cloth holes leading to slurry leaks and internal bypassing, and process variability requiring constant adjustments. An operational review was completed and recommendations presented.

USA – Mining and Metals

Filter Press | Site Service
Sub-sector: Rare Earths

Several programming changes were made to the two filters. Key points included improving the user interface for operators and identifying unresolved mechanical and programming issues requiring a future visit. Other issues included SCADA communication problems, missing plates, plates falling out, a crashing cloth washer, poorly formed cakes, and blown rupture discs.

MEXICO – Mining and Metals

Tower (Vertical) Filter Press | Site Service
Sub-sector: Zinc and Lead

The seven tower filters had been bottlenecking operations due to suboptimal performance, underutilization, and equipment deterioration. Recommendations included removing trash blockages, improving plate quality, optimizing preventive maintenance, enhancing carbon control, adjusting slurry filling rates, and upgrading safety measures. These interventions improved overall efficiency at the mine.

USA – Mining and Metals

Filter Press | Site Service
Sub-sector: Rare Earths

Updated the valve sequence to allow operators to run the filter in automatic, as they had been running it manually. Added buttons for “regeneration” and independent wet-cake operation.

CANADA – Mining and Metals

Filter Press | Site Service
Sub-sector: Aluminum Oxide

Filter presses had been experiencing premature membrane failures. Work included meticulously studying the situation, pointing out weaknesses in the membrane material elasticity. We met with site personnel and discussed these findings in detail.

USA – Mining and Metals

Filter Press | Site Service
Sub-sector: Rare Earths

Three pressure leaf filters were installed on separate rare-earth circuits. We completed I/O checks, ran dry and water cycles, and established communication between filters and plant DCS, addressing wiring issues and updating programs for usability.

MEXICO – Mining and Metals

Filter Press | Site Service
Sub-sector: Gold

A truck transporting the new filter press fell onto its side, causing significant damage. Upon inspection, the equipment was deemed no longer fit for service.

USA – Mining and Metals

Filter Press | Site Service
Sub-sector: Industrial Sand

The four filter presses had been running since 2013, with approximately 25,000 cycles on each. The main structure appeared in good condition, with no noticeable corrosion or other damage. The two biggest challenges were plate shifting and slurry pumping. Work included shifter re-work, preventive maintenance, optimization, and operator training.

MEXICO – Mining and Metals

Filter Press | Site Service
Sub-sector: Gold Tailings

The filter press dewatering circuit for dry-stack tailings was the mill’s bottleneck. Progress included reduced cycle times, fewer leaks, and drier cakes. Optimization steps and additional filters were recommended to achieve sustainable production.

USA – Mining and Metals

Filter Press | Site Service
Sub-sector: Frac Sand

Eighteen large filter presses were installed across three sites under a tight schedule. Work included mechanical and electrical assembly, dry-cycle testing, and commissioning with OEM representatives and engineering teams.

USA – Mining and Metals

Filter Press | Site Service
Sub-sector: Frac Sand

Completed tasks included head mounting, beam assembly, tie-rod assembly, cloth-wash and drip-tray installation, and control-panel mounting. Detailed steps and next actions were identified and presented in a report.

USA – Mining and Metals

Filter Press | Site Service
Sub-sector: Wastewater

Two filter presses were installed in a new wet-screening wastewater system. Initial visits covered mechanical/electrical inspections and slurry startup. Subsequent visits resolved issues and provided full commissioning support with on-site operator training.

USA – Mining and Metals

Filter Press | Site Service
Sub-sector: Coal

Work included filter-press inspections and recommendations addressing design, stress relief, squeeze-system safety, hydraulic schematics, and cylinder sizing. As OEM service contractor, conducted a comprehensive evaluation and provided optimization recommendations to improve safety and reliability.

CANADA – Oil and Gas

Filter Press | Site Service
Sub-sector: Oil Sands Wastewater

Maintenance training was provided that included an introduction to hydraulics, components of the hydraulic power unit, hydraulic pumps, and hydraulic valves. It continued with hydraulic actuators, fluid conditioning, and preventive maintenance of the hydraulic unit. Training wrapped up with a field visit, post-test, and a recap with questions.

USA – Oil and Gas

Thickener | Site Service
Sub-sector: Industrial Wastewater

The clarifier was refurbished for a wastewater circuit. Much of the structure was repaired, the drive was rebuilt, and four scum scrapers were added. It was recommissioned and had been running for approximately three weeks. The main scope was rebuilding the “combination drive,” which included a 5-hp motor for the turbine (floc mixer) and two 3-hp motors for the rake. Difficulties encountered included erratic load-cell readings, turbine mixer drive vibrations, and scum scrapers snagging on the scum boxes. Work included draining and cleaning the tank, repairing/replacing scum scrapers, inspecting the turbine for interference, and replacing the turbine mixer motor gearbox to control speed.

USA – Power Generation

Filter Press | Site Service
Sub-sector: Fly Ash

While commissioning the new waste dewatering plant, several key tasks and issues were addressed regarding the filter presses. Initial assembly involved completing the main frames and focusing on installing plates, cloth wash, and guarding, with progress being hindered by personnel turnover. Work included mechanical assembly, overall wiring, and preparing for dry cycle testing. Successful software testing with the customer’s DCS controls was completed, despite communication challenges. Over 100 slurry cycles were run across the four filters, while addressing conveyor, compressor, and pump issues, and other mechanical challenges. Regular follow-up visits for optimization and tuning, along with operator and maintenance training, were provided.

USA – Power Generation

Filter Press | Site Service
Sub-sector: Fly Ash

Two filter presses and skids were installed on a waste stream. The filters were guided through the final stages of installation, with communication established between the filter press PLCs and other plant systems. Initial trials included dry and water cycles and final commissioning involved successful slurry runs, collecting samples, and running cloth wash cycles. Final adjustments were made before full slurry runs, wrapping up loose ends from the initial installation.

USA – Power Generation

Filter Press | Site Service
Sub-sector: Fly Ash

The larger of two filter presses was used to filter wastewater, producing approximately 25,000 pounds of cake per day. The filter was installed in 2012 and ran reasonably well but faced capacity and mechanical/reliability issues. Cake moisture was not an issue (acceptable at ~50 % H₂O), but filtrate quality remained an ongoing issue (requiring <8 ppm). Observations and recommendations were made, following the structure and sections of the customer’s Filter Press Audit Scope of Work.

USA – Power Generation

Filter Press | Site Service
Sub-sector: Fly Ash

Work was done to bring the filter press back into square (approximately 2 inches out) while the heads needed to be shifted. The procedure involved removing the plate stack and Follower Head, removing mounting bolts at feet, measuring diagonals where sidebars met heads, moving heads to equalize diagonals, inspecting for damage, re-anchoring legs (allowing Tail Head to float), re-installing the plate stack and movable head, closing the press and checking for movement and square, and adjusting the shifter mechanism. The press became out of square due to misaligned shifter shuttles.

USA – Power Generation

Vacuum Drum | Project Management
Sub-sector: Fly Ash

Successfully managed a $10 M vacuum filtration project, overseeing the entire process from planning to implementation. Tasks included budgeting, scheduling, resource allocation, risk assessments, and quality control. Coordinated cross-functional teams, ensuring compliance with industry standards and timely completion within budget. Regular updates were provided to stakeholders, addressing concerns promptly. The proactive approach led to the successful completion of the project, meeting all client specifications and exceeding expectations.

USA – Power Generation

Vacuum Belt | Project Management
Sub-sector: Fly Ash

Customer required immediate assistance in managing a new HBVF project to meet their quality standards, remain on time, and stay within budget. Prompt and clear communication with the customer was crucial. An experienced Project Manager was needed to oversee and complete the project. Successful metrics included finishing on time, completing under budget, fulfilling all scope requirements, using project management software to track and communicate the project schedule and status, and ensuring customer satisfaction. Project success was confirmed by comparing target milestones to actual performance, target budget to actual spending, scope versus what was supplied, demonstrating clear communication, and overall customer satisfaction.

USA – Power Generation

Vacuum Drum | Engineering
Sub-sector: Fly Ash

Completed an engineering package for a vacuum drum wire winder. This comprehensive package included detailed design plans, specifications, and technical drawings to ensure precise manufacturing and installation. Addressed all mechanical and electrical aspects, ensuring seamless integration with existing systems. Thorough analysis covered performance optimization, safety measures, and durability enhancements. Provided a full set of assembly instructions, maintenance guidelines, and troubleshooting procedures. The package was meticulously prepared to meet the highest industry standards and facilitate efficient production and operation of the vacuum drum wire winder.

USA – Pulp and Paper

Filter Press | Site Service
Sub-sector: Lignin

The filter press dewatering circuit for the lignin boost system ran at a sustainable rate, despite some filter press plate failures. Site work aimed to better understand the operation and offer suggestions to improve the reliability and efficiency of this filtration system. Potential paths forward were identified and presented in a detailed report.

USA – Water Treatment

Filter Press | Site Service
Sub-sector: Wastewater Treatment

Two new filter presses were installed, tested and commissioned as part of a new wastewater treatment system at a natural gas power plant. Work covered everything from mechanical installation verification, hydraulic functionality checks, and PLC/HMI logic validation through dry and water cycle testing. The next phase included slurry cycle testing to confirm control sequences, communication, and safety interlocks, followed by system tuning, operator training, and maintenance planning.

CANADA – Water Treatment

Compressors | Site Service
Sub-sector: Water Intake

A new compressor system was installed on the two intake screens for the new water treatment plant. During the visit, the unit was commissioned and operator training provided. Minor issues encountered during the start-up were addressed, ensuring a smooth installation and efficient operation of the system.

USA – Water Treatment

Filter Press | Site Service
Sub-sector: Steel Wastewater

The filter press initially operated manually, with valves and hydraulics forced into position. When a plate was scraped and the light curtain was tripped, the system shut down and the Feed Inlet valve opened, dumping slurry into the open filter. Improvements included adding relays and updating logic to prevent the light curtains from shutting down all outputs, affecting only the HPU. The PLC logic for Auto Mode was updated and tested during dry cycles. Work involved addressing any bugs that arose and further filter press troubleshooting expert support, optimizing the system based on production feedback. Acted as an industrial filtration consultant, ensuring proper safety logic and a sustained operation.

CANADA – Water Treatment

Compressors | Site Service
Sub-sector: Water Intake

A new compressor system was installed on the single intake screen for the new water treatment plant. The unit was commissioned and operator training was provided.

USA – Water Treatment

Filter Press | Site Service
Sub-sector: Toxic Waste

The filter presses at the toxic wastewater cleanup plant had been running well but faced plate leaking/failure issues. Key tasks completed included replacing squeeze header relief valves, reducing squeeze header backpressure settings, improving rod spacer sizing, making general programming changes, completing Control Narrative verification checks during dry cycles, and completing the first slurry cycles with new plates.

USA – Water Treatment

Filter Press | Site Service
Sub-sector: Groundwater Remediation

The 25-year-old filter press was running on a groundwater remediation waste stream at a former pharmaceutical plant. The long-term filter operator recently left, leaving the press in somewhat disrepair. We were able to identify current issues, provide operator training, and present a preventative maintenance plan. Potential paths forward were identified and presented in a detailed report.