Two-in-One Washing & Filtration Unit
Other Equipment
1. Product Overview
The Two-in-One Washing & Filtration Unit (also known as a closed filtration & washing machine or "two-in-one" filter) is a multifunctional unit that performs two process steps, filtration (solid-liquid separation) and filter cake washing, inside the same closed vessel. It consists of a shell with a heating/cooling jacket, a retractable or removable base plate, a filter plate (perforated plate + filter cloth, or stainless steel sintered metal mesh), a lifting agitator (combining reslurrying, turning and scraping discharge), a hydraulic lifting and quick-opening clamping device, a discharge valve, sight and light glasses, CIP/SIP ports and an electrical control system. Inside the closed vessel the material passes in sequence through feed filtration, filter cake washing (reslurry washing / displacement washing / spray washing), dewatering and closed discharge, so that toxic, hazardous, flammable and explosive materials never come into contact with operators or the environment. It is widely used for solid-liquid separation and washing purification in APIs and pharmaceutical intermediates, fine chemicals, pesticides, dyes and pigments, food additives, new energy materials and other industries. Equipment features: closed operation, two process steps in one machine, high washing efficiency, low filter cake moisture content, low solvent consumption and product loss, compliance with GMP and CIP/SIP requirements, optional nitrogen blanketing and explosion-proof configuration, and a significant reduction in manual labor intensity.
2. Working Principle
The suspension is pressure-fed by nitrogen or drawn by vacuum through the feed valve into the filtration zone of the shell. Under the differential pressure across the filter plate (pressure filtration or vacuum filtration), the mother liquor passes through the filter cloth or sintered metal mesh and is discharged and collected, while the solids gradually build up on the filter medium to form a filter cake. After filtration the washing stage begins: the washing liquid is distributed evenly through the spray pipe (spray washing), or the agitator is lowered and rotated at low speed to reslurry the cake back into a suspension (reslurry washing), or fresh washing liquid is used to displace the mother liquor held in the cake pores (displacement washing), followed by renewed dewatering. The above cycle can be repeated as many times as required until the impurities and mother liquor residues in the cake meet the process specification. After washing, the agitator descends to the base plate surface, scrapes the filter cake to the discharge port and discharges it through the side discharge valve; on removable base plate models the hydraulic cylinder lowers and withdraws the base plate, which is then tilted to dump the cake, facilitating filter cloth replacement and complete cleaning of the machine.
3. System Classification
Classified by structural type and discharge method:
Vertical fixed base plate two-in-one: the base plate is fixed and the material is discharged through a side discharge port or a bottom discharge valve / small and medium volumes, conventional materials, sites with limited space
Vertical removable base plate two-in-one: a hydraulic cylinder lowers and withdraws the base plate, which is tilted to discharge the cake, leaving no dead corners for cleaning / flammable and explosive, toxic and hazardous materials, or products with high cleanliness and cleaning requirements
Horizontal two-in-one: the shell is arranged horizontally with a horizontal agitator shaft, allowing a larger volume and filtration area / large throughput, more continuous duty conditions
4. Detailed Technical Parameters
4.1 Common Materials of Construction
| Material | Applicable parts | Remarks |
|---|---|---|
| 304 stainless steel | Shell, base plate, agitator, filter plate | General-purpose type, suitable for common chemical and food applications |
| 316L stainless steel | Shell, base plate, agitator, filter plate | First choice for pharmaceutical and fine chemical service, excellent corrosion resistance |
| Duplex stainless steel 2205 | Shell, base plate, agitator | Resistant to chloride ions and stress corrosion, long service life |
| Titanium (TA2) / Hastelloy C-276 | Shell, base plate, filter plate | For strongly corrosive media, optional as required, high cost |
| Carbon steel + PTFE lining / rubber lining | Shell inner wall, base plate | For strong acid service, combining strength with corrosion resistance |
4.2 Typical Specification Table
| Nominal volume (L) | Filtration area (m²) | Shell inner diameter (mm) | Agitator power (kW) | Discharge method |
|---|---|---|---|---|
| 100～300 | 0.3～0.8 | Φ600～800 | 1.5～3 | Side discharge port |
| 500～1000 | 1.0～2.5 | Φ1000～1200 | 3～5.5 | Side discharge / base plate lifting |
| 1500～3000 | 3～6 | Φ1400～1800 | 5.5～11 | Retractable & tilting base plate |
| 4000～6000 | 8～12 | Φ2000～2400 | 11～18.5 | Retractable & tilting base plate |
| 8000～10000 | 15～20 | Φ2400～2800 | 18.5～30 | Retractable & tilting base plate / tilting discharge |
4.3 Design Conditions and Performance Indicators
| Parameter | Specification |
|---|---|
| Design pressure | Shell: -0.1～0.6 MPa; jacket: 0.3～0.6 MPa |
| Design temperature | -20～200℃ (depending on material of construction and jacket heating medium) |
| Filtration differential pressure / vacuum level | Pressure filtration differential pressure ≤0.4 MPa; vacuum filtration ≥-0.08 MPa |
| Filter cake thickness and moisture content | Filter cake thickness ≤300 mm; filter cake moisture content generally ≤30% (depending on material and washing method) |
| Filtration accuracy | Filter cloth 5～100 μm; sintered metal mesh 1～50 μm |
| Surface treatment and sealing | Internal surface Ra≤0.4 μm (GMP grade, electropolishing available); mechanical seal / gland packing + nitrogen blanketing port |
5. Electrical Parameters
| Applicable region | Voltage | Frequency |
|---|---|---|
| China / Russia / Central Asia | 380V | 50Hz |
| Middle East / Southeast Asia / Africa | 400V / 415V | 50Hz |
| South Korea | 380V | 60Hz |
| Americas (if required) | 440V / 480V | 60Hz |
| Explosion-proof configuration (optional) | ExdⅡBT4 / ExdⅡCT4 | — |
| Note: voltage, frequency and explosion-proof requirements must be specified for the agitator motor, hydraulic station, control cabinet and instruments. |
6. Selection of Core Components
| Component | Common brand / material | Features and application |
|---|---|---|
| Filter medium | Customized (filter cloth / sintered metal mesh) | Filter cloth is low in cost and easy to replace; sintered mesh offers high strength, stable accuracy and can be regenerated by back-blowing |
| Agitation and lifting system | Customized (304/316L blades + hydraulic / screw lifting) | Performs reslurry washing, turning and scraping discharge, with variable frequency speed control |
| Base plate sealing and quick-opening device | Silicone rubber / fluoro rubber sealing ring + clamp or tooth-engagement quick opening | Ensures sealing and rapid opening and closing; removable base plate models are equipped with a hydraulic lifting trolley |
| Discharge valve and nozzles | Quality domestic brand / customer-specified brand | Large-diameter side discharge valve or bottom valve, preventing material bridging and residue |
| Instrumentation and control (optional) | Siemens, E+H, quality domestic brands | Monitoring of pressure, temperature, level and weighing; PLC + touch screen, remote control available |
| Hydraulic station and power unit | Quality domestic brand | Drives base plate lifting, tilting and quick-opening clamping, with a manual emergency device |
7. Typical Application Fields
APIs and pharmaceutical intermediates: solid-liquid separation and filter cake washing after reaction, replacing conventional suction filters and filter presses, meeting GMP and aseptic requirements
Fine chemicals and dyes & pigments: filtration and washing of dyes, pigments and intermediates, reducing solvent consumption and waste liquor discharge
Pesticides and veterinary drugs: toxic and hazardous materials handled under closed conditions, with nitrogen blanketing and explosion-proof motors
Food and additives: food-grade materials of construction and surface treatment, used for washing and purification of food additives
New energy materials: filtration, washing and purification of lithium battery cathode material precursors, ternary materials and similar products
8. Design Standards and Certification
| Standard | Description |
|---|---|
| GB/T 150.1～150.4-2024 | Pressure vessels (general requirements, materials, design, manufacturing inspection and acceptance) |
| TSG 21-2016 | Safety Technical Supervision Regulation for Stationary Pressure Vessels |
| NB/T 47013-2015 | Nondestructive testing of pressure equipment |
| GB/T 36030-2018 | General technical requirements for in-place cleaning and sterilization of pharmaceutical machinery (equipment) (CIP/SIP) |
| GB/T 36036-2018 | Guideline for validation of cleaning and sterilization of pharmaceutical machinery (equipment) |
| JB/T 20188-2017 | Method for compiling model designations of pharmaceutical machinery products (applied by reference to this type of equipment) |
| GMP (2010 Revision) | Good Manufacturing Practice for pharmaceutical products (pharmaceutical applications) |
| ISO 9001:2015 / CE / EAC / GOST-R | Quality management system; CE, EAC and GOST-R can be obtained according to market requirements |
Note: there is no dedicated national or industry standard for two-in-one washing & filtration equipment. Its pressure vessel parts are executed in accordance with the GB/T 150 series and TSG 21, and for pharmaceutical applications the general requirements of JB/T 20099-2022 "Pharmaceutical Filtration, Washing and Drying Machine" may be applied by reference.
9. Optional Customization
| Option | Details |
|---|---|
| Specification customization | Nominal volume 50～10000 L; filtration area 0.2～20 m² |
| Discharge method | Fixed base plate side discharge / retractable & tilting base plate / tilting discharge |
| Heating and cooling | Jacket heating (hot water, steam, thermal oil) or cooling (chilled water, glycol) |
| Material and surface | 304 / 316L / duplex steel / titanium / Hastelloy; internal surface polished to Ra≤0.4 μm or electropolished |
| Safety and automation | Nitrogen blanketing, explosion-proof motor, PLC + touch screen, remote monitoring, weighing and metering, automatic CIP/SIP program |
10. Warranty Terms
| Equipment condition | Warranty period | Warranty scope |
|---|---|---|
| New equipment | 12 months | Shell, base plate, agitation system, filter plate, seals, valves |
| Refurbished equipment | 6 months | Shell, base plate, agitation system, filter plate, seals, valves |
| Idle equipment (as-is supply) | 3 months | Main functional components |
11. Packaging and Delivery
| Item | Packaging method |
|---|---|
| Equipment body | Fastened with steel straps on a wooden pallet, flange faces fitted with protective covers, nozzles fitted with protective caps |
| Agitator and lifting parts | Packed separately in wooden cases to prevent impact and deformation |
| Filter plate and filter cloth / sintered mesh | Packed flat, filter cloth sealed against moisture |
| Seals and wearing parts | Waterproof sealed packaging, then packed into cartons |
| Control cabinet and hydraulic station | Packed in wooden cases, desiccant placed inside the control cabinet |
| Documentation supplied | Certificate of conformity, material certificates, pressure test report, operation manual, spare parts list |
| Container capacity estimate | Below 1000 L: approx. 1 x 20-ft container holding 2～3 units; around 3000 L: approx. 1 x 20-ft container holding 1 unit; above 6000 L: a 40-ft container or break bulk vessel is recommended |
| Installation service | On-site installation guidance and commissioning can be provided; technicians can be dispatched for large projects (travel, accommodation and meal costs borne by the buyer) |
12. Information Required for Inquiry
12. Information Required for Inquiry Material name, solids content and solid particle size; liquid phase properties (corrosiveness, viscosity, whether flammable or explosive); required throughput or batch charge; requirements for filter cake thickness and moisture content; washing method, type of washing liquid and required number of washing cycles; specifications for filtrate clarity and impurity residues; required nominal volume and filtration area of the equipment (if known); material requirements (shell, base plate, agitator, filter medium); discharge method and installation space limitations; whether a heating/cooling jacket and heating medium conditions are required; whether nitrogen blanketing, explosion protection and CIP/SIP are required; local voltage and frequency; equipment condition preference: new / refurbished / idle; delivery terms: FOB/CIF/DDP; destination port or delivery address (for freight calculation).