WO2020049543A1

WO2020049543A1 - System and method for onsite and/or offsite filter plate and cloth assembly maintenance

Info

Publication number: WO2020049543A1
Application number: PCT/IB2019/057588
Authority: WO
Inventors: James CHAPONNEL; Todd Wisdom; Reuben NEUMANN
Original assignee: Flsmidth A/S
Priority date: 2018-09-07
Filing date: 2019-09-09
Publication date: 2020-03-12

Abstract

A system and method for refurbishing filter plate assemblies of an industrial horizontal filter press is disclosed. The system may comprise multiple stations and the method may comprise one or more process steps associated with each of the stations. A station may ready the plate assemblies, provide for checking the function of spray nozzles, provide for the removal of filter cloths and/or feed eye grommets, or provide for the washing of plates. A final station may be used for final assembly and inspection. A rework station may be provided to hold filter plate assemblies which are not suitable to return to service in the industrial horizontal filter press. Stations may perform single operations, or they may be equipped for performing multiple operations at once, without limitation.

Description

SYSTEM AND METHOD FOR ONSITE AND/OR OFFSITE FILTER PLATE AND CLOTH

ASSEMBLY MAINTENANCE

FIELD OF INVENTION

Embodiments of the invention relate to novel methods and apparatus for refurbishing, dressing, and/or repairing filter plate assemblies for industrial horizontal filter presses.

BACKGROUND

In-situ cloth cleaning, cloth replacement, spray nozzle repair, and/or plate replacement or refurbishment for filter presses having a plurality of filter plate and cloth assemblies can be cumbersome, timely, and/or dangerous. Conventional“ready racks” only serve to provide a temporary holding place for used, worn, or damaged filter plate assemblies.

For example, for a 152-chamber horizontal filter press, there may be 304 cloths per filter, with each cloth having an average lifespan of 1500 to 4500 filtration cycles. This may correspond to 8.8 to 20 days, respectively, between plate maintenance occurrences. As another example, a l20-chamber horizontal filter press may have 240 cloths per filter, with each cloth having an average lifespan of 4500 filtration cycles. This may correspond to approximately 24 days between plate maintenance occurrences, without limitation.

A typical plate maintenance occurrence may include 10 plate refurbishments per day (or approximately 6% of plates within a particular horizontal filter press. This may amount to 90 minutes total time per day for plate maintenance. An exemplary down time (i.e., non-operational period) for a typical plate maintenance occurrence may be approximately 5-10 minutes if there is no spare filter.

Another example of conventional preventative maintenance may include plate maintenance performed every 4500 cycles, wherein a spare horizontal filter press is employed and operated during plate maintenance of another horizontal filter press.

In some scenarios, for side beam filters, cloths may be changed from above a horizontal filter press. This may be accomplished by using a crane or hoist to lift a number of filter plate and cloth assemblies upward and off of the side support beams of the horizontal filter press. Operators must inspect, repair, and replace broken plates or worn cloths while standing on/around the top of the affected horizontal filter press. Hanging cloths can be removed independent of the plates.

In-situ plate and cloth assembly maintenance may be performed more quickly than procedures which require plate assembly removal from the horizontal filter press. However, the limited access to plates, cloths, and components thereof (e.g., grommets) may discourage strict adherence to prescribed maintenance cycles. Moreover, in-situ plate and cloth assembly maintenance may introduce issues regarding safety (e.g., due to limited space, poor access, and pinch points). For better access and higher quality maintenance, plates can be removed from an affected horizontal filter press; however, this could bring the horizontal filter press down for an extended period of time (e.g., a week).

To further elaborate on filter down time, non-operation of a horizontal filter press leads to lost availability. For example, it is not unlikely that approximately one filter will be in cloth changing and maintenance mode every 1 to 2 days. Filter cloth replacement typically makes up 80% of all horizontal filter press maintenance. The total down time for a complete filter plate and cloth assembly replacement for a horizontal filter press can take 2.5 to 3 hours, when considering that lockout and tagout can total roughly 30 minutes, the time to perform 8 lifts of 20 plate and cloth assembly stacks (e.g., for a l52-chamber horizontal filter press) can average roughly 2 hours, the time it takes to perform 6 separate lifts of 20 plates (e.g., for a l20-plate horizontal filter press) can average roughly 1.5 hours, and the removal process of lockout/tagout can take another roughly 30 minutes.

Accordingly, outside filter plate maintenance would result in higher availability. If performed offsite (or onsite location which is remote from a filter(s)), the time for plate and cloth maintenance would become less important. Moreover, the refurbishment work for plate and cloth assemblies could be performed by appropriate specialized personnel, rather than expensive highly-valuable plant operators or plant maintenance personnel.

OBJECTS OF THE INVENTION

It is, therefore, an object of embodiments of the present invention, to provide a system and method for local or offsite filter plate and cloth assembly maintenance which can minimize downtime of horizontal filter presses, improve safety, and improve total cost of ownership (TCO), without limitation.

It is a further object of embodiments of the present invention, to provide a system and method for local or offsite filter plate and cloth assembly maintenance which can reduce risk and cost uncertainty by fixing cost per ton for cloth and plate maintenance.

It is further desired to avoid underestimating plate and cloth maintenance costs, without limitation.

It is a further object of embodiments to lower operation costs, reduce the number of expensive plant operators and/or plant maintenance personnel needed to carry out plate assembly refurbishment operations.

It is yet another objective to employ a“preventative” maintenance approach rather than a “reactive” maintenance approach.

Other objectives of embodiments may include reducing filter downtime, improving availability, and improving safety, without limitation.

BRIEF SUMMARY

A system 3 for refurbishing a filter plate assembly 5 is disclosed. The filter plate assembly 5 may be of an industrial horizontal filter press 4 used in a filtration operation or plant 1. According to some embodiments, the system 3 may comprise a first end 21 and a second end 39. A readying station 7 may be located proximate the first end 21 of the system. The system 3 may comprise a grommet and cloth removal station 8, a wash station 9, and/or an assembly station 12, without limitation. At least one support rail 15 of the system 3 may be supported by supports 26. The supports 26 may be configured for suspending the filter plate assembly 5 and others like it.

The readying station 7 may precede the grommet and cloth removal station 8. The grommet and cloth removal station 8 may precede the wash station 9. The wash station 9 may precede the assembly station 12. The system 3 may comprise a final inspection station 13 proximate the second end 39 and following the assembly station 12. The system 3 may comprise a pre-assembly station 10 between the wash station 9 and the assembly station 12. The system 3 may comprise a rework station 14 proximate the assembly station 12.

Embodiments of the system 3 may comprise a loading station 50 may be located proximate the first end 21. The loading station 50 may be configured for removing the filter plate assembly 5 from a hauler 47. The loading station 50 may be configured for providing the filter plate assembly 5 to the system 3 for cleaning and refurbishment.

Embodiments of the system 3 may comprise an unloading station 59 proximate the second end 39. The unloading station 59 may be configured for removing the filter plate assembly 5 from the system 3 after it has been cleaned and refurbished and/or for loading the filter plate assembly 5 onto a hauler 47.

The at least one support rail 15 may comprise a trolley 53 for conveying the filter plate assembly 5 from the first end 21 to the second end 39 such that the filter plate assembly 5 is coplanar with the at least one support rail 15, without limitation. The at least one support rail 15 may comprise two parallel support rails 15 for conveying the filter plate assembly 5 from the first end 21 to the second end 39 such that the filter plate assembly 5 is perpendicular with and spans across the space separating the two parallel support rails 15, without limitation. According to some embodiments, the system 3 may comprise a torque tool 22. The torque tool 22 may be configured to remove multiple fasteners 52 from a grommet 42, simultaneously, without limitation. The torque tool 22 may be configured to secure multiple fasteners 52 to a grommet 42 simultaneously, without limitation.

Embodiments of the system 3 may comprise a crane 11 or an overhead plate carrier hoist 44 configured to lift the filter plate assembly 5 or a plurality thereof. Embodiments of the system 3 may comprise a storage rack 45 configured to receive and temporarily store a plate stack 46 comprising the filter plate assembly 5 or a plurality thereof.

The wash station 9 may comprise a splash guard comprising at least one panel 27, 28, 29 for preventing overspray to surrounding areas of the system 3. For example, one or more end panels 27, top panels, or side panels 29 may be provided. The panels may be flexible or rigid and may be metallic or polymeric, without limitation. The system 3 may comprise at least one walk 16, stair 17, or safety railing 18.

The system 3 may comprise at least one hauler 47 for moving the filter plate assembly 5 to or from the system 3. The at least one hauler 47 may be used for moving the filter plate assembly 5 to or from the industrial horizontal filter press 4. The hauler 47 may be selected from the group consisting of: a trailer, a flat bed, a truck, a train car, a forklift, a cart, or a combination thereof, without limitation. In some embodiments, the hauler 47 and/or the system 3 may comprise a storage rack 45 for supporting a stack 46 of filter plate assemblies 5.

The system 3 may be provided to a floor 20 of the filtration operation or plant 1 using the industrial horizontal filter press 4. However, in some embodiments, the system 3 may be provided to a location which is remote of the filtration operation or plant 1 using the industrial horizontal filter press 4. One or more bins 51, 55, 58 for holding new or used components of the filter plate assembly 5 may be provided to the system 3. As a non-limiting example, the one or more bins 51, 55, 58 may be selected from the group consisting of: a grommet bin 51, a cloth bin 55, a spare part bin 58, or a combination thereof. Embodiments of the system 3 may comprise a wash water manifold 33 configured to be connected to the filter plate assembly 5.

The system 3 may comprise a wash wand 37 configured for cleaning the filter plate assembly 5. The wash wand 37 may be operably connected to a pressurized water source 35.

The wash station 9 may comprise at least one spray bar 31 , such as a horizontal sprayer bar, without limitation. The wash station 9 may comprise at least one flexible tube 30 operably connected to a pressurized water source 35. The wash station may include at least one hydraulic joint 32 connecting the spray bar 31 to the flexible tube 30, without limitation.

Embodiments of the system 3 may comprise a plate index mechanism 54 adjacent the readying station 7. A floor drain configured with a sump 56 may be provided at a lower region of the wash station 9. The system 3 may comprise a plate wheel inspection/replacement station 57 for inspecting and removing rollers on each filter plate assembly 5. The wash station 9 may comprise a stationary wash station 9a. The wash station 9 may comprise a nozzle check and replace station 9b, without limitation.

The nozzle check and replace station 9b may comprise a lift 34. The nozzle check and replace station 9b may comprise a floor opening 43.

A method for refurbishing a filter plate assembly 5 of an industrial horizontal filter press 4 used in a filtration operation or plant 1 is also disclosed. The method may comprise the step of providing the system 3 according to one of the embodiments discussed above. The method may further comprise any combination of the following steps in any logical order: removing the filter plate assembly 5 from the industrial horizontal filter press 4; conveying the filter plate assembly 5 to the system 3 ; providing the filter plate assembly 5 to the readying station 7 ; removing a grommet 42 and used filter cloth 40 from the filter plate assembly 5; washing the filter plate assembly 5 in the wash station 9; installing a grommet 42 and new filter cloth 49 to the filter plate assembly 5; conveying the filter plate assembly 5 to the industrial horizontal filter press 4; and, installing the filter plate assembly 5 in the industrial horizontal filter press 4. The various method steps may be practiced by the same entity or different steps may be practiced by different entities. In some embodiments of the method, the step of removing a grommet 42 or reinstalling a grommet 42 may comprise turning multiple fasteners 52 simultaneously using a torque tool 22. The step of conveying the filter plate assembly 5 to the system 3 and the step of conveying the filter plate assembly 5 to the industrial horizontal filter press 4 may involve the use of a hauler 47 or plate carrier hoist 44, without limitation.

BREIF DESCRIPTION OF THE DRAWINGS

To complement the description which is being made, and for the purpose of aiding to better understand the features of the invention, drawings illustrating exemplary, non-limiting embodiments have been added to the present specification as an integral part thereof, in which the following have been depicted with an illustrative and non-limiting character. It should be understood that like reference numbers used in the drawings (if any are used) may identify like components. In the drawings: FIG. 1 depicts a filtration operation or plant 1 employing one or more filters 4 in a filtration zone 2, and further incorporating a system 3 for refurbishing filter plate assemblies 5, according to some embodiments.

FIG. 2 depicts a non-limiting exemplary embodiment of a system 3 for refurbishing filter plate assemblies 5 which may be employed in the filtration operation or plant 1 shown in FIG. 1.

FIGS. 3 and 26-28 depict a non-limiting exemplary embodiment of a filter 4 which may be employed in the filtration operation or plant 1 shown in FIG. 1 , in particular, an industrial horizontal filter press.

FIGS. 4, 5, 22, 23, and 32-34 show alternate views of a system 3 for refurbishing filter plate assemblies according to the embodiment shown in FIG. 2.

FIGS. 6, 7, and 35-37 depict a non-limiting exemplary embodiment of a readying station 7 of the system 3 in FIGS. 4 and 5.

FIGS. 8, 9, 11, 38, and 40 depict a non-limiting exemplary embodiment of a grommet and cloth removal station 8 of the system 3 in FIGS. 4 and 5.

FIGS. 10, 14-17, and 40-41 depict a non-limiting exemplary embodiment of a wash station 9 of the system 3 in FIGS. 4 and 5.

FIGS. 12, 13, and 42 depict non-limiting exemplary embodiments of a torque tool 22 which may be employed in a grommet and cloth removal station 8.

FIGS. 18 and 19 depict a non-limiting exemplary embodiment of a crane 11, pre assembly station 10, assembly station 12, and rework station 14 downstream of the wash station

9.

FIGS. 20, 21, 43, and 44 depict a non-limiting exemplary embodiment of a final inspection station 13, and rework station 14 adjacent an unloading zone 59. FIGS. 24, 29, and 30 depict a storage rack 45 and plate carrier hoist 44 system which may be employed for temporary storage of filter plate assemblies 5 and stacks 46 thereof, according to some non-limiting embodiments. Such storage racks 45 may be positioned adjacent loading 50 or unloading 59 zones and make up an integral component of system 3.

FIG. 25 depicts link 49 reassembly or disassembly which may take place at a station 7, 13 or storage rack 45 within the system 3. Link removal and/or installation may be performed while filter plate assemblies 5 are arranged in a plate stack 46 within a storage rack 45 - including when on a hauler 47.

FIG. 39 depicts an exploded view of an exemplary filter plate assembly 5 for use in a filter 4 according to non-limiting embodiments, and which may be disassembled in grommet and cloth removal station 8, or reassembled in assembly station 12, without limitation. The figure depicts a used 40 or new 48 filter cloth secured to a filter plate 41, and an upper flood wash bar 60 which may be connected to a pressurized water source 35 via a wash water manifold 33 of the system 3 during refurbishment.

FIGS. 31 and 45 depict methods incorporating a system 3 for refurbishing filter plate assemblies 5, according to some embodiments.

In the following, the invention will be described in more detail with reference to drawings in conjunction with exemplary embodiments.

DETAILED DESCRIPTION

The following description of the non-limiting embodiments shown in the drawings is merely exemplary in nature and is in no way intended to limit the inventions disclosed herein, their applications, or their uses.

A filtration operation or plant 1 may comprise a filtration zone 2 having a number of filters 4 (e.g., horizontal filter press). Each filter 4 may comprise a plurality of filter plate assemblies 5 supported by support rails 6. According to embodiments of the invention, the filtration operation or plant 1 comprises an onsite or offsite system 3 for refurbishing the filter plate assemblies 5. The system 3 may be managed and operated locally, or may be

managed/operated by a third-party service provider. The system 3 may comprise a first (e.g., front) end 21 proximate a loading zone 50 and a second (e.g., back) end 39 proximate an unloading zone 59.

Used filter plate assemblies 5a ready for overhaul may be removed from a filter 4 of the operation or plant 1 by a plate carrier hoist 44 and aggregated into a stack 46 which is then conveyed, via a hauler 47, to the system 3. The hauler 47 may be any vehicle or suitable moving apparatus (e.g., trailer, flat bed, truck, train car, forklift, cart, etc.) which is adequately configured to move the stack 46 of used filter plate assemblies 5a to a location away from the filter 4. The hauler 47 may comprise one or more storage racks 45 sized to receive and hold a plurality of filter plate assemblies 5.

The used filter plate assemblies 5a may be delivered to a readying station 7 of the system 3 by one or more haulers 47 in a loading zone 50. The readying station 7 may comprise one or more storage racks 45 that may be provided with a plate index mechanism 54. One or more walks 16, stairs 17, and/or safety rails 18 may be provided to areas of the readying station 7. Adjacent the readying station 7 may be provided a grommet and cloth removal station 8. The plate index mechanism 54 may receive a used filter plate assembly 5a from the readying station 7 and move it to the grommet and cloth removal station 8. Here, the used filter plate assembly 5a may be stripped by removing fasteners 49 to separate one or more grommets 42 from a feed eye portion of the used filter plate assembly 5a. Used cloths 40 may also be removed from used filter plate assemblies 5a in this station 8.

The grommet and cloth removal station 8 may comprise a torque tool 22 for removing grommet fasteners 52 from a used filter plate assembly 5a. In some preferred embodiments, as shown in FIGS. 12 and 13, the torque tool 22 may have a mount 25 connected to a swing arm for stowing the torque tool and for routing power and/or fluids thereto. The torque tool 22 may comprise multiple rotatable shafts 23 - each being provided with a driver tool 24 (e.g., a socket). The driver tool 24 may be of the self-centering/self-aligning type. The torque tool 22 may be of the type described in U.S. Patent No. 6,305,245 which is hereby incorporated by reference, in its entirety, for any and all purposes as if fully set forth herein.

One or more grommet bins 51 (e.g., for collecting and/or storing grommets 42 or fasteners 52) may be provided to the grommet and cloth removal station 8, without limitation. Moreover, one or more cloth bins 55 (e.g., for collecting and/or storing used filter cloths/dirty filter media) may be provided to the grommet and cloth removal station 8, without limitation.

After progressing through the grommet and cloth removal station 8, a stripped filter plate assembly 5b (e.g., with used cloth and feed eye grommet removed) may enter a wash station 9. The wash station may comprise any apparatus known in the art which is adequately configured for cleaning a filter plate assembly 5. According to some embodiments, a washer may comprise a splash guard to prevent overspray of high pressure wash water. The splash guard may comprise one or more end panel(s) 27, one or more top panel(s) 28, one or more side panel(s) 29, or a combination thereof, without limitation.

Wash station 9 may comprise a stationary wash station 9a. A spraying device, such as a spray bar 31, may be operatively connected to a pressurized water source 35 (e.g., plumbed hose) via a wash water manifold 33 and configured for washing one or more stripped filter plate assemblies 5b. A tube, which may be rigid, but preferably flexible, may be connected to a spray bar 31 and the wash water manifold 33 via one or more hydraulic joints 32 or couplings. The tube may be rolled around a spool via a mechanical lifter to raise and lower the spray bar 31. Raising and lowering spray bar 31 may allow wash water from the pressurized water source 35 to rinse surface areas of the stripped filter plate assembly 5b. When fully raised by the mechanical lifter, a stripped filter plate assembly 5 may pass under spray bar.

As shown in FIGS. 14-17, embodiments may comprise a washer having multiple spray bars 31 and/or configured to wash a plurality of stripped filter plate assemblies 5b

simultaneously, without limitation. As shown in FIGS. 40 and 41, embodiments may comprise a washer configured to wash one stripped filter plate assembly 5b at a time, without limitation.

Wash station 9 may include a nozzle check and replace station 9b before or after stationary wash station 9a. It is further envisaged that the nozzle check and replace station 9b may be placed upstream of the grommet and cloth removal station 8 in some embodiments. The nozzle check and replace station 9b may be configured to assist an operator 38 of the system 38 to remove debris from a used filter plate assembly 5a (e.g., including a used cloth 40 associated therewith). The nozzle check and replace station 9b may further be configured to allow an operator 38 to pre-wash hard-caked areas of a used 5a or stripped 5b filter plate assembly. Like the stationary wash station 9a, nozzle check and replace station 9b may comprise a pressurized water source 35 (e.g., plumbed hose) for attaching a wash water manifold 33 to an upper flood wash bar 60 of a used filter plate assembly 5a as shown in FIGS. 10 and 41, without limitation. The stationary wash station 9a may additionally or alternatively comprise a wash wand 37 that may be provided with a stand 36 or holder. Below and proximate to wash station 9, a floor 20 supporting components of the system 3, may be provided with a floor covering 19 and/or a floor drain 56 (e.g., configured with a sump pump), without limitation.

After moving through wash station 9, a washed stripped filter plate assembly 5c may be moved (e.g., via plate index mechanism 54) to a pre-assembly station 10 behind a washer of the wash station 9. Here, an operator 38 may perform cursory inspection of cleaned plate 41 surfaces to determine if it is in acceptable condition for reuse in filter 4. If worn or damaged, the washed stripped filter plate assembly 5c may be labeled a reject filter plate assembly 5d (for rework, failed inspection), and moved to a rework station 14 (e.g., via a crane 11). The rework station 14 may comprise for instance, one or more reject racks containing reject filter plate assemblies 5d to be re- washed, refurbished, re-worked, or scrapped, depending on condition.

If cursory inspection in pre-assembly station 10 reveals a satisfactory condition of the washed stripped filter plate assembly 5c, it may proceed along support rails 15 via plate index mechanism 54 to an assembly station 12 where clean or new grommets 42 and cloths 48 can be installed back on the washed stripped filter plate assembly 5c. In the case of the embodiment shown in FIGS. 32-44, washed stripped filter plate assembly 5c may be moved through system 3 stations via a single support rail 15, wherein the plate index mechanism 54 is configured as a single track or trolley 53, without limitation. The assembly station 12 may share similarities with the grommet and cloth removal station 8. One or more grommet bins 51 (e.g., for collecting and/or storing grommets 42 or fasteners 52) may be provided to the assembly station 12, without limitation. Moreover, one or more cloth bins 55 (e.g., for storing new filter cloths 48 for installation onto a washed filter plate assembly 5c) may be provided to the assembly station 12, without limitation. A spare part bin 58 (e.g., for holding an assortment of OEM replacement parts for a filter plate assembly 5) may be provided to the pre-assembly 10 and/or assembly 12 stations according to some embodiments, without limitation. For example, spare part bin 58 may comprise spare rollers for a plate 41, or links 49 for connecting refurbished filter plate assemblies 5e together prior to re-installation into filter 4.

Once reassembly has been performed in assembly station 12, a completed refurbished filter plate assembly 5e (e.g., a washed filter plate assembly 5c with new cloth 48 and washed or new feed eye grommet 42 installed) may be moved to a final inspection station 13 via the plate index mechanism 54. The final inspection station 13 may comprise a plate wheel

inspection/replacement station 57 where rollers affixed to plate 41 sidearms (if present) may be inspected and/or replaced if necessary.

A lift 34 (e.g., a scissor lift, forklift, movable platform, elevator, crane man basket, wheelable ladder, or the like) may be provided within a floor opening 43 or suspended adjacent, over, or under support rails 15 to provide access to upper portions of filter plate assemblies 5a,

5b, 5c, 5d, 5e at different stations of the system 3. For example, a lift 34 may be provided at or adjacent any one or more of the grommet and cloth removal station 8, nozzle check and replace station 9b, pre-assembly station 10, assembly station 12, rework station 14, and final inspection station 13. Support rails 15 of the system 3 may be supported and/or reinforced by a number of supports 26 to define a frame of the system 3.

EXAMPLE

Embodiments of the system 3 and method may operate as follows. Filter plate assemblies 5 a may be placed in one end of the system 3 and held in a ready rack at a readying station 7 where an operator may have provided working platforms to put them at a comfortable working height to remove plate links from the filter plate assemblies 5a (if present). A plate index mechanism 54 (such as the ALP™ (Automatic Large Plate) fully automated shuttle shifter found on FLSmidth® Shriver® filter press products) may be provided to the ready rack unit of the readying station 7. The plate index mechanism 54 may include a shifter that may grab a first filter plate assembly 5a in the ready rack and advance it to a subsequent grommet and cloth removal station 8 via the support rails 15. The grommet 42 and used cloth 40 may be removed from the filter plate assembly 5a.

After the filter plate assembly 5 is stripped, the stripped filter plate assembly 5b may proceed to a wash station 9. The wash station 9 may comprise a nozzle check and replace station 9b where an operator 38 may connect a hose operably connected to a pressurized water source 35 with a quick connect wash water manifold 33 to the upper flood wash bar 60 of a filter plate assembly (if present), to test the wash nozzles of the filter plate assembly. The system 3 may be configured such that this nozzle check and replace station 9b is provided/occurs before or after the grommet and cloth removal station 8. In other words, wash nozzles may be tested before or after old cloth 40 removal and/or grommet 42 removal. FIG. 10 shows nozzle testing occurring with cloth 40 and grommet still intact on a filter plate assembly. This process, if performed during nozzle check and replace station 9b may additionally serve to remove excess debris from the used cloths 40.

During disassembly of a used filter plate assembly 5a at the grommet and cloth removal station 8, an electric or hydraulic torque tool 22, such as a wrench containing the correct number of driver tools 24 (e.g., sockets) and the correct flange pattern configuration pertaining to a grommet 42 may then be swung into proximity of the grommet 42 (e.g., from the side, from the underside of a support rail 15, or, from a separate support fixture). The torque tool 22 may then be placed over/on the feed eye grommet 42, and then the fasteners 52 (e.g., nuts, bolts) removed from the feed eye grommet 42. The torque tool 22 may then be swung back out of the way (e.g., to the side, up, or down), to allow the operator 38 to remove the feed eye grommet 42 from the used filter plate assembly 5a. If holes, depressions, or lower openings 43 in the floor 20 are not permissible, a scissor lift 34 design (as shown in FIG. 10) may not be optimal. In such embodiments, a set of mobile stairs (e.g., with a counter levered platform) could be rolled in from the side above the support rails 15 to provide operator access to the upper portion of the plate. A small step ladder may also be used. From this perched position, the operator 38 may drop (i.e., remove) the used cloths 40 from the used filter plate assembly 5a from an ergonomic elevated location. Optionally, a wash wand 37 supported by a stand 36 as shown in FIG. 10 may be provided to clean portions of used filter plate assemblies.

A plate index mechanism 54 (e.g., an ALP-type FLSmidth® Shriver® plate shifter) may then take the stripped filter plate assembly 5b to a wash station 9 (e.g., a stationary or“S- WASH” station 9b) where the stripped filter plate assembly 5b may receive at least one pass of a washer to clean the plate grid surfaces before taking it to the next station. Many types of washers are envisaged. The washer may comprise a wash water manifold 33, one or more rigid or flexible tubes 30, one or more sprayer bars 31, and one or more hydraulic joints 32 as shown in FIG. 15. Washing apparatus of the wash station 9 may further include or alternatively comprise a wash wand 37 supported by a stand 36 as shown in FIG. 10.

After leaving the wash station 9, a washed stripped filter plate assembly 5c may enter a pre-assembly station 10. The pre-assembly station 10 may be used for inspection of a washed stripped filter plate assembly 5c. Thereafter, the washed stripped filter plate assembly 5c may proceed along support rails 15 directly to an assembly station 12 or moved to a rework station 14, e.g., via a crane 11, plate carrier hoist 44, or hauler 47, without limitation.

Embodiments of the assembly station 12 may resemble or mirror the aforementioned grommet and cloth removal station 8. A set of mobile stairs with a counter levered platform may, for example, be rolled in from the side above the support rails 15 to provide operator 38 access to upper portions of a washed stripped filter plate assembly 5c. Alternatively, a lift 34 may be used. From here, an operator 38 may drop new cloths 48 into place, and/or replace any wash nozzles that have been identified as out of specification or damaged at an earlier station.

An electric or hydraulic torque tool 22 (e.g., such as a wrench containing the correct number of driver tools 24 and flange pattern configuration matching the grommet 42 to be installed) would again, be swung into place (e.g., from the underside of a sidebar, drop in from above, or enter from a separate support fixture), and placed over the feed eye grommet and onto the fasteners 52 (e.g., nuts or bolts) to torque them to hold the new cloth 48 to the washed stripped filter plate assembly 5c. The tool 22 would then be swung back to its storage/idle configuration. The torque tool 22 may be configured to torque grommet 42 fasteners 52 to specification in one step. Optionally, it may be stowed to allow the operator 38 to replace and torque the feed eye grommet to the plate with the correct torque setting. Filter plate orifices could then be checked with an orifice gauge of the correct size and replaced if they are found to be out of tolerance.

The plate index mechanism 54 may then take the freshly dressed filter plate assembly 5e to the staging end 39 of the system 3 where an operator 38 may replace the plate links 49, perform a final inspection, and stage the plates into sets of 10. Any rejects at this final inspection station 13 stage, may be hoisted, e.g., via a crane 11, to another rework station 14 or“reject rack” for further inspection, investigation, and dressing. Those plates or plate and cloth assemblies in the rework station 14 may be transferred back to the first readying station 7, and once again, enter the system 3 process again. Parts of rejected filter plate assemblies 5d may undergo processing in any of the aforementioned stations 7, 8, 9, 9a, 9b, may be reworked in the rework station, or disposed/recycled according to diagnosis by an operator 38.

In some embodiments, rework station 14 may be connected to or operatively integrated with the system 3, or it may be positioned at another location of the floor 20 which is remote or generally isolated from the rest of the system 3, without limitation.

In some embodiments, roughly about ¼ to 5 filters 4 worth of filter plate assemblies 5 may be remanufactured per day. In some embodiments, 1-3 filters 4 worth of plates may be remanufactured per day using the disclosed system and method, without limitation. Filter plate assemblies 5 may be refurbished per a service contract with a vendor. In a hypothetical instance where there are seventeen (17) M2020 32 mm x 152 filters 4 in a particular filtration operation or plant 1, it is envisaged that there might be 4 haulers 47 (e.g., trucks) per day going round trip between the filtration operation or plant 1 (onsite/local) to an offsite/remote location. The offsite/remote location may be provided with the system 3 for refurbishing plate and cloth assemblies 5 disclosed herein, and it is here at the offsite/remote location that method steps disclosed herein may be practiced. It is also anticipated that about 40 filter plate assemblies 5 per hauler 47 may be provided. For example, a stack 46 of twenty (20) plates per storage rack 45 - with two storage racks 45 on each hauler 47 (as suggested on the right side of FIG. 44). Each storage rack 45 may be, for instance, provided on a single customized low deck dropped flatbed trailer.

In some embodiments, a dirty/used set of filter plate assemblies 5a may be provided at one end 21, a clean set provided at the other opposite end 39, and one or more work stations 7, 8, 9, 10, 11, 12, 13, 14 in the middle as shown and described. The readying process may be batch, but is preferably continuous. The process may be highly manual, semi-automatic, or automatic in nature, without limitation. Preferred embodiments may be configured as a continuous process with minimal crane usage. However, if/where necessary, cranes 11 and/or plate carrier hoists 44 are preferably configured to move many filter plate assemblies 5 together as a stack 46 (see, for example, FIGS. 29 and 30).

In some embodiments, after washing steps are performed at wash station 9, Washed stripped filter plate assemblies 5c may be inspected and those plates that are in need of more repair may be put into a rework station 14 (e.g., a reject holding rack, rework ready rack, or the like), without limitation. A crane 11 or similar device may be used to easily transport such assemblies 5c to the rework station 14. These defective assemblies 5d may be sent through the system 3 once more or otherwise repaired (e.g., rollers replaced, new cloth 48 installed, new grommet 42 installed, spray nozzles repaired and/or de-clogged, fasteners 52 replaced and/or re- torqued, etc.)· Once repaired, the filter plate assembly can then be examined at final inspection station 13 and may be allowed go back into service and into the filter plate assembly 5 rotation procedure described.

Where used herein - and in the drawings, the terms“plate,”“plate and cloth assembly,” “filter plate assembly” and/or the like may be used interchangeably or referred to informally. It is important to note that depending on various stages of refurbishment and/or servicing using the systems and methods described herein, apparatus may be in various stages of completion (with washed plate and new cloth, with unwashed plate and new cloth, with washed plate and old cloth, with washed plate and no cloth, with feed eye grommet, without feed eye grommet, with spray nozzle, without spray nozzle, with or without plate rollers, with or without plate links 49 etc. Accordingly, such terms have been used informally throughout this description and may have similar or slightly different meanings.

It should be understood that any one or all of the stations, functions, method steps, apparatus and/or components of apparatus may be manually-activated, semi-automated, or fully- automated, without limitation.

It should further be understood that any one of the s stations, functions, method steps, apparatus and/or components of apparatus may involve the provision and/or use of one or more plate index mechanisms 54, without limitation.

It should further be understood that feed eye grommet removal and installation tools shown and described herein may be provided in the singular (wherein one device is shared between two stations), or, they may be provided in a plurality (wherein each station comprises its own tool), without limitation. For less automated, and more manually-oriented embodiments, the same feed eye grommet installation/removal torque tool 22 may be shared between two stations 8, 12, 13. For example, the torque tool 22 may be mounted to a carriage or trolley cart that moves along the system and/or is supported by support rails 15. As another non-limiting example, torque tool 22 may be provided to a lift (e.g., wheelable cart or lift 34) or hauler 47 (e.g., a forklift) to be shared between two stations within the system 3.

In some embodiments, a feed eye grommet removal and installation tool 22 may be provided with a jig which secures to a geometry or profile of a plate (e.g., self-aligning feature, plate edge guide, plate boss centering recess feature, or the like), in order to more quickly or better align the tool with feed eye grommet nuts, bolts, or other fasteners 52.

It should be known that the specific features, process steps, and possible benefits shown and described herein in detail are purely exemplary in nature and should not limit the scope of the invention. Moreover, although the invention has been described in terms of particular embodiments and applications, one of ordinary skill in the art, in light of this teaching, can generate additional embodiments and modifications without departing from the spirit of or exceeding the scope of the invention.

Accordingly, it is to be understood that the drawings and descriptions herein are proffered by way of example to facilitate comprehension of the invention and should not be construed to limit the scope thereof.

REFERENCE NUMERAL IDENTIFIERS . Filtration operation or plant

. Filtration zone

. System for refurbishing filter plate assemblies

. Filter (e.g., horizontal filter press)

. Filter plate assembly

a. Used filter plate assembly ready for overhaul

b. Stripped filter plate assembly (e.g., with used cloth and feed eye grommet removed)

c. Washed stripped filter plate assembly

d. Reject filter plate assembly (for rework, failed inspection)

e. Refurbished filter plate assembly (e.g., with new cloth and washed or new feed eye grommet installed.

. Support rail

. Readying station

. Grommet and cloth removal station

. Wash station

a. Stationary wash station

b. Nozzle check and replace station

0. Pre-assembly station

1. Crane

2. Assembly station (e.g., grommet and cloth installation station)

3. Final inspection station

4. Rework station (e.g., Reject rack, assemblies to be re-washed or re-worked)5. Support rail (e.g.,“sidebar”)

6. Walk

7. Stairs

8. Safety rail

9. Floor covering

0. Floor First end

Torque tool (e.g., multi-fastener torque wrench)

Shaft

Driver tool (e.g., socket)

Mount

Supports

Splash guard - End panel(s)

Splash guard - Top panel(s)

Splash guard - Side panel(s)

Tube (e.g., rigid or flexible)

Spray bar (e.g., horizontal sprayer bar)

Hydraulic joint or coupling

Wash water manifold

Lift (e.g., scissor lift, forklift platform, elevator, crane man basket) Pressurized water source (e.g., plumbed hose)

Stand

Wash wand

Operator

Second end

Used cloth

Plate (cloth removed)

Grommet

Floor opening

Plate carrier hoist

Storage rack

Plate stack

Hauler (e.g., trailer, flat bed, truck, train car, forklift, cart, etc.) New cloth

Links

Loading zone

Grommet bin (e.g., for collecting or storing grommets, fasteners)

Claims

CLAIMS What is claimed is:

1. A system 3 for refurbishing a filter plate assembly 5 of an industrial horizontal filter press 4 used in a filtration operation or plant 1, the system 3 comprising:

a first end 21;

a second end 39;

a readying station 7 proximate the first end 21;

a grommet and cloth removal station 8;

a wash station 9;

an assembly station 12; and

at least one support rail 15 being supported by supports 26 for suspending the filter plate assembly 5.

2. The system 3 according to claim 1 , wherein the readying station 7 precedes the grommet and cloth removal station 8; the grommet and cloth removal station 8 precedes the wash station 9; and the wash station 9 precedes the assembly station 12.

3. The system 3 according to any one of the preceding claims, further comprising a final inspection station 13 proximate the second end 39 and following the assembly station 12.

4. The system 3 according to any one of the preceding claims, further comprising a pre assembly station 10 between the wash station 9 and the assembly station 12.

5. The system 3 according to any one of the preceding claims, further comprising a rework station 14 proximate the assembly station 12.

6. The system 3 according to any one of the preceding claims, further comprising a loading station 50 proximate the first end 21 for removing the filter plate assembly 5 from a hauler 47 and providing the filter plate assembly 5 to the system 3 for cleaning and refurbishment.

7. The system 3 according to any one of the preceding claims, further comprising an unloading station 59 proximate the second end 39 for removing the filter plate assembly 5 from the system 3 after it has been cleaned and refurbished and/or for loading the filter plate assembly 5 onto a hauler 47.

8. The system 3 according to any one of the preceding claims, wherein the at least one support rail 15 comprises a trolley 53 for conveying the filter plate assembly 5 from the first end 21 to the second end 39 such that the filter plate assembly 5 is coplanar with the at least one support rail 15.

9. The system 3 according to any one of claims 1-7, wherein the at least one support rail 15 comprises two parallel support rails 15 for conveying the filter plate assembly 5 from the first end 21 to the second end 39 such that the filter plate assembly 5 is perpendicular with and spans across the space separating the two parallel support rails 15.

10. The system 3 according to any one of the preceding claims, further comprising a torque tool 22 configured to remove multiple fasteners 52 from a grommet 42, or secure multiple fasteners 52 to a grommet 42 simultaneously.

11. The system 3 according to any one of the preceding claims, further comprising a crane 11 or overhead plate carrier hoist 44 configured to lift the filter plate assembly 5 or a plurality thereof.

12. The system 3 according to any one of the preceding claims, further comprising a storage rack 45 configured to receive and temporarily store a plate stack 46 comprising the filter plate assembly 5 or a plurality thereof.

13. The system 3 according to any one of the preceding claims, wherein the wash station 9 comprises a splash guard comprising at least one panel 27, 28, 29 for preventing overspray to surrounding areas of the system 3.

14. The system 3 according to any one of the preceding claims, further comprising at least one walk 16, stair 17, or safety railing 18.

15. The system 3 according to any one of the preceding claims, further comprising at least one hauler 47 for moving the filter plate assembly 5 to or from the system 3 and to or from the industrial horizontal filter press 4.

16. The system 3 according to claim 15, wherein the hauler 47 is selected from the group consisting of: a trailer, a flat bed, a truck, a train car, a forklift, a cart, or a combination thereof.

17. The system 3 according to claim 15, wherein the hauler 47 and/or the system 3 comprises the storage rack 45 of claim 12.

18. The system 3 according to any one of the preceding claims, wherein the system 3 is provided to a floor 20 of the filtration operation or plant 1 using the industrial horizontal filter press 4.

19. The system 3 according to any one of claims 1-17 wherein the system 3 is provided to a location which is remote of the filtration operation or plant 1 using the industrial horizontal filter press 4.

20. The system 3 according to any one of the preceding claims, further comprising one or more bins 51, 55, 58 for holding new or used components of the filter plate assembly 5; the one or more bins 51, 55, 58 being selected from the group consisting of: a grommet bin 51, a cloth bin 55, a spare part bin 58, or a combination thereof.

21. The system 3 according to any one of the preceding claims, further comprising a wash water manifold 33 configured to be connected to the filter plate assembly 5.

22. The system 3 according to any one of the preceding claims, further comprising a wash wand 37 configured for cleaning the filter plate assembly 5 which is operably connected to a pressurized water source 35.

23. The system 3 according to claim 22, wherein the wash station 9 comprises at least one spray bar 31, at least one flexible tube 30 operably connected to a pressurized water source 35, and at least one hydraulic joint 32 connecting the spray bar 31 to the flexible tube 30.

24. The system 3 according to any one of the preceding claims, further comprising a plate index mechanism 54 adjacent the readying station 7.

25. The system 3 according to any one of the preceding claims, further comprising a floor drain with sump 56 provided at a lower region of the wash station 9.

26. The system 3 according to any one of the preceding claims, further comprising a plate wheel inspection/replacement station 57.

27. The system 3 according to any one of the preceding claims, wherein the wash station 9 comprises a stationary wash station 9a.

28. The system 3 according to any one of the preceding claims, wherein the wash station 9 comprises a nozzle check and replace station 9b.

29. The system 3 according to claim 28, wherein the nozzle check and replace station 9b comprises a lift 34.

30. The system 3 according to claim 28 or 29, wherein the nozzle check and replace station 9b comprises a floor opening 43.

31. A method for refurbishing a filter plate assembly 5 of an industrial horizontal filter press 4 used in a filtration operation or plant 1, comprising the steps of:

providing the system 3 according to any one of the preceding claims;

removing the filter plate assembly 5 from the industrial horizontal filter press 4;

conveying the filter plate assembly 5 to the system 3;

providing the filter plate assembly 5 to the readying station 7;

removing a grommet 42 and used filter cloth 40 from the filter plate assembly 5;

washing the filter plate assembly 5 in the wash station 9;

installing a grommet 42 and new filter cloth 49 to the filter plate assembly 5 ;

conveying the filter plate assembly 5 to the industrial horizontal filter press 4; and, installing the filter plate assembly 5 in the industrial horizontal filter press 4.

32. The method according to claim 31 , wherein the step of removing a grommet 42 or reinstalling a grommet 42 comprises turning multiple fasteners 52 simultaneously using a torque tool 22.

33. The method according to claim 31 or 32, wherein the step of conveying the filter plate assembly 5 to the system 3 and the step of conveying the filter plate assembly 5 to the industrial horizontal filter press 4 involves the use of a hauler 47 or plate carrier hoist 44.

34. A system for refurbishing a filter plate assembly 5 of an industrial horizontal filter press 4 used in a filtration operation or plant 1 substantially as shown and described.

35. A method for refurbishing a filter plate assembly 5 of an industrial horizontal filter press 4 used in a filtration operation or plant 1 substantially as shown and described.