Header Laterals design facilitates the media bed filtration process in water and wastewater treatment.
Many industries use media bed filtration. This use can take the form of ion exchange for water softening/demineralization, sand filtration, activated carbon, or other media bed fluid treatment processes. However, regardless of whether the application is in waterworks, power companies, pulp and paper, steel, or any other industries, the problems tend to be similar. In the process of media bed filtration, the same problems occur again and again: resin or media leakage, excessive pressure drop, screen clogging, and backwash/rejuvenation requirements are too high. These problems can be solved by using properly designed and specified equipment and internal components of the equipment (arguably the most important investment in media bed filtration).
To ensure proper design results, the design engineer needs to understand the system pressure. Is it designed to avoid clogging? In the event of a hydraulic failure, is it able to withstand the strains it may withstand and still retain the medium? Can its size keep the particles normally used? Will it pass the required traffic? Is it designed to provide differential pressure to ensure uniform flow? Has corrosion been considered? Is a suitable alloy provided and specified? Can it be repeatedly rinsed successfully without clogging?
A typical query for a manufacturer of filtration products may be to require a "header side pipe" to form a distribution system for the activated carbon tower or desalination tank. Manufacturers can be provided with requirements for horizontal distribution/collection systems. Given flow data and container details, this data can of course be used to generate a set of header side pipes. In fact, a variety of header side tubes that meet these specifications may be produced. The question is: which design is best for the narrator? Although the term "horizontal header" is often used, the use of other configurations (such as the "hub lateral" system, "leg drop nozzle" configuration, and other configurations) may serve the process better and be more economical. Ideally, manufacturers' application engineers will ask their customers a series of questions designed to elicit more specific information about the customer’s overall needs. For example, they may wish to discuss the media bed filtration process to ensure that the process is understood and key areas are fully considered. A preliminary understanding of the details of such processes is essential to reduce overall maintenance and costs and obtain the best products.
Header Laterals benefits and applications
Wedge wire is generally recommended because of its high strength and ease of cleaning. It can be supplied in a variety of forms for distribution/collection systems, the most common of which are nozzles and lateral configurations. A variety of end configurations are available on the side to suit. Typically, wedges are applied to the drill rod. This design provides better support and allows the design of engineering drill molds to ensure optimal distribution and collection and maximum use of the bed.
All of the above are based on the accurate determination of media retention requirements. The notch size of the wedge wire product is critical to ensure that all analyses, design, and manufacturing methods are implemented. In consideration of tolerances, many wedge wire products on the market are still based on original drilling applications. They are usually manufactured with dimensional tolerances of +/- 0.002 inches or greater. When trying to retain 0.010 inches of ion exchange media, the results were obvious. Modern computer numerical control (CNC) machinery and International Organization for Standardization (ISO) quality procedures can result in intolerances of +/- 0.001 inches or better.
In any process of distributing fluid through the medium, the obstruction must be eliminated. It is important to maintain a uniform distribution as described above, direct the fluid to flow uniformly through the bed, and maximize media contact. Dredging causes the media to run out prematurely and requires premature regeneration. Therefore, the flow characteristics and final performance of the process are determined inside the container. Technology-oriented manufacturers use electronic design automation (EDA) to provide answers. Special considerations such as mesh size in water treatment processes such as ion exchange are critical. The function of the sieve is to keep the resin beads in place while promoting fluid flow through the bed.
Wire mesh sieving also often achieves good results in filtration applications, but it does not provide the reliability of wedge wire. Since the cross-section of the wire constituting the mesh is circular, there is always a tendency for particles to stay and block. A wedge-shaped wire is made of triangular wire continuously wound on longitudinal support wire. The wires are soldered at each intersection. Triangular cross-section wedges with flat fixed surfaces are easier and more effective to clean and backwash. In addition, water pressure, system stress, and careless handling may cause the wire cloth to be scratched or torn. For these reasons, many engineers prefer the strength of the wedge wire, resistance to clogging, ease of backwashing, and dimensional stability.
Many systems also use downstream protection in the form of basket filters or resin traps. A wedge wire is also an ideal filter medium for this application. Rugged and sturdy, it retains the reserved process conditions. The nature of the wedge wire construction allows it to be scrubbed, cleaned, and washed without damage. The basket can be designed to suit pipeline size, pressure drop requirements, changing configurations, and process conditions.
As a result, Header Laterals provides engineers with an excellent retention medium that can be used for long-term design and manufacture of container internal parts, resin collectors, and other filtration products, resulting in long-term cost savings and improved efficiency.