SMART FILTRATION FOR SMART MINES: REAL-TIME FILTER CLOTH FAILURE DETECTION WITH FLS INTELLIPLATE MINING CONGRESS 2026 Michael Madsen FLSmidth A/S, Denmark (Presenting author: michael.madsen@flsmidth.com) Mining Technology, Pressure Filtration Mining Division, Filtration & Dewatering ABSTRACT In filter press applications, filter media is an essential component that is subject to wear and eventual failure. Once a cloth has failed, if gone undetected for many cylces, the filter plate will be subjected to excessive wear and quickly fail. The filter plate is a much more costly replacement than the filter media. Early cloth failure detection, therefore, is considered an integral part of condition monitoring to prevent additonal filter press component failures and to keep filter production at optimal levels. In the context of a production plan, predicting how many cycles a cloth can go through before failure can be challenging and must be predicted so that supply chain management can have the necessary filter media on-hand, and maintenance teams can change out a torn filter cloth without disrupting filter production. To effectively support the operator and maintain production, a solution must do more than just detect cloth failure—it must precisely identify which cloth within the filter press plate stack has failed. Without both capabilities, operators are left without the critical insights needed to make fast, consistent decisions that maintain optimal filter press production performance. The FLS Intelliplate™ Sensor is purpose-built to meet this challenge. By directly measuring filtrate turbidity from individual filter plates, it isolates cloth failure with pinpoint accuracy while eliminating external variables that often complicate torn filter media diagnostics. This targeted approach not only streamlines troubleshooting but also enhances the reliability and efficiency of the entire filtration process.
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