Figure 1 – Intelliplate™ Sensor KEYWORDS Turbidity Sensor, Filtration, Pressure Filtration, Intelliplate, Filter Media Failure Detection 1. MECHANISMS TO FILTER MEDIA FAILURES Filter media failures encompass a range of mechanisms that can significantly impair the operational efficiency and reliability of a filter press. Common failure modes include cloth blinding—where accumulated solids obstruct the pores of the filter media, thereby reducing permeability and filtrate flow; inappropriate filter media selection, resulting in suboptimal chemical or mechanical compatibility with process streams; and physical degradation such as abrasion, chemical attack, or thermal stress. These failure mechanisms manifest as increased cycle times, reduced cake dewatering efficiency, elevated filtrate turbidity, and premature cloth replacement, all of which contribute to higher operational costs and decreased system throughput. However, for the scope of this paper and the proposed detection methodology, the focus will be limited to mechanical failures characterized by filter media tearing or the development of holes in the filter cloth. These specific failure modes pose immediate risks to filtrate quality and process integrity, as they directly enable unfiltered solids to bypass the filtration barrier, leading to rapid deterioration of both filtrate clarity and overall filter press performance. Mechanical abrasion: Incomplete cloth wash will leave filtered cake in the chamber to be re-compressed during the next cycle. Continuous cycles will eventually abrade holes in the cloth along the seal edge, stay-bosses, and feed shoes.
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