Filter Breakthrough is a phenomenon that occurs during the solid-liquid separation process, particularly in filtration. It refers to the situation where solid particles pass through the filter element, resulting in a contaminated filtrate.
This article introduces what Filter Breakthrough is, why it occurs, how to detect it, the consequences of breakthrough, how to prevent it, and Vithy Filtration’s solutions to address this issue.
What is “Filter Breakthrough”?
Filter Breakthrough occurs when the filter element fails to retain all the solid particles present in the liquid being filtered. This can happen due to various reasons, such as the size of the particles being smaller than the pore size of the filter, the filter becoming clogged, or the pressure applied during filtration being too high.
Filter Breakthrough can be categorized as follows:
- 1. Initial Breakthrough: Occurs at the start of filtration before the filter cake forms, where fine particles pass directly through the pores of the filter element. This is often due to improper filter cloth/membrane selection or mismatched filtration rating.
- 2. Cake Breakthrough: After the filter cake has formed, excessive operating pressure, cake cracking, or "channelling" can cause solid particles to wash out with the liquid. Common in filter presses and leaf filters.
- 3. Bypass Breakthrough: Caused by poor equipment sealing (e.g., damaged seal surfaces of filter plates or frames), allowing unfiltered material to enter the filtrate side. This is an equipment maintenance issue.
- 4. Media Migration: Specifically refers to fibers or material from the filter element itself breaking off and entering the filtrate, also a form of breakthrough.
Vithy Filtration_Filter Element
Why does “Filter Breakthrough” happen?
- ● Particle Size: If the solid particles are smaller than the filter’s pore size, they can easily pass through.
- ● Clogging: Over time, the accumulation of particles on the filter can lead to clogging, which may create larger voids that allow smaller particles to pass through.
- ● Pressure: Excessive pressure can force particles through the filter element, especially if the filter is not designed to withstand such conditions.
- ● Filter Material: The choice of filter material and its condition (e.g., wear and tear) can also affect its ability to retain particles.
- ● Electrostatic Effects: For micron/submicron particles (e.g., certain pigments, mineral slurries), if the particles and the filter element carry like charges, mutual repulsion can prevent effective adsorption and retention by the medium, leading to breakthrough.
- ● Particle Shape: Fibrous or platy particles can easily "bridge" to form large pores, or their shape allows them to pass through circular pores.
- ● Liquid Viscosity and Temperature: Low-viscosity or high-temperature liquids reduce fluid resistance, making it easier for particles to be carried through the filter by high-velocity flow. Conversely, high-viscosity liquids aid particle retention.
- ● Filter Cake Compressibility: When filtering compressible cakes (e.g., biological sludge, aluminum hydroxide), increasing pressure reduces cake porosity but may also "squeeze" fine particles through the underlying filter cloth.
Vithy Filtration_Mesh Filter Cleaning Process
How to Detect “Filter Breakthrough”
1. Visual Inspection:
● Regularly inspect the filtrate for visible solid particles. If particles are observed in the filtrate, it indicates that Filter Breakthrough is occurring.
2. Turbidity Measurement:
● Use a turbidity meter to measure the turbidity of the filtrate. An increase in turbidity levels can indicate the presence of solid particles, suggesting Filter Breakthrough.
3. Particle Size Analysis:
● Conduct particle size analysis on the filtrate to determine the size distribution of particles. If smaller particles are detected in the filtrate, it may indicate Filter Breakthrough.
4. Filtrate Sampling:
● Periodically take samples of the filtrate and analyze them for solid content using techniques such as gravimetric analysis or microscopy.
5. Pressure Monitoring:
● Monitor the pressure drop across the filter. A sudden change in pressure may indicate clogging or breakthrough, which can lead to Filter Breakthrough.
6. Conductivity or Chemical Analysis:
● If the solid particles have a different conductivity or chemical composition than the filtrate, measuring these properties can help detect Filter Breakthrough.
7. Flow Rate Monitoring:
● Monitor the flow rate of the filtrate. A significant change in flow rate may indicate that the filter is either clogged or experiencing Filter Breakthrough.
Consequences of “Filter Breakthrough”
● Contaminated Filtrate: The primary consequence is that the filtrate becomes contaminated with solid particles, which can affect downstream processes or product quality.
o Catalyst Recovery: Breakthrough of precious metal catalyst particles leads to significant economic loss and reduced activity.
o Food & Beverage: Cloudiness in wines or juices, affecting clarity and shelf life.
o Electronic Chemicals: Particulate contamination reduces chip yield.
- ● Reduced Efficiency: The efficiency of the filtration process is compromised, leading to increased operational costs and time.
- ● Equipment Damage: In some cases, solid particles in the filtrate can cause damage to downstream equipment (e.g., pumps, valves, and instruments), leading to costly repairs.
- ● Environmental Pollution & Waste: In wastewater treatment, solid breakthrough can cause effluent suspended solids to exceed standards, violating environmental regulations.
How to Avoid “Filter Breakthrough”
- ● Proper Filter Selection: Choose a filter with an appropriate pore size that can effectively retain the solid particles present in the liquid.
- ● Regular Maintenance: Regularly inspect and maintain filters to prevent clogging and ensure they are in good condition.
- ● Control Pressure: Monitor and control the pressure applied during filtration to avoid forcing particles through the filter.
- ● Pre-filtration: Implement pre-filtration steps to remove larger particles before the main filtration process, reducing the load on the filter.
- ● Use of Filter Aids: In some cases, adding filter aids (e.g., activated carbon, diatomaceous earth) can form a uniform pre-coat layer on the filter element as an "interception bed. This can help improve the filtration process and reduce the risk of Filter Breakthrough
Vithy Solutions:
1. Precise Rating: Vithy engineers will customize the selection of filter elements micron rating based on the operating conditions you provide, ensuring that the accuracy of the filter elements is suitable for your specific conditions.
2. High-Quality Filter Elements: By establishing our own production line for filter elements (filter cartridges, filter bags, filter meshes, etc.), we ensure that the raw materials used for these filter elements are sourced from globally recognized high-quality filtration materials. Produced in a clean production environment, our filter elements are free from adhesive-related contaminants and fiber shedding, ensuring excellent filtration effect and a long service life. Additionally, they are certified under ISO 9001:2015 and CE standards.
Vithy Filtration_Filter Element Factory
3. Self-Cleaning Setting: Our self-cleaning filters are equipped with controls for time, pressure, and differential pressure. When these parameters reach the set values, the control system will automatically initiate the cleaning of the filter elements, discharging the sewage and effectively reducing filtration breakthrough, thereby improving the quality of the filtrate.
Vithy Filtration_Filter Control System
Vithy Filtration is committed to providing innovative solutions to address filter breakthrough, ensuring that our customers achieve reliable and high-quality filtration results. We invite you to explore our offerings and discover how we can support your filtration needs.
Contact: Melody, International Trade Manager
Mobile/WhatsApp/WeChat: +86 15821373166
Email: export02@vithyfilter.com
Website: www.vithyfiltration.com
Post time: Dec-15-2025
