High-Capacity Coolant Filtration System: Overview

Table of Contents
1.System Overview
1.1Key Benefits
1.2Dual Pressure Vessel Design
1.3Performance Specifications
2.Coolant Filtration Process
3.Component Specifications
3.1A. Pumps and Control Valves
3.2B. Tank Assembly (Oil-Water Separator)
3.3C. Pressure Control Valve
3.4D. Flow Control Valve
3.5E. Heater and Heating Exchanger (Optional)
3.6F. Skimmer
3.7G. Tank Level Sensor
3.8H. Pressure Differential Sensor
3.9J. Filter and Housing
3.10K. Controls & Instrumentation
3.11L. Dosing and Make-Up System

1，System Overview

The High-Capacity Coolant Filtration System is a robust solution for high-volume coolant processing, recycling, and delivering substantial coolant flows to machine cutting or stamping tools. Its core function is mitigating overheating caused by extreme friction during manufacturing operations, ensuring stable equipment performance.

Key Benefits

Already deployed across local production facilities, this system features user-friendly operation that minimizes filter management time while maintaining consistent performance from startup to filter replacement. This reliability ensures effective contaminant capture and uniform filtration efficiency throughout its service life.

• Reduced operator intervention requirements
• Lower filter media disposal costs
• Superior contaminant removal efficiency
• Compact footprint (high volume filter design)

Dual Pressure Vessel Design

Unlike traditional “pressure plate” designs, this system employs a dual pressure vessel configuration that sets industry efficiency benchmarks. The two vessels operate in tandem, splitting filtration responsibilities evenly. When the active vessel reaches contaminant capacity, the system automatically diverts coolant flow to the standby vessel pre-loaded with clean filter media.

• Fully automatic operation with adjustable run speeds
• Coolant level detection sensors in each tank
• Optional Variable Frequency Drives (VFDs) for all pumps

Performance Specifications

This pressure vessel design eliminates filter change downtime and minimizes operator input. Engineered to handle flow rates from 5 to 20 cubic meters per hour with filtration precision ranging from 5 to 50 micrometers.

2，Coolant Filtration Process

2.1 After the initial heating cycle to reach the specified temperature, the dirty coolant is pumped by Pump P1 through either Filter F1 or F2 with 5μm filtration precision. The bypass pressure relief valve (PSCV) at the filter outlet regulates downstream pipeline pressure, ensuring a constant temperature and pressure supply of filtered, clean lubricating coolant to machining equipment.

2.2 Post-machining dirty coolant flows by gravity through the manifold and returns to the sump tank.

2.3 Pump P2 transfers the dirty coolant from the sump tank to the dirty tank, where it undergoes static separation, oil skimming, and particle sedimentation. After reheating, the coolant re-enters Step 1 for continuous circulation.

2.4 The system features automatic temperature control, with a 15kW electric heater regulated by high-precision thermocouples.

2.5 Equipped with automatic liquid level and dosing controls: when the water level drops below the set threshold, the automatic dosing system activates to replenish the system with clean, well-mixed, properly proportioned lubricating coolant.

2.6 Filters F1 and F2 are each fitted with a differential pressure switch (PS). Excessive contamination in either filter triggers automatic switching, with a control panel alarm indicating the need for filter element replacement.

3， Component Specifications

A. Pumps and Control Valves

Two pumps are configured: one supplies unfiltered coolant to machines via the filter, while the other pumps dirty filtered coolant from the sump tank to the dirty tank

P1: flow rate 10 m³/h, head 60m, 3KW/380V/50HZ

P2: flow rate 10 m³/h, head 25m, 1.2KW/380V/50HZ

Manually operated isolation valves allow pump removal without emptying coolant reservoirs.

Electric internal thread ball valve DN40 (three-piece, 304 stainless steel, DC24V; with passive contact signal feedback)

B. Tank Assembly (Oil-Water Separator)

Constructed from 3mm welded stainless steel, the tank system offers an operating capacity of approximately 2,520 liters. With a flow rate of 5-10 m³/h, theoretical settling time for dirty coolant is 15-25 minutes. Coalescing media or inclined tubes enhance oil-water separation and particle sedimentation.

C. Pressure Control Valve

An adjustable constant-pressure control valve is installed at the coolant supply system outlet. It opens to stabilize pipeline pressure when exceeding the set value.

ZZYP-16CK, 170~420KPa, DN40 (1.5″), WCB carbon steel body, 304 stainless steel + R.PTFE

D. Flow Control Valve

100x Series Remote Control Float Valve regulates main valve opening based on sump tank liquid level, controlling P2 pump outlet flow to prevent excessive flow from lowering sump tank level and causing frequent pump cycling. This protects P2 pump and extends its service life.

E. Heater and Heating Exchanger (Optional)

15kW electric immersion heater with electronic control raises coolant to operating temperature pre-startup after extended shutdowns, eliminating tool thermal fluctuations.

If the factory has an air compressor, the heat exchanger is available as an optional configuration connected in series with the filter pump, providing energy-saving benefits and reducing factory operating costs.

F. Skimmer

An electric continuous rope-mop skimmer (2–22 ft/min speed range) in the unfiltered reservoir removes tramp oil, discharged to a collector drum.

G. Tank Level Sensor

Magnetic flap gauge provides clear level indication. Reed switch sensor detects set levels to monitor status and control component operation.

H. Pressure Differential Sensor

Differential pressure sensor detects filter housing inlet/outlet pressure difference. When clogging causes pressure exceeding set value (typically 1.5bar for high-flow elements), the system switches filters and alarms.

J. Filter and Housing

High-flow filter with 304 stainless steel housing(3D model drawing download). All units pass 10bar pressure testing to prevent leakage and ensure performance.

High-flow filter elements: 20-inch element delivers 10 m³/h security flow rate, equivalent to total flow of 10×30-inch melt-blown PP elements.

K. Controls & Instrumentation

Fully integrated electrical/pneumatic controls with instrumentation monitor filter/pump performance, primary/bypass inlet pressures, and coolant temperature. System logic is PLC-controlled.

L. Dosing and Make-Up System

Coolant dosing system uses Dastron proportioning pump to meter/mix neat oil and water, delivering fresh emulsion. Premix is auto-added to dirty tank via float level control in unfiltered reservoir to replenish losses.

How to replace the filters & media?

please refer to Filter Changeover & Media Change Out