High Performance, Robust Leaf Filter Elements Engineered for Peak Efficiency

Leaf Filter Elements: Core Component of Pressure Leaf Filter

Filter Leaf Elements are the most critical internal components of Pressure Leaf Filters, designed for efficient solid-liquid separation in continuous and batch filtration processes. RajFilters manufactures high performance Filter Leaf Elements that provide a large filtration area, uniform cake formation, and superior filtrate clarity while operating under pressure.

These elements are extensively used in industries where the removal of fine suspended solids from liquids is essential to achieve product purity, process efficiency, and operational reliability.

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Working Principle of Pressure Leaf Filter

Pressure Leaf Filters are used for solid–liquid separation and operate based on pre-coating and pressure filtration. A suitable filter aid (about 0.5–1%), such as bleaching earth, Supercel, Hyflo, or Super Flo, is mixed with the liquid to be filtered to form the pre-coat.

The unfiltered liquid is pumped into the filter vessel, where the filter aid gradually forms a uniform pre-coat on both sides of the filter leaves. During this initial stage, the filtrate appears cloudy. Once the pre-coat layer is established, pressure builds up, and suspended impurities are retained.

Clear liquid passes through both sides of the leaves, flows through internal tubular channels, and is discharged from the bottom. All leaves are connected to a common manifold. As impurities accumulate, a wet filter cake forms on both sides of the leaves, gradually choking them. When fully choked, the pressure rises to 3–4 kg/cm², and the filtrate flow nearly stops.

Cake Dewatering, Drying & Discharge Process

At this stage, the pump is stopped, and steam or compressed air is applied from the top without releasing pressure to recover retained liquid and further compress the cake. Any unfiltered liquid in the conical bottom is returned for reuse.

In a Pressure Leaf Filter, the cake can be dried using steam or hot air and then discharged from the bottom using mechanical or pneumatic leaf vibrators. Cake drying typically takes 30–45 minutes, and discharge takes 5-10 minutes. For wet cake discharge, water spray nozzles are provided.

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Construction and Design

Each filter leaf element is built around a sturdy stainless steel frame that holds the mesh layers under tension. The mesh stack typically includes one coarse drain layer and multiple finer filter layers. 

Weavings may include plain weave, Dutch weave, or reverse Dutch weave to achieve the desired filtration rating. Filter leaves can be fabricated as flat rectangular plates (for vertical filters) or round discs (for horizontal filters). Vertical leaves normally have a bottom outlet for gravity cake discharge, while horizontal leaves use a central hub outlet.

Filter leaf elements are supplied as single-mesh plates for basic filtration or as standard multi-layer (five-layer) assemblies for finer filtration and higher solids capacity. All leaves are custom-fabricated to match the specific dimensions and performance requirements of the filter vessel.

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