Filtersafe’s Smartweave Screen: Water Filtration at a Whole New Level

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Most eCommerce clicks not only put new clothes or appliances in your virtual shopping cart, they also are putting your packages on cargo ships for delivery. The continued dependence on online shopping has meant more work for  international shipping vessels, which are constantly moving from one corner of the globe to another – and they’re discharging ballast water in every port they visit.

This can be dangerous for our oceans, as zooplankton, phytoplankton, and other microorganisms that hitch a ride in ballast tanks can damage the native ecosystems if they are deposited into a new body of water. Therefore, it is essential that ships filter their ballast water before releasing it back into the sea.

As a company founded by engineers, Filtersafe has been dedicated to finding innovative solutions to filtering sea water. The current seawater screens often suffer two main problems: blockage, which can result in pressure depressions and a decreased flow rate, and an inability to filter out smaller microorganisms.

To address these issues, the Filtersafe engineers created the Smartweave screen. This unique technology is a weave-wire screen specifically designed to tackle the challenge of seawater filtration. By using a combination of weave wire filtration screens, protective screens, and a reinforcement layer — as well as the automated cleaning power of our Everclear system — this innovative, highly effective screen filters out sediment and microorganisms, protecting native marine life in every port. Its combined efficacy and durability make the Smartweave screen a filtering element ships can rely on for years.

 

How It’s Made

Filtersafe understands the unique challenges facing ballast water filtration (one of the most challenging seawater applications). Seawater contains microscopic particles that can cause harm when transferred to other ecosystems and encourage the creation of corrosion within the ships’ interior. Filtering out elements this small requires a complex and multi-layered system, so the Smartweave designers created exactly that.

The Smartweave screen is made up of three stainless steel weave-wire screens and a fourth reinforcement layer to enhance the screen’s integrity. This includes one filtration control layer, two protective layers on either side, and one reinforcement layer. We then take this combination of screens and sinter them together, creating one mega-screen that is durable enough to filter without additional support.

These screens are available in a variety of sizes, from 500 microns down to 10. This allows ship owners to choose a Smartweave screen that best suits their vessels’ unique needs. The Smartweave seawater screen is also made from 904L stainless steel: an stainless steel that offers high corrosion resistance, higher quality, and a longer-lasting screen than the standard 316L stainless steel and other options in the market today.

The innovation and careful design work behind Smartweave have made it one of the top weave-wire screens for seawater filtration today. This screen offers enhanced strength and top performance, so shippers can trust that their ballast water is safe to discharge and is compliant with the IMO G8 requirements.

 

How Does It Work?

All the innovation in the world doesn’t matter if a product doesn’t work. The engineers at Filtersafe know how important seawater filtration is, and so they’ve spent years testing and perfecting the Smartweave screen. As a result, Smartweave is one of the most effective filtration systems available today, keeping zooplankton, phytoplankton, and sediment out of ballast water across the world.

The term “zooplankton” refers to small microorganism and the immature stages of larger species. It is vital to filter these from ballast water, as they can be detrimental to the native ecosystem at a port of call. According to tests from Filtersafe and other research groups, the Smartweave screen removes 99.95% of zooplankton from ballast water – more than any other filter available today.

Shippers also need to filter phytoplankton from their ballast water before releasing it into the sea. Phytoplankton, or microscopic marine algae, are an important food source in the ocean’s ecosystems – but only if they’re in the right location. While phytoplankton can be very small (as small as 10 microns), Smartweave is an effective filter for them, too. that the Smartweave screen removes 100% of phytoplankton larger than the micron of your selected screen.

Finally, a filter must be able remove sediment and other suspended solids from any ballast water. Once again, Smartweave delivers here:  A series of tests we conducted on our filter show that even in extreme conditions when the TSS levels reached 2500 ppm, we were able to decrease the decrease suspended solids from 2500 ppm to 100 ppm – a removal rate of 98%.

 

Constantly Improving

Today, Filtersafe treats 25% of the world’s ballast water – and all because of unique, innovative, and effective products like the Smartweave screen. For some teams, the Smartweave screen’s impressive filtration rates would be enough to call the filter a success. But Filtersafe is dedicated to making the ballast water filter even better.

The team is constantly innovating and perfecting our ballast water treatment systems. We’ve outfitted our Smartweave screens with our Everclear cleaning sequence, which automatically returns your filter to its original operating parameters. This ensures peak performance and an optimum flow rate – and provides the user with peace of mind.

Each Smartweave screen is used in conjunction with Filtersafe’s patented nozzles – the Nozzlex system. This uses suction technology to clean the screen thoroughly and completely with each use(without damaging it). These features help maintain the Smartweave’s exceptional performance, so captains can focus on their cargo and getting to their next location and not just about meeting USCG or IMO water treatment standards.

*Efficacy is dependent on the size and distribution of the TSS.

Filtersafe’s NozzleX: An Innovation that will Save Your Filter Screen

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At Filtersafe, we understand that water filtration is essential to helping many industries run smoothly. However, we also understand that today’s filtration technologies can always be improved — which is why we strive to be a leader in the world of water filtration. Our engineers have decades of experience in the industry, and they’re dedicated to creating the top technologies for automatic filtration.

One such technology is the NozzleX suction scanner – an innovative tool that enables the cleaning of organic and inorganic material from your filter’s screen, without wearing down the nozzle or wearing out the screen. With a typical automatic screen filter, the nozzles sit on a bar called a raiser. The raiser moves the nozzle heads back and forth along the length of the screen, while also rotating the nozzles in a corkscrew motion. The nozzles scan the surface, and by using negative pressure, dislodge debris one square inch at a time. While this does help the screen filter water effectively in the short term, the force from the nozzle can damage the screen and shorten its lifespan.

NozzleX, by contrast, uses low head pressure (as low as 23psi) to clear off all the buildup on the screen without damaging it. First, the raisers move the nozzles in such a way that 100% of the screen is scanned and cleaned. Next, in contrast to other filters, NozzleX nozzles safely come into contact with the screen, utilizing gentle pressure to pull materials off of the screen without impacting the screen’s integrity. This results in improved performance and a longer lifespan for your ballast water filter or other filtration technologies.

 

How it Works

The NozzleX uses passive suction to remove organic matter like debris and sediment from the filter screen. Through an innovative combination of consistent force and passive pressure, whereby the nozzle both actively removes material from the filter while allowing the naturally occurring changes in pressure to carry it away, this nozzle makes cleaning your filtration system an easy and automatic process.

This patented system moves around the filter screen automatically, using as little as 1/32nd the force of typical cleaning nozzles to offer a thorough cleaning with minimal wear. Then, the nozzle disposes of reject water through the system’s flushing chamber, guaranteeing that buildup won’t remain on your screen.

NozzleX is part of Filtersafe’s Everclear cleaning system, which includes the Smartweave screen filter. Working together, these two technologies provide exceptional filtration power while minimizing space. This ensures that operators can use their filtration system as long as possible.

 

Benefits of NozzleX

In the world of water filtration, NozzleX is truly a revolution. This unique cleaning tool offers several significant benefits to an automated filtration system, which can make a real difference in the quality and longevity of a system. Here are just a few of the unique benefits you can get from using NozzleX:
  

    • Continual System Operation: Firstly, NozzleX runs as part of the automated filtration system. There’s no need to halt system operation and clean out your filtration screens; instead, NozzleX will clean your screens throughout the filtration process.
    • Minimal Surface Area: In addition to its consistent cleaning functionality, the NozzleX is exceptionally compact. The nozzle takes up a mere 1% of the screen area, which allows your filtration system to continue running even while it’s being cleaned, and without significantly hindering the flow rate. This will result in greater filtration capacity and greater overall efficiency for your system.
    • Improved Performance: Dirty or clogged filters can have a serious impact on a filtration system’s efficacy. In fact, Filtersafe testing has shown that some systems lose performance in as little as six hours. In that time, a system’s flow rate can drop from about 3,000 m3/hr to less than 1,900 — but NozzleX maintains a consistent flow rate throughout its operations. With NozzleX, you’ll be able to get the optimum performance from your filtration system all day long.
    • Zero Screen Wear: Finally, one of the greatest benefits NozzleX provides is the way it minimizes screen wear. Other nozzle-based cleaning systems use significant force to remove debris from their filters, which can lead to punctures and other damage that cuts the screen’s lifespan short. NozzleX, in contrast, equalizes system pressure to use far less force — around 1.6 Bar (23psi) of head pressure. This means your filter screens suffer next to zero wear, allowing them to operate much longer than other screens.

     

    Why It’s Important

    The importance of a properly functioning nozzle is simple – a water filtration system only works when it’s clean. Whether you are filtering ballast water before filling your tanks, protecting your oil and gas exploration equipment safe from organic oceanic materials, or prefiltering water for desalination, each filtration system should have the same thing in common  a reliable nozzle to clean your screen.

    So, why not let NozzleX do the job for you?

    NozzleX ensures that a filtration system stays clean throughout operations, thereby making sure that the system remains effective and efficient. As part of Filtersafe’s Everclear system, NozzleX will provide users with a completely clean filter screen — and that will help guarantee superior performance from your filtration system.

     

    To learn more about the NozzleX cleaning technology, contact Filtersafe today. Our team will be happy to answer questions and help you find the system that best suits your industry and your organization’s unique filtration needs.