Filtersafe Launches Interactive Savings Calculator to Help Desalination Plants Cut Costs by Switching from Cartridge Filters
Karmiel, Israel, June 6, 2025 —Filtersafe, a global leader in advanced filtration solutions, has launched a new online savings calculator that enables desalination plant operators to estimate the annual cost savings of replacing cartridge filters with Filtersafe’s automatic screen filtration solutions.
By entering a few key parameters—such as flow rate, cartridge usage, and maintenance costs—users receive a tailored savings projection in just minutes. The tool was designed for operational and engineering teams seeking to improve performance while lowering OPEX.
“Our goal is to make it as easy as possible for plant managers and engineers to evaluate the value of switching,” said Ben Gido, Head of R&D at Filtersafe. “This tool lets them do that in minutes, using their own data.”
The calculator is freely accessible and requires no login, making it fast and easy to explore real-world savings potential
The savings calculator is part of Filtersafe’s broader commitment to sustainability—one that began with the invention of the world’s first filter designed specifically for ballast water treatment to prevent the spread of invasive marine species. Today, that same dedication drives our mission to help seawater, industrial, and municipal facilities reduce operational costs, eliminate downtime, and minimize environmental impact through smarter filtration solutions.
Filtersafe is a global leader in automatic filtration technology, serving the marine, energy, municipal, and industrial sectors. With patented SmartWeave® screen technology and a commitment to innovation, Filtersafe helps customers protect critical systems, reduce costs, and operate more efficiently.
Media Contact: Samantha Paperin, Chief Marketing Officer samantha@filtersafe.net http://www.filtersafe.net
At Filtersafe, we’re not just pioneering technology—we’re navigating challenges, overcoming adversity, and reshaping the way desalination works. Our team takes immense pride in the world’s first large-scale desalination facility to operate without traditional cartridge filters, located in Israel’s Western Galilee. This milestone represents years of dedication, collaboration, and a vision for more sustainable water solutions.
As a team based in northern Israel, we’ve had our share of hurdles. Relocating our factory from the Tefen Industrial Zone to Karmiel this summer was no small feat. Following the events of October 7, many of us experienced evacuations and continued working under the constant backdrop of missile threats. Our Chief Screen Technologist, Ben Gido, exemplifies the heart of our team: balancing reserve duty (miluim) on his kibbutz with spearheading groundbreaking innovation at Filtersafe. His family, like others, was evacuated for safety, but his commitment never wavered.
Through these challenges, our factory has remained operational. Disruptions in Red Sea shipping and regional tensions have tested our limits, but they’ve also strengthened our resolve. We know the stakes—delivering sustainable water solutions isn’t just about technology; it’s about perseverance and purpose.
Reimagining RO Membrane Protection
Cartridge filters have long been the norm for reverse osmosis (RO) membrane protection, but their drawbacks are clear: high costs, waste production, and inefficiency. That’s why we developed an alternative—a self-cleaning screen filter that’s changing the game. Built from SMO254 stainless steel, our system protects RO membranes, conserves energy, and eliminates the need for disposable cartridges.
Our technology cleans itself every two hours, removing accumulated debris and maintaining peak performance without the labor-intensive maintenance or environmental waste associated with cartridge filters. Plants using our solution have seen up to 90% energy savings and significantly lower operating costs, transforming desalination economics.
Sustainability That Matters
The environmental impact of cartridge filters is massive—they generate enormous amounts of solid waste. Our solution offers a sustainable path forward, reducing carbon footprints and operational waste while helping facilities save millions.
For us, this isn’t just about numbers; it’s about making desalination a viable solution for water-scarce regions worldwide. We’ve successfully piloted our system at multiple Mediterranean facilities, and the Western Galilee installation marks a turning point—not just for Israel, but for the global desalination industry.
A Team Effort with Global Impact
We’re not just innovators; we’re collaborators. From engineers to logistics coordinators, every member of our team has played a role in bringing this vision to life. Our CEO, Etai Dagan, sums it up best:
“Filtersafe’s self-cleaning filtration technology is more than a technical achievement—it’s a testament to what’s possible when resilience and innovation come together. We’re proud to lead the way in making desalination more efficient, sustainable, and accessible.”
Filtersafe’s reach extends far beyond Israel. With offices in Australia, Singapore, Eastern Europe, and North and South America, we’re bringing tailored solutions to diverse sectors, including agriculture, aquaculture, and industry.
Join the Conversation at IDRA World Congress
We believe collaboration drives progress. From December 8-12, our team will be at the IDRA World Congress, ready to share our journey and explore how our filtration solutions can help your desalination project.
This isn’t just about Filtersafe; it’s about advancing the industry together. Let’s create a future where sustainable water solutions are the norm, not the exception.
Israel’s latest desalination facility is set to become the world’s first to operate without traditional cartridge filters, thanks to Filtersafe’s revolutionary self-cleaning water filtration technology.
Karmiel, Israel – For Immediate Release – Filtersafe, a leader in advanced automatic filtration solutions, proudly announces its role in equipping Israel’s latest desalination facility with cutting-edge technology that breaks industry norms. This groundbreaking 140 MMY desalination plant, under construction in Israel’s Western Galilee, is the first of its kind globally to eliminate the need for disposable cartridge filters, replacing them with Filtersafe’s fully automatic self-cleaning filters for RO (Reverse Osmosis) membrane protection.
This landmark shift to cartridge-free operation introduces a major advancement in desalination technology, offering substantial benefits in energy savings, reduced labor requirements, and environmental impact. Traditional cartridge filters, which generate significant waste and require frequent replacement, are replaced by Filtersafe’s FS1806 filters, which feature SMO254 stainless steel screens with a filtration degree of 20 microns. These robust, sustainable screens provide exceptional protection for RO membranes, handling up to 2,500 m³/hr per filter, totaling a capacity of 32,000 m³/hr for the plant.
“Introducing our self-cleaning filtration technology in Israel’s sixth desalination plant marks a monumental step for the industry,” said Etai Dagan, CEO of Filtersafe. “Our technology allows for uninterrupted, efficient RO protection without the waste and high costs associated with cartridges. This installation exemplifies a new, eco-friendly direction in desalination that maximizes operational efficiency and contributes to the fight against the global water crisis.”
The Environmental and Economic Impact
The shift away from cartridge filters addresses a significant environmental challenge within desalination: solid waste production. Cartridge filters, typically made of non-degradable materials, require constant replacement, contributing to both high operational costs and waste. Filtersafe’s self-cleaning system, in contrast, eliminates these consumables, slashing waste production and energy costs by up to 90% annually.
Technological Innovation for Sustainable Water Solutions
With Filtersafe’s system, the plant’s RO membranes are continuously protected by a self-cleaning stainless steel mesh that effectively filters out debris and particles. This automated process not only prevents pressure buildup but also reduces energy consumption by restoring the filter’s performance every two hours.
By leveraging Filtersafe’s advanced filtration solution, the plant ensures a stable, cost-effective source of potable water for the region, all while significantly lowering its environmental footprint. The implementation of this technology heralds a shift in the global desalination sector towards sustainable practices that align with environmental stewardship and resource efficiency.
About Filtersafe: Filtersafe is at the vanguard of automatic filtration solutions for industrial water treatment. Its pioneering technology significantly enhances the protection and efficiency of reverse osmosis membranes, reducing maintenance and boosting system effectiveness. Filtersafe tailors its solutions to meet diverse client needs across various sectors, including Agriculture, Heavy & Light Industry, and Ballast Water, besides Desalination.
Stay tuned for more updates on how Filtersafe is shaping the future of water treatment globally!
Filtersafe revolutionizes desalination pre-treatment with a self-cleaning filtration system, eliminating the need for disposable cartridge filters and achieving significant cost and environmental benefits.
Filtersafe, a leading innovator in water filtration technology, today announced the submission of a patent for its revolutionary desalination solution. This patent covers a system that utilizes automatically maintained screen filters, eliminating the need for disposable cartridge filters typically used in pre-treatment processes for reverse osmosis (RO) desalination plants.
The Problem: Costly and Inefficient Disposable Filters
Desalination is a critical process for turning seawater into freshwater for drinking, irrigation, and industrial purposes. However, traditional pre-treatment processes rely on disposable cartridge filters to remove particles before the water enters the RO membranes. These filters require has high energy demand due to head loss and require frequent replacement, leading to high operational costs and creating a significant environmental burden from discarded cartridges.
The Filtersafe Solution: Self-Cleaning and Sustainable
Filtersafe’s patent-pending desalination solution addresses these challenges with a self-cleaning filtration system. The system utilizes screen filters with a filtration down to 12 microns that automatically clean themselves using a fraction of the filtered water. This eliminates the need for disposable cartridges, resulting in:
Reduced operational costs: Significantly lower energy demands and filter maintenance expenses.
Environmental benefits: Minimized waste generation from discarded cartridges, and lower carbon footprint.
Improved efficiency: Continuous filtration without downtime for filter changes.
Extended filter life: Durable screen filters designed to last for years instead of months.
Proven Performance and Benefits
Independent testing has demonstrated the effectiveness of the Filtersafe desalination solution. The system has been shown to:
Maintain a consistently low differential pressure across the filter.
Achieve a high filtrate recovery ratio, minimizing water waste.
Effectively remove particles exceeding the size specified by the screen filter.
A Sustainable Future for Desalination
“We are thrilled to announce the filing of our latest patent, which represents a major milestone in our mission to revolutionize water filtration technology,” said Filtersafe CEO, Etai Dagan. “This innovative reverse osmosis screening device embodies our commitment to providing sustainable and efficient solutions for the desalination industry. By significantly enhancing the protection and performance of RO membranes, our new system not only reduces operational costs but also contributes to the longevity and reliability of water treatment facilities. We are confident that this breakthrough will set a new standard in the industry and reinforce Filtersafe’s position as a leader in advanced filtration solutions.”
About Filtersafe
Filtersafe is a leading developer of advanced filtration technologies for various applications, including desalination, industrial processes, and municipal water treatment. The company is dedicated to providing innovative solutions that address the growing global demand for clean water while minimizing environmental impact.
Desalination is an invaluable solution for the global water crisis, particularly in arid regions. As the industry is already matured, there are few opportunities for new breakthrough technologies or cost-saving innovations. However, Filtersafe has found one such opportunity: replacing the cartridges that protect the RO membranes with automatic, self-cleaning filters. This article is a summary of the White Paper Filtersafe published on the research it conducted on the scientific viability and cost-saving claims discovered when a desalination plant uses automatic self-cleaning filters over the current industry standard of cartridge filters for RO membrane protection.
Protecting RO Membranes During Desalination
Reverse osmosis (RO) membranes are the heart of the desalination process, requiring protection from particulate matter and biofouling to maintain efficiency and longevity. Traditional methods involve multiple stages of filtration, including coarse filtration, ultrafiltration (UF), and multi-media filtration (MMF). Despite these stages, an additional filtration step is necessary to ensure the RO membranes are safeguarded from potential contaminants, as microscopic stray particles can puncture the membrane and jeopardize this critical stage in the desalination process.
A Critical Evaluation of Automatic Filtration Systems
Advanced pre-filtration systems utilizing automatic self-cleaning filters, such as those offered by Filtersafe, provide a compelling alternative to conventional cartridge filters. An automatic self-cleaning screen filter offers reliable and efficient filtration – down to 20 microns which offers comparable results to cartridges for RO membrane protection – with minimal energy consumption and maintenance costs, translating to significantly lower OPEX for desalination plants.
Comparative Analysis of Desalination Plant Filters
Traditional cartridge filters, often used for the final stage of pre-treatment in desalination plants, present several drawbacks. High energy consumption, frequent replacement needs, and substantial waste generation contribute to increased operating costs and environmental concerns. Filtersafe’s automatic filters address these issues by incorporating a self-cleaning mechanism that minimizes the need for manual intervention, dramatically reducing the labor cost associated with this phase of the desalination process, and ensuring consistent filtration performance, ultimately lowering OPEX.
The Downsides of Cartridge Filters in Desalination
Cartridges need to be replaced frequently, as often as every 1-3 months, to ensure their efficient operation. As cartridges filter, they begin to clog, requiring higher energy expenditure to force the same amount of water through the increasingly less porous cartridge. Filtersafe’s automatic filters offer a significant reduction in energy consumption compared to traditional cartridge filters. By maintaining a low differential pressure (dP), these filters ensure minimal and consistently low energy use while effectively protecting RO membranes.
Alternatively, cartridges need to be changed frequently to prevent biofilm accumulation, which if it dislodges and makes its way downstream, can cause biofouling of the membranes and a costly replacement.
The Advantages of Horizontal Filters in Desalination Plants
Filtersafe’s horizontal filters are specifically designed for high flow rates while maintaining a compact footprint. This design makes them ideal for desalination plants, where space and efficiency are critical considerations. Their capacity to process large volumes of water (up to 5,000 m3/hr per unit depending on the desired degree of filtration) significantly enhances the plant’s overall operational capacity.
Optimizing Industrial Seawater Desalination RO Systems
Opportunities for new OPEX savings in desalination plants are few and far between. This new horizon for OPEX savings (via reduced energy costs, lower manpower, and removing the need to purchase and dispose of cartridge filters) offers desalination plants a critical new way to reduce operational expenditures, making the plants a more worthwhile investment for municipalities looking to secure their water supply.
Filtersafe’s automatic filters also provide continuous, clean filtration with minimal need for manual intervention. This reduces labor costs and ensures uninterrupted plant operation, promoting both economic and operational efficiency.
Beyond Cost Savings: Environmental Considerations
The shift towards automatic self-cleaning filters represents a significant step forward in desalination technology, not just with regard to cost savings. These filters contribute to a more sustainable desalination process by eliminating the need for disposable cartridges. The OPEX and environmental savings are twofold – both removing the need to purchase cartridges, as well as not needing to deal with their frequent disposal, reducing waste generation and the carbon footprint of the plant.
Conclusion
Filtersafe’s automatic self-cleaning filters offer a compelling alternative to traditional cartridge filters in desalination plants. These advanced filtration systems significantly reduce energy consumption, labor costs, and waste generation, contributing to the overall efficiency and sustainability of desalination operations. As the demand for freshwater continues to grow, embracing such innovative technologies will be crucial for meeting future water needs in an environmentally responsible manner.
References
For further insights into the operational and economic benefits of automatic filters in desalination plants, consider reviewing Filtersafe’s white paper and case studies on the subject. These resources provide comprehensive data and real-world examples that highlight the transformative potential of these advanced filtration systems.
With 15 years of successfully filtering saltwater for marine applications, Filtersafe’s CEO and Founder saw the next logical application for his filtration solutions: Desalination.
After years of extensive tests, scholarly reviews, and pilot projects, Filtersafe proudly launched its activity in the Desalination sector in 2019. Below you can see the numerous case studies and project spotlights of Filtersafe filters in Desalination installations around the world.
Filtersafe offers solutions for the two important filtration steps in the Desalination process: UF/MMF (Ultrafiltration/Multi-Media Filtration) Pretreatment and Reverse Osmosis (RO) Membrane Protection
Filtersafe’s solution for RO protection is especially noteworthy, as until now there hasn’t been a real alternative to cartridge filters for this critical step in the filtration process. Filtersafe’s solution delivers exceptional filtration quality, at least as good as what 5 micron filtration cartridges provide, while minimizing energy use, labor hours, and consumables. You can read more about the OPEX cost savings, some as high as 90%, Filtersafe provides to RO Desalination plants in their white paper here.
Desalination projects, from small installations meant to filter water for an off the grid farm’s use in Australia, to massive plants producing enough water for up to 1,000,000 people a day in the middle of the arid Middle East, all choose Filtersafe over the alternative options for a few common reasons:
Very low reject water
High energy savings
Lower CAPEX (for UF/MMF pretreatment)
Lower OPEX (for RO protection)
Explore a diverse range of case studies below, showcasing successful installations in a variety of desalination filtration applications. These case studies demonstrate the transformative results Filtersafe filters have brought to desalination plants worldwide, highlighting increased plant uptime, reduced operational costs, and reliable operation. The variety of projects below will provide valuable insights and practical examples of how Filtersafe filters have become an invaluable asset for desalination plants across the globe.
In addition to the case studies below, you can see the dollar value that Filtersafe’s alternative to cartridge filters for RO membrane protection brings desalination plants in our white paper: Automatic FIlters: Desalination’s Alternative for OPEX Savings.
This easy-to-read report summarizes years of research, tests, and trials, which have allowed us to come forward with the promise of reduced OPEX costs when switching from cartridge filters to our self-cleaning filters.
Filtration of seawater is a necessity across a diverse range of industries – such as intake for a desalination plant, ballast filtration for an oil tanker, or to maintain pressure and the production rate. When running a complex operation there are plenty of unexpected expenses to deal with on a regular basis, and the last thing anyone wants is a preventable failure of their filtration equipment. This is especially pertinent when dealing with seawater because it is filled with corrosive elements that can lead to material failure like corrosion or strength degradation. Therefore it’s important to have a quality, durable filtration system.
As part of the search for the best system, an often underappreciated but critical component to its success is dependent on which alloy the screen filter, the heart of the system, is made of. The filter screen is the physical barrier that prevents particles (organic and inorganic alike) that are larger that its pore size from passing through with the water. Corrosion to the screen can damage its ability to be cleaned, clog its open area and inhibit water flow, or degrade the screen’s structural integrity, letting particles larger than its pore size to get through and compromise the integrity of the system. Various seawater filtration industries struggle with the same decision as to which is the best.
Seawater filters have unique and specific requirements: they need to be non-corrosive, as well as effective at removing debris of various sizes, which can harm down-stream processes. This is extra important in industries that rely on very fine filtration (100-5 microns), such as in desalination and ballast water filtration. In these cases, the screens must also be highly effective at removing phytoplankton and zooplankton from the water. Any seawater processing application requires a durable pre-filtration protection system so that time and money isn’t wasted over the years to repair poorly protected systems. With this in mind, let us look at the most common alloys used in seawater filtration and determine which alloy best suits your system.
316L
316L stainless steel, also known as “marine grade stainless steel,” is the second-most common stainless steel used in manufacturing today (after 304 stainless steel). This alloy is made up of iron, chromium (about 16%), nickel (10%) and molybdenum (2%), as well as trace amounts of quantities of silicon, phosphorus, and sulfur. Although it is a popular choice, the latest advice from the International Stainless Steel Forum is that AISI 316 and its derivatives “are no longer recommended for permanent contact with seawater.” We’ll see some of the reasons behind this decision in the Cons section.
Pros
316L stainless steel is a popular choice for seawater filtration. This is in part due to the alloy’s widespread use throughout many industries, making it widely available, as well as the benefits described below.
Some Corrosion-Resistance
Like all of the alloys discussed here, 316L stainless steel contains chromium. This element is an important part of the chemical makeup; it creates a thin film over the alloy when exposed to oxygen, which helps prevent the steel from becoming corroded over time.
The chromium in the alloy does provide a degree of protection that prolongs the steel’s – and by extension, the filtration system’s – lifespan. However, it is important to note that 316L does not provide complete protection from corrosion. While the alloy can offer reasonable protection in the short term, its particularly susceptible to pitting corrosion caused by inconsistent salinity levels in the seawater.
Tolerant to Higher Temperatures
Temperature fluctuations are most acutely felt in the shipping industry, as seawater can vary wildly in temperature between locations, seasons or even times of the day. 316L can tolerate water temperatures up to Celsius (68 degrees Fahrenheit), which means it is able to successfully stand up to most seawater.
Low Cost
One of the biggest benefits of 316L stainless steel is its relatively low cost and wide availability. Manufacturers can purchase 316L scrap relatively inexpensively, which makes it a highly accessible material for filtration system engineering.
Cons
Despite 316L’s popularity, there are some industry experts who believe that this stainless-steel alloy is inappropriate for use specifically in ballast water treatment systems. These professionals cite issues with the welding process as a major drawback – and the consequences of these issues certainly warrant a second look in other seawater applications as well.
High Ferrite Content
One of the biggest drawbacks in using 316L stainless steel for seawater filtration can occur during the welding process. 316L must be welded under very strict conditions, or else it might develop a high ferrite content in the weld seam. Ferrite can diminish an alloy’s ability to resist corrosion. Even a small amount (around 2%) of ferrite content in a weld seam can result in a less effective finished product.
Since 316L stainless steel is prone to developing excess ferrite during production, it can make some filtration experts leery of using this alloy in their systems. In fact, some argue that the potential for high ferrite content in 316L stainless steel can lead to greater incidence of pitting corrosion or crevice corrosion. This kind of damage can require significant repair or even a completely new filtration system – effectively counteracting the reduced costs of using the 316L alloy.
Duplex 2205
Duplex 2205 is a stainless steel characterized by its strength. With a makeup of 22% chromium, 3% molybdenum, and about 5% nickel, it is about on par with 904L in terms of corrosion resistance. However, duplex 2205 is (as the name suggests) a duplex stainless steel; this means that it contains both austenite and ferrite phases in its metallurgical structure, giving the alloy a greater overall durability.
Pros
Duplex 2205 is the most popular of the duplex stainless steels, and it is often used in pipework systems for offshore oil and gas. This alloy’s strength and chemical composition, as well as its durability against seawater in offshore uses, makes it a logical choice on paper.
Good Corrosion Resistance
Duplex 2205 has a PREN average of 35.9 – just shy of 904L stainless steels average of 36.7. This indicates that this alloy would be able to fair just as well as 904L when dealing with pitting corrosion, crevice corrosion, or any other type of destructive wear and tear within the filtration system. Theoretically, duplex 2205 would be a reasonable alloy for a seawater filter.
Cons
While duplex 2205 has had plenty of success within the oil and gas industry when used as a solid structure such as piping, it’s not used often in complex manufacturing procedures such as a weaved screen mesh used in seawater filtration. This is likely due to two main issues: There are challenges when working with it and its lower temperature threshold for corrosion.
Hard to Work With
One of Duplex 2205’s assets, it’s strength, is actually a double-edged sword. Since the alloy is so strong, it makes it difficult to work with, and requires special heavy machinery that is not commonplace. In addition, it makes it very challenging to mold the steel into the very tiny and delicate structures, such as ballast water filters or desalination filters that require filtration down to 10 microns.
Corrodes Faster than 904L
While Duplex 2205 has better corrosion resistance than 316L, it still corrodes at a lower temperature than 904L (50C vs 55C for 904L).
904L
Another popular alloy used in seawater filtration is 904L stainless steel. This alloy contains many of the same elements as 316L steel, but it is comprised of higher levels of chromium (about 19%), nickel (23%), and molybdenum (4%).
904L stainless steel is most famously used in luxury watches (Rolex, for example, swears by this alloy), but it is also a popular metal for seawater filtration. This is because the high amounts of nickel in this alloy makes it particularly corrosion resistant, protecting your seawater filter from damage.
Pros
Choosing the right alloy is essential for a durable and effective seawater filtration system. When alloys have similar compositions, like 316L and 904L, the decision may seem insignificant; however, 904L stainless steel has some major benefits that can make a big difference for a seawater filter.
Highly Corrosion-Resistant
As we mentioned above, 904L is highly resistant to corrosion due to the high levels of nickel in its composition. This means that seawater filtration systems made with 904L tend to have a longer lifespan than their competitors.
In fact, 904L stainless steel has an average pitting resistance equivalent number (PREN) of 36.7 – more than 10 points higher than 316L’s PREN average (26.1). This is an important parameter to consider when designing seawater filters, as it will help determine how effective the filter’s corrosion resistance and durability will be over its life.
Widespread Availability
Another benefit 904L has to its credit is its availability in the market. This alloy is readily available from most suppliers, which means that engineers and manufacturers can procure the metal and produce filtration systems much more easily than they might with other metals.
Cons
While 904L stainless steel offers both practical and logistical benefits, it is not a perfect alloy. Some engineers or manufacturers may opt for another metal due to the one major flaw that accompanies using this metal: the cost to use it.
Higher Cost
The costs of most alloys vary based on the amount of chromium and molybdenum in the metal. As we’ve mentioned previously, 904L stainless steel has higher levels of both these elements compared to 316L – which means that it tends to be about 1.3 times more expensive.
This price difference might drive some budget-conscious manufacturers to a lower-quality alloy. However, it is important to mention that the greater strength and durability of 904L stainless steel means that filters made from this alloy are less likely to need repairs during their lifespan. The cost savings you will earn from this lack of repairs more than offsets the cost of the alloy itself.
254 SMO
Like the two alloys we’ve already mentioned, 254 SMO is an austenitic stainless steel. However, this alloy was originally developed for use in chloride-heavy environments – such as seawater cooling pipes, heat exchangers, pulp and paper plants and more. The metal contains a similar amount of chromium as 904L, but it has a greater amount of molybdenum (6% vs. 4% in 904L).
With this composition in mind (not to mention the alloy’s intended use), it is no surprise that 254 SMO is an alloy that generates lots of interest among seawater filtration engineers. There are unquestionable benefits that come with using this alloy – but there are also a few drawbacks that can complicate its use.
Pros
The greatest benefit of using 254 SMO for seawater filtration is its corrosion resistance. The chemical composition of this alloy makes it highly resistant to both microbiologically induced corrosion and chemical corrosion – making it incredibly durable against seawater even after prolonged exposure.
Excellent Corrosion Resistance
254 SMO has a PREN average of 43.8, which means it has the greatest protection against corrosion of all the alloys studied here. It also has a low carbon content (around .02%), which means that there is little risk of ferrite development during production. These two facts mean that 254 SMO is one of the best alloys for protecting your seawater filtration system from the corrosive effects of seawater.
Cons
The excellent protective qualities of 254 SMO might make it seem like the gold standard in seawater filtration materials. However, at least in their ballast water treatment systems, few developers use it – why? 254 SMO is often passed over due to two flaws in its practicality.
High Cost
As we mentioned earlier, alloy costs vary depending on the amount of chromium and molybdenum in the steel. 254 SMO contains higher levels of these elements than both 316L and 904L stainless steel – which means that it tends to cost much more than its competitor alloys.
254 SMO can cost as much as three times more than 316L, and many manufacturers are unwilling to spend more to produce their filtration systems. This cost is above the threshold deemed “acceptable” by most industry professionals (unlike 904L stainless steel, which has a slightly higher cost but offsets the cost of maintenance).
Limited Availability
One of the hinderances that limits 254 SMO from being suggested for more seawater filters is that this alloy is not produced regularly due to its higher costs.
Which Alloy is Best?
Due to the nature of seawater filtration and its association with heavy industry, engineers of all applications endeavor to build filtration systems standing up to the ravages of seawater — all without costing you too much money. At the same time, the cost of using a lower-quality alloy will corrode more easily and lead to expensive problems – specifically more frequent maintenance and reduced filtration capabilities as corrosion overtakes the screen. These outcomes will, in the long run, increase operating costs, as equipment owners will have to pay for more frequent servicing, and where applicable such as in regulated industries like ballast water management systems (BWMS), potential fines for non-compliance of malfunctioning systems.
The solution? Invest in a filtration system that’s made from a durable, yet cost-efficient material. And when it comes to choosing the best alloys for seawater filtration without consideration of cost – SMO 254 is definitely the favored alloy. When dealing with a high end application where even the smallest downtime can be very costly such as in the oil & gas or desalination sector, the initial investment in using a Filter with an SMO 254 screen pays off in the long run. However, when a cost-effective solution is required, there is one option that stands head and shoulders above the competition: 904L stainless steel.
904L stainless steel is the ideal marriage of strength, corrosion resistance, and accessibility – all at a reasonable cost to manufacturers. Seawater filters made from this alloy will stand up to corrosion and keep your filtration system running effectively for many years, saving you thousands in fees and maintenance costs.
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.
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.
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.
A Closer Look At Other Nozzles
NozzleX vs Dynamic Spring-Loaded Nozzles
While Filtersafe relies on its patented proximity nozzle to consistently clean the screen at any pressure, dynamic spring-loaded nozzles use brute force to ensure their nozzles clean sufficiently at low operating pressure. More force means that both the nozzle and screen wear out faster, in fact, some dynamic spring-loaded nozzles need to be replaced every few weeks!
Floating & Brush-Loaded Nozzles vs Patented Proximity Nozzle
Some nozzles ‘float’ along the screen, never coming into contact with the screen. This reduces nozzle wear but decreases cleaning efficiency and in fact allows dirty backflow to slip out of the nozzle back into the filter’s interior, since there isn’t enough pressure keeping the dirty water inside of the nozzle head and moving towards the flush valve. Brush-loaded nozzles are intended to provide more ‘elbow grease’ to the nozzle’s cleaning capacity. However, the bristles wear out incredibly quickly, leaving the filter owner with what is essentially the previously described undesirable floating nozzle. Even before the bristles break and deform, they can push particles into the screen.
The Patented Concept That Sets Us Apart
Our nozzle is one of the most highly engineered aspects to our filter. Let us explain how this simple yet unique design provides the most effective and durable nozzle available.
Efficient Design
Each nozzle contains just 4 individual pieces. The low number of moving parts reduces the opportunities for something to break. In addition, you will not find a spring anywhere inside our nozzles! While other nozzles use springs to force the nozzle head close to or onto the screen when there is low operating pressure, our patented nozzle design equalizes the pressure inside and outside of the nozzle head, allowing it to be on the screen without utilizing damaging force.
Optimal Screen Interface
Because the nozzle is always firmly on the screen with minimal force, it causes absolutely no damage to the screen. Firstly, the nozzle is always applied with minimal, gentle force on the screen at all pressure ratings, and always less than 350 g/cm2. This means that the nozzle does not push dirt and suspended solids into the screen. This is a not uncommon occurrence that not only reduces the filtration capability of the screen, but can also create holes and invalidate the promised micron rating.
AdditionalBenefits 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 due to a buildup of a ‘cake’ like layer of dirt. In that time, a system’s flow rate can drop 37%, but NozzleX maintains a consistent flow rate throughout its operations. With NozzleX, your system always fully recovers so 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.
Let NozzleX Clean 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.
Clean water is essential for all living things. Humans, animals, and plants all need clean water to live — which is why water filtration is a massive industry today. Whether you’re watering crops on a large farm, pumping ballast water at a foreign port, or simply getting a glass of water from your refrigerator, you are likely to be using water that’s gone through some form of filtration.
As the name suggests, filtration “filters out” harmful substances from our water, making it debris-free and usable in commercial systems. But how exactly does this process work? The answer depends on the type of filtration system you use.
Why Water Filtration Matters
Before we can discuss how filtration purifies our water, it is first important to understand why we filter water at all. According to the United States Geological Survey (USGS), water is a “universal solvent” — in other words, it can easily dissolve a great number of other substances.
While water solvency makes it an effective cleaning tool, it also makes it easy for contaminants to combine with the water itself. Debris, bacteria, and microorganisms can make themselves at home, and this can cause real harm to plants and animals who are exposed to contaminated water.
This membrane filtration spectrum chart shows the process of separation for various materials at increasingly smaller sizes.
Filters are necessary to protect your system from any debris or other contaminants in your water. If particles manage to get into a system, the equipment can suffer from buildup, clogging, and a host of other issues that can shorten the lifespan of the machines. In fact, these risks are so great that many organizations also implement a prefiltration stage. Systems that use ultrafiltration, for example, often use prefiltration to keep out larger particles and protect their primary filter from clogs or other damage.
For people working in industries like agriculture, water treatment, desalination, and much more, having clean water is vital to keeping your customers healthy and your business thriving. Therefore, these industries must rely on filtration to keep their water in safe and healthy conditions.
How Filtration Helps
Simply put, filtration removes the impurities from water, nearly eliminating the risk from any debris or particles that might have been present. This results in filtered water that is cleaner and purer than in its original state, making it safe for use in ballast tanks, industrial systems, and much more.
Filtered water can help prevent contamination of other things. For example, farmers use filtered water to prevent chemicals or bacteria from changing the pH levels in their soil. pH balance is a key component in growing various crops, and therefore farmers cannot have unexpected contaminants changing their soil composition.
Similarly, filtration is necessary for cargo ships that plan to dump ballast water at their next port. The ocean is a wide and varied ecosystem, and microorganisms from one area could drastically alter the ecosystem in another place. Filtering ballast water before dumping it at a port will prevent animals or bacteria from entering a new part of the ocean and drastically altering its biodiversity.
Ultimately, any industry that uses water to run their business can benefit from filtering their water before use. Investing in filtration will result in cleaner and safer water for everyone.
How Filtration Works
Water filtration has been a part of society since 500 B.C.E. when the Greek scientist Hippocrates developed a cloth filter for purifying water. Since that time, humans have developed and tested countless filtration methods for their water, from boiling it under the hot sun to using charcoal to chlorine to kill microorganisms.
But how does filtration work today? Some of the earliest filtration methods (like charcoal filters) are still used in some capacity. However, modern technology has opened the door to a wide range of different filtration methods. The most common filtration systems are:
Particle Filtration (two types are discussed below)
Membrane Filtration
Reverse Osmosis
Particle Filters
Screen Filters
One of the most common types of water filtration system is a screen-based filter. The vast majority of all commercial and industrial filtration systems first start with a screen to filter out as much suspended material as possible, before heading to treatment or use.
Screen filters use a mesh screen (usually made from polyester or stainless steel) to trap dirt, sediment, and other debris that might be in the water.
Screen filters were one of the earliest filtration tools developed by mankind, and they remain a highly effective method for purifying water even today. However, it is important to note that screen filters have one major drawback: they’re a flat, 2-D system. The standard screen filter doesn’t have any depth, and that means that the screen can become clogged very easily. Many get around this issue by regularly cleaning the filter – either by removing and cleaning it routinely or by using a self-cleaning system that removes debris automatically and keeps the screen fully functional throughout its life cycle.
There are different levels of screen filters that use varying sizes of mesh, which allows you to determine how many particles your filter captures. Additionally, some manufacturers, including Filtersafe, have created multi-layered screens, which capture a greater number of contaminants as the water moves through them. These tools make removing sediment, sand, and microorganisms a quick and painless process, thereby making it easier to have clean and pure water for your operation.
Candle Filters
Candle filters are another approach for removing fine particles.
Also known as backwashing tubular filters, candle filters are not automatic like many screen filters are, instead of using gravity to produce clean water. Named for its candle-like shape, this filtration system uses a filter cartridge (which is usually made from ceramic or a fine sieve) to filter particles out of the water as it runs through the filter. This system can be an effective way to eliminate sediment, bacteria, and other particles from your water, though most industrial users prefer automatic filtration systems.
Membrane filtration: Micro-, Ultra-, and Nanofiltration
When filtration needs to be done to a much finer degree than particle filters can manage (below 10 microns), membrane filters are the solution (though screen filters are the first step for filtering water, before they pass through membranes). This means that the system uses hydrostatic pressure to force water through a membrane; as the water passes through, any particles or contaminants in the water become trapped, resulting in pure filtered water.
There are three main types of membranous filtration: microfiltration, ultrafiltration, and nanofiltration. While these three types use the same process to filter water, they differ in the size of particles they can trap. The key difference is the size of the pores in each membrane:
Microfiltration membranes have a pore size of around 0.1 microns, which means it can catch particles, but not dissolved substances. Microfiltration (MF) membranes developed specifically to solve complex process challenges such as microbial removal, protein fractionation, and pretreatment to other membrane processes. Microfiltration membranes have the most open pore sizes of all polymeric membranes. With a pore size range of 0.1 to 10μm, microfiltration membranes are capable of separating large suspended solids such as colloids, particulates, fat, and bacteria, while allowing sugars, proteins, salts, and low molecular weight molecules pass through the membrane.
Ultrafiltration membranes have a pore size of around 0.01 micron, which means it can catch smaller particles and smaller contaminants such as viruses. However, ultrafiltration cannot trap dissolved substances.
Nanofiltration membranes have a pore size of 0.001 microns. As one of the smallest pore sizes available (only reverse osmosis membranes are smaller), this filtration type can trap virtually all organic matter, multi-valent salts, and other particles in the water. In addition, nanofiltration membranes are capable of rejecting multivalent salts and larger molecules, while selectively rejecting varying amounts of monovalent salts.
Reverse Osmosis (RO) Filters
The term “osmosis” refers to the phenomenon of a solvent (like water) passing through a semipermeable membrane into a solute or dissolvable substance. When this happens, the water will dissolve and “pick up” some of the solute molecules, resulting in a water-and-solute mixture that is equally concentrated on either side of the membrane.
Reverse osmosis, as the name suggests, reverses this phenomenon – removing particles from a water source through the use of a membrane. This type of filer is most commonly used for desalination in conjunction with a media filtration or ultrafiltration system as a prefilter.
In reverse osmosis, the semipermeable membrane (which is most commonly made of cellulose acetate) does not allow the water to dissolve the solute; instead, it acts as a barrier that keeps material such as minerals or microorganisms from passing through the filtration system. Through this method, you can get purified water that is debris free. The membranes are very delicate and need an additional layer of filtration to protect them from debris that can puncture, or biofilm that can contaminate the water. Typically, this filtration is done by cartridge filters, but using Filtersafe’s automatic self-cleaning filters instead is both more sustainable and brings significant cost savings to desalination plants.
Compared to traditional filtration technologies that rely on a screen or filter to remove particles, reverse osmosis (RO) is a pressure-driven separation process that employs a semipermeable membrane and the principles of crossflow filtration.
Reverse osmosis water treatment provides the finest level of filtration. The RO membrane acts as a barrier to all salts and inorganic molecules, as well as organic molecules with a molecular weight greater than approximately 100 Da (Daltons). It is therefore a highly effective process for removing contaminants such as:
Endotoxins/pyrogens.
Insecticides/pesticides.
Herbicides.
Antibiotics.
Nitrates.
Sugars.
Soluble salts.
Metal ions.
Get the Best Filtration System for Your Needs
There are a variety of water filtration systems available today, and they each serve a unique purpose. Whether you are purifying water for a water treatment plant, to nourish your crops, or for any other industrial purposes, it is critical to have the right tools at your disposal to do your work effectively – and that means finding the right filtration system for your needs.
And no matter which filtration technology you use for your system, you will need a prefiltration screen to protect and increase your system’s lifespan. A simple prefiltration system will prevent excess wear and tear on your machinery and save you in maintenance costs! Filtersafe has over 30 years of experience in advising and supplying the best system for your needs, helping you protect your systems and reduce costs and downtime. Contact us today to learn how our team can help your facility get cleaner, better water.
This article uses a case study to demonstrate why an automatic self-cleaning filter is at least as good, if not better, than the standard cartridge filters currently used in water filtration before desalination or other treatments of drinking water.
As part of the search for the best system, an often underappreciated but critical component to its success is dependent on which alloy the screen filter, the heart of the system, is made of. The filter screen is the physical barrier that prevents particles (organic and inorganic alike) that are larger that its pore size from passing through with the water. Corrosion to the screen can damage its ability to be cleaned, clog its open area and inhibit water flow, or degrade the screen’s structural integrity, letting particles larger than its pore size to get through and compromise the integrity of the system. Various seawater filtration industries struggle with the same decision as to which is the best.
