Woven wire and mesh cloth materials for filter and architectural applications

Heanjia is a professional supplier of high quality weaving solutions. We have the potential to weave all grades of stainless steel, and special alloys for use in refining and petrochemical plants, and standard materials for separation and screening applications. We produce a vast range of weave patterns including square mesh, rectangular and slotted opening. We can weave a wide range of openings with a vast range of wire diameter specifications.

For wire cloth and mesh products, Heanjia maintains a wide range of wire cloth products, in wide range of material grades, crimp styles and meshes. We supply the wire cloth in the various parts of the world for use in different applications such as:

Sifiting, sizing, filtration , separation, glare control, hand rails, safety guards, bug control, process screens, livestock, medical equipment, filters, fuel cells, mud screens, separator, waste processing, centrifuge screens, fuel cells, hydraulic systems, separator screens, filters, strainers, oil, fuel,air and water filter, liquid screening, catalyst support screens, and cathode screens.

Mesh Cloth Material

Wire cloth or mesh screens are produced from standard and super metals and alloys for use in specific applications. Commonly used materials are:

Stainless steel – SS 316

Copper

Aluminum

Nickel and nickel super alloys are Monel 400, Hastelloy B, Hastelloy C, Inconel 600, Incoloy 800 and Nichrome.

Wire space cloth – It has a special role in determining the sizing, screening and separating, usually defined by the opening size instead by mesh count. Wire mesh with opening 0.25 inch ad above is called as space cloth. Open area percent and weight are essential factors for various applications of wire mesh cloth. Square space cloth is made in woven form. Woven wire mesh clothes are popularly used for specific opening counts that make them suitable for use in different applications.

Square mesh wire cloth is offered in different mesh and weaving sizes. The mesh count is specified by the count of openings in a linear inch measured from the center of a wire to a point of other wire. Woven mesh is stable and rigid cloth as it offers good mechanical properties.

The high quality filter wire cloth comprises heavy warp wire that has higher strength and higher durability as compare to square weave mesh. Considering its highly precise geometrical structures that our production procedures, our filter cloth comprises uniform porosity that is far superior to fiberous or synthetic filter screens.

Macro filter wire cloth Inconel mesh features larger count of wires in shute direction as compare to warp direction of the mesh. It can be easily cleaned and can be woven in different materials into various weaving patterns.

The strength and versatility produced by the woven wire mesh make it a perfect choice for many designers and fabricators. This durable mesh can be sheared, formed, fabricated and finished to the required specifications.

Heanjia also produces handrail infill panels in appealing mesh patterns. It can be used in various architectural applications of domestic and commercial buildings. Contact us to get your mesh fabricated from durable and reliable materials that provide long term performance.

Effective methods to clean the filter screens for longer service

Filter screens are a granular media representing contact filtration. The suspended solids in the fluid stream are held in the media by impinging on individual media granules, adhering to the media surface and getting entrapped in the dead-end channels between media granules.

Surface filtration is a physical sieving process using a medium like woven screen element to show a physical barrier to particles extremely large to pass through its holes. Mesh screens for sieves, filters and basket strainers adhere to this filtration mechanism. This method shows an absolute barrier to ridged particles that are larger than the openings in the filtration screen. Common examples of screen filters are with housings and stainless steel weave-wire or perforated screen elements.

Filter cleaning method

The filters are cleaned by various methods. In few methods, the screens are removed, discarded and replaced with a new element and in other methods, the screens are reused. Commonly used methods are:

1. Manual cleaning: In this, manual cleaning of the filter is performed by removing the screen and cleaning it manually. Cleaning is performed by running water, high pressure jet, brush or other sources. The filter is then reassembled before the flow restarts. In other different types of filters, a device is used to mechanically clean the screen.
2. Direct flushing of nickel mesh is performed by opening the dirty side of mesh during the filtration process. The screen is directly flushed to remove the debris without reversing the flow direction. This method is used only in few conditions.
3. The back flushing method of cleaning can be conducted manually or automatically. It needs the filter screen to be taken out. Water is the flown through the screen in a reverse direction to eliminate the solids from the media and remove them from the equipment. This method is used to clean sand filters. This method involves a drawback. As soon as the cleaned open area of the screen reaches the same square level as inlet and outlet flanges, the speeds become equal throughout the filter system and further cleaning cannot occur. As standard filters have screen open areas equal to 5-10 times the cross-sectional area of the inlet and outlet flanges, the differential pressure throughout the screen counts zero after a short back-flush cycle however only a nominal part of the screen gets cleaned. This method needs frequent cleaning.
4. Forced back-flushing: Suction scanning process involves development of a suction force by reversing the flow through a small region of screen. The differential pressure between the positive working pressure of the system and atmospheric pressure develops hence pulls the debris layer, known as filter cake. This small region is then moved across the screen surface to significantly clean the whole screen. This cleaning method can be used manually or automatic. When the flush valve on the bottom of the filter is opened, it connects the inside of a hollow tube, known as suction scanner, positioned down the middle of the cylindrical screen element to atmospheric pressure.

Understanding The Applications Of Tungsten Mesh

Tungsten wire mesh results from non-alloy tungsten wire weaving. The finished tungsten wire mesh imbibes the characteristics of tungsten, such as low evaporation rate, refractory potential, and high tensile strength, etc. Due to excellent heat resistance and high electrical resistivity, tungsten wire mesh is the preferred material for radiation shielding, heating element of vacuum furnace. Apart from this, it also finds uses for its high density and corrosion resistance, which is often used as filter or sieve materials for acid and alkali environmental conditions. The following points feature a few uses and applications of this mesh.

Uses of Tungsten mesh

• Non-corrosion along with alkali resistance.
• Great hardness and has no broken wire.
• Smooth and clean surface.
• Very high melting point and good high temperature resistance
• Stable chemical properties

Reasons to use tungsten mesh

Tungsten Mesh is used in high-temperature filtration along with screening applications. Due to this high-strength material, it is also widely used across various industries. It is resistant to corrosion and oxidation attack in acidic and alkaline media and therefore suitable for elevated temperature filtration applications. The material also offers superior high-temperature mechanical characteristics and smallest coefficient of thermal expansion among all the other metals. With excellent thermal creeping resistance and maximum service temperature that goes up to 3400 degrees Celsius, the sturdiness of Tungsten is highly suitable for industrial use. Furthermore, Tungsten Mesh is highly durable and the surface of the mesh is flat, flawless, and clean. Therefore, it finds significant use as filter and screening material for mechanical, vacuum equipment, electrical, heating and other special applications.

Tungsten Mesh Applications:

Chemical industries, acid production, scientific research labs and universities, filter, vacuum apparatus, hydrogen production, fire hazard security and heat shielding

Tungsten mesh properties:

1. Tungsten mesh offers the highest furnace service temperature about 3000 degrees Celsius with excellent optical heat transfer performance for specific temperature uniformity.
2. Mild wire tear will not never affect the service life of the mesh in any case.
3. The mesh element has the ability to perform at minimum temperature when compared to the limit of service temperature.

 

1. Due to large surface area of tungsten mesh it decreases the watt density resulting in enhanced service life of the element.
2. Tungsten mesh is produced in the specific sizes, shapes and styles to fit any type of vacuum furnace
3. As the thermal stress is hard to avoid during the heating operations in the high temperature furnaces, the inherent flexibility of tungsten mesh and weave designs, is capable of handling the stress more significantly.
4. Tungsten metal mesh also sustains dimensional stability during frequent heat cycling. Due to the large radiating area of the mesh, its surface life is increased considerably by decreasing the surface watt loading on the heating elements.

Design of the mesh

Tungsten mesh is known to eliminate the thermal and mechanical stress and therefore provides significantly enhanced element life. During the production of this mesh, each wire coil whether weft or warp is woven together with second coil to produce regular mesh network over the entire length and width of the element thereby offering incomparable thermal service. Due to closely controlled diameters of the wires, accuracy in mesh production is assured throughout the element.

Sieving screens for heavy processing filtration applications

Heanjia is a popular manufacturer of screens for use in nets and filter components. Our prominent position is the result of our experience of 30 years in screen designing, manufacturing combined with commitment and knowledge of our employees. We develop and deliver screens for different industrial processes for example screening, sieving, classification, dehydration, separation and filtration.

We focus our energy and efforts on the constant development of our products that directly influence the technologies and development of businesses. With better classification, filtration and separation processes, we strive to make our products more effective.

Classification of Screens

Woven Mesh: This mesh group comprises screens of simple and diagonal weave. Woven mesh is characterized by extensive clearance and durability and they can be cleaned easily. Simple woven mesh offers the features of simplicity and high precision. Each strand wire is precisely woven for right mesh size and effective material segregation in comparison to other type of weave. Its applications range from filtration to screen printing.

Diagonal weave: The strand wires create  diagonal pattern to produce mesh with larger diameter of wire with the exact mesh size as compare to simple weave.

Applications of woven mesh include sieving large particle materials, gas, liquid and filtration of air. These mesh screens are made from carbon, stainless steel and high nickel base super alloys.

Wire mesh screens are used as filter elements and support cylinder with square perforations. They act as medium to large flow rates in inline filters, return line filters and suction line filters. The mesh elements are usually used as a cost-effective and reusable solution. On the basis of requirements, different types of mesh screens are used like twill line, dutch weave etc. Wire mesh filter elements are usually surface filters that means they are contaminated more quickly as compare to single use elements. For the reuse, it should be kept in mind that elements finer than 40 micro-m can be cleaned in the ultrasonic bath.

Cleaning of Mesh screens

Stainless steel mesh elements need cleaning after service. Although only a specific level of cleaning is possible. For the best results, the elements should be cleaned by using specific system. Although the cleaning effect is not feasible to predict, it is based on different conditions.

Filtration rating – Mesh with finer filtration rating, cannot be cleaned easily.

Service pressure: Higher the service pressure, the more firmly contamination particles are embedded in the filter material.

Particle type: If the contamination comprises of several fibers, the level of cleaning is more complicated as compare to the case when cube type particles are present.

Additionally, it should be kept in mind that during each type of cleaning processes, it is possible to recover about 80 to 90% of the initial filter area i.e. after four to five cleaning cycles, the result is not sensible economically.

Woven wire Monel mesh screens are suitable for use on regular basis in heavy duty applications. They can withstand hazardous conditions or other chemicals specified to meet your requirements. They can be used in hydrocarbon contamination and other chemical resistant applications.

Mesh Cathode- Excellent material for batteries

Copper mesh foil is commonly used as a substrate for coating anode materials in Li-Ion battery and supercapacitor research. The weight of Mesh Copper foil is 40% less than that of solid foil and can accept more electrode materials. Copper mesh is widely used as battery current collector, electrolyzers and fuel cells. The mesh can withstand more flexure as it is made from two separate wires. It is suitable for current collectors, gas diffusion electrodes, electrode substrates and flow field screens. It can be formed into discs or cut into mesh tapes. The mesh tapes are supplied in small width up to 20mm and mesh can be annealed and cleaned. Copper wire mesh can be customized and woven in different configurations and properties. Copper Wire Mesh is available in various types of weaves and wire diameters. The finish edge mesh is designed using special machines and this finish edge will increase the mesh stability and provide a safety edge for handling and protects a battery separator.

High purity uniform shaped Copper Mesh can be used as screen or gauze and standard metal mesh size has a range of 0.75mm to 1mm to 2mm diameter with strict tolerances and alpha values (conductive resistance) for uses such as gas detection and thermometry tolerances. Custom wire alloys and gauge sizes are fabricated and various high purification processes are used to produce the materials including solid state, crystallization and sublimation. Custom compositions are produced for commercial, research applications and new proprietary technologies. Various advanced materials and rare earth metals are cast into bar, rod or plate form, solution forms, organometallics and other machined shapes. Copper is produced as ingot, pellets, powder, granules, pieces, discs and in compound forms such as oxide. The processing methods directly impact performance when engineering battery materials to achieve targeted responses. Characteristics such as porosity and tortuosity of cathode microstructures that offers higher energy density and limit factors such as dendrite growth and SEI ultimately contributing to battery failure are influenced by optimizing the chemical and physical composition of starting materials. Various types of advanced cathode, anode and electrolyte materials in high and ultra high purities with strict controls for particle size and distribution, physical morphology and surface area are manufactured as per the specifications of the customers. Engineers and researchers with expertise in fields such as thin film synthesis and electrochemistry select materials for custom electrode compositions and electrolyte formulations in order to reduce the production costs. Materials are formed in various forms including micro, macro and nanoscale powders and dispersions. Materials are produced in a variety of compositions including ceramics, graphitic carbon, metals and mixed metal oxides. Materials are also produced in various chemical compounds for coatings, active materials, precursors and conductive additives. Materials are supplied for the fabrication of components at various stages of battery design including wires, connectors, copper & aluminum foils mesh electrode for current collectors, strips for cell housings, chargers, metal foils and semiconductor crystals for integrated circuits of ancillary electronics such as on-board power supply and battery management systems.

Mesh Electrode- Exchange Current Density increases with increase in temperature in alkaline medium

The assessment of NiZnS electrode is done for its use in oxygen evolution reaction in alkaline media. Coating of Mesh Electrode was performed using the ternary composition of NiZnS using four methods such as

• Pulse Electrodeposition
• Sonoassisted Pulse Electrodeposition
• Direct Current Electrodeposition
• Sonoassisted Direct Current Electrodeposition

As per the oxygen evolution studies carried out using these electrodes, higher current density for the electrode was prepared by Sonoassisted Pulse Electrodeposition compared to those prepared by other methods. Study of the effect of Plating current density, Temperature and Pulse duty cycle on the electrochemical parameters of the alloy coating was also done. Study of the surface morphologies of various coating was done using Scanning Electron Microscopy. Study of long term stability of the electrodes prepared was done in alkaline medium. Exchange Current Density (j o) increased with increase in temperature and was highest for Sonoassisted Pulse Electrodeposited Electrode.

Hydrogen as a fuel for power generation and transportation is increasingly being addressed to overcome issues associated with fossil fuels. Hydrogen can be produced by steam reformation of hydrocarbon fuel, electrolysis of water and thermolysis of water. There have been many efforts recently to generate hydrogen by photo-electrochemical methods and photochemical methods. In spite of various efforts, steam reformation has been the main process for bulk hydrogen production followed by electrolysis of water. Alkaline electrolysis using potassium hydroxide (KOH) electrolyte and acid electrolysis using ion-conducting membranes are the two common processes to produce hydrogen by electrolysis. Each of these two processes has their own advantages and disadvantages with respect to operation, cost, etc.

The alkaline electrolyser is characterized by the use of a strongly alkaline aqueous solution, as the hydroxide ions (OH−) are the charge carriers (25-30 wt% KOH to maximize the ionic conductivity). The reactions that take place in the electrolysis cells of these units are as follows:

Anode: 20H−→1/2 o2 + 2e− + H2O                                            (1)

Cathode: 2H2O + 2e−→H2 + 2 OH−                                           (2)

Cell reaction: H2O→H2 + ½ O2                                                   (3)

The Oxygen Evolution Reaction (OER) in equation (1) is known to have high activation over potential in alkaline solutions resulting in substantial energy losses. Materials with high catalytic activity and low overpotential are required for the OER. The oxides of Ru and Ir are considered as the best OER catalysts for use in acid and alkaline solution, but the high cost of these materials and their poor long-term performance in alkaline solution hinder their widespread commercial utilization. Nickel-based alloys are low cost and their wide availability together with low overpotential for the OER makes them the material of choice as anodes in alkaline water electrolysis.

As per previous studies, binary alloys such as Ni-Fe, Ni-Co, Ni-Bi and Ni-Zn show an increase in the catalytic activity in OER and have comparable kinetic parameters to that of the noble metals (Pt, Ru, Pd). This increase has been assigned to the synergetic features of the elements forming the alloy and to the electrode surface area increase. Moreover, studies have shown that addition of sulphur in the alloy helps in activation of gas evolution so that the resistance offered due to the adherence of the bubbles on the electrode decreases.

Heanjia supplies various mesh cathodes for use in diverse applications. Contact us for more details.