Advancing FGD Gypsum Dewatering with Synthetic Disc Filtration Technology
Across the coal-fired power sector, operators are increasingly investing in cleaner production, reduced water consumption, and higher-efficiency flue-gas-desulfurization (FGD) processes. As a critical downstream stage, gypsum dewatering directly affects environmental performance, wastewater minimization, plant housekeeping, and long-term system reliability.
Driven by these objectives, Wuxi Tongzhiren Machinery & Equipment Manufacturing Co., Ltd. continues to deploy its high-efficiency synthetic disc dewatering systems—also known as vacuum synthetic-disc filters — for coal-fired power plants across multiple new-build and retrofit projects throughout China.
Over recent months, several installations have progressed from manufacturing and shipment through to on-site erection, commissioning, and continuous operation. These projects now support power plants in North, Northeast, Central, and East China with stable gypsum-handling capacity and energy-efficient filtration performance.
New Builds and Retrofit Projects Delivered in Quick Succession
Recently commissioned projects include:
Inner Mongolia Huineng Changtan Power Plant
China Energy Guangdong Taishan Power Plant
Henan Nanyang Zhongyuan Chemical Power Plant
Heilongjiang Daqing Power Plant
Hubei Energy Jingzhou Jiangling Power Plant
Shandong Dongying Shengli Oilfield conveyor retrofit project
Among them, the Daqing and Dongying Shengli Oilfield projects have become strong regional reference cases. Since start-up, the synthetic disc dewatering systems have demonstrated stable throughput, controlled filter-cake moisture, and reliable vacuum operation—earning positive feedback from plant operators and maintenance teams.
Alongside new installations, Tongzhiren remains closely involved in long-term service programs and legacy-unit modernization. Multiple dual-vacuum-system retrofit projects are currently under support, including the Pingxiang Anyuan Power Plant in Jiangxi Province, where synthetic disc filtration equipment has operated steadily since 2018—providing long-term validation under demanding FGD gypsum conditions.
Why Synthetic Disc Dewatering Upgrades Matter
Conventional FGD gypsum systems based on vacuum belt filters typically require large footprints, high auxiliary power consumption, frequent maintenance, and intensive housekeeping. These factors can limit optimization efforts—particularly in retrofit projects where space is restricted, and operating environments are challenging.
Tongzhiren’s proprietary vacuum synthetic-disc filter systems were developed specifically to help coal-fired power plants pursue:
• Lower auxiliary energy demand • Reduced freshwater intake • Cleaner dewatering buildings • Higher system availability • Predictable long-term environmental performance • Carbon- and water-intensity reduction
Through integrated mechanical design and process optimization, the synthetic disc platform offers a practical, scalable upgrade path for both brownfield and greenfield power-plant projects.
Core Advantages of the High-Efficiency Synthetic Disc Dewatering System
Compared with traditional vacuum belt filters, Tongzhiren’s synthetic disc solutions deliver measurable environmental and operational benefits:
Substantially Lower Energy and Water Consumption
For equivalent gypsum throughput, electrical demand can be reduced by more than 75%, while water usage drops by approximately 80%. Continuous cloth washing is eliminated, with only short cleaning cycles required before shutdown—directly conserving freshwater resources and lowering operating costs.
Compact Footprint for Retrofit Projects
Occupying only about 30% of the space required by belt-filter systems, the synthetic disc configuration frees valuable floor area in existing plants and reduces civil-engineering scope for new installations.
Strong Adaptability to Variable Slurry Conditions
The micro-porous filtration layer formed by the synthetic disc surface and filter cake supports stable operation even when coal-washing effluent, oily wastewater, or FGD sludge enters the circuit—maintaining consistent dewatering performance under fluctuating feed conditions.
Improved Workplace Conditions and Vapor Control
Centralized dewatering zones and integrated steam-blocking structures suppress the release of hot vapor, improving visibility, safety, and maintenance conditions while supporting modern environmental management practices.
Higher Vacuum Efficiency and Lower Life-Cycle Cost
Individual-sector vacuum sealing enhances effective vacuum utilization and stabilizes cake moisture. With compact construction and advanced automation, overall maintenance expenditure is typically about 30% of that for belt-filter systems, supporting a lower total cost of ownership over the equipment life cycle.
Long-Term Commitment to Sustainable Power-Plant Operations
Founded in 2001, Tongzhiren has focused on solid–liquid separation technology for more than two decades. Since launching its proprietary synthetic disc platform in cooperation with engineering institutes in 2014, the company has expanded large-scale deployment across China.
Today, Tongzhiren equipment operates at more than 80 power plants, with over 160 installed units supporting major utility groups, including Huaneng, Huadian, China Energy, Datang, Zhejiang Energy, Guangdong Energy, and Shaanxi Energy.
Looking ahead, Tongzhiren continues to concentrate on:
• Energy-efficient FGD solutions • Water-saving gypsum dewatering • High-availability filtration systems • Carbon-intensity reduction • Long-term environmental performance
By advancing vacuum synthetic-disc filtration technology and reliable gypsum-handling systems, Tongzhiren remains committed to supporting cleaner, more efficient coal-fired power generation and delivering practical OEM solutions for the next generation of FGD upgrades.