Genius Filters & Systems Private Limited

genius ceramic filters are used for protection of gas turbines and reduction of emissions from environmentally- conscious coal fired, electric power stations, in gasification of fossil fuels and biomasses, for the recovery of valuable substances and for separation of very fine pyro-phoric dusts from process gases, for incernation of low level radio active wastes, for compressed air line, for water filtration and for vent plug of lead acid battery.

genius ceramic filter elements are produced using the latest ceramic techniques to provide a hollow porous ceramic which is fired at a temperature in excess of 1000°c. The chemically inert ceramic filter can be stored for eternity without losing its effectiveness. Generally, the ceramic filters have a collection efficiency not less than 90 to 99% down to particle size of 25 to 5 microns.

The Modern air using machines and systems such as Gas Turbines are more compact and highly efficient in performance and hence demands very best inputs of Clean Air. GENIUS Gas turbine GT AIR INTAKE FILTER ELEMENTS are most suited for all latest high performance gas turbines which are sometimes subjected to extreme dusty, stormy and humid conditions. GENIUS cartridges are manufactured from Impregnated cellulose or synthetic blend filter media that are pleated to create mechanical pleat separators for maintaining equal space between two pleats. The pleated media stack is supported by expanded metal outer retainer and zinc plated perforated inner retainer to bring stability in filter paper stack. Further, special adhesive is applied on two end caps and outer surface of the cartridge to establish rigidity and stabilization in completed filter cartridge.

Genius manufactures cartridges with all sizes and shape for replacement market and also offers economical, high-quality spare cartridges equivalent to Donaldson, Pneumafil, AAF, Delberg, Farr etc. Following the International standards like ASHRAE, BS, ARAMCO etc. the filters are subjected to in-house testing procedures as per customer’s requirements. The life of GT filter cartridges can be extended by means of GENIUS PRE-FILTER WRAPS. Made of high loft media, they are designed to capture large particles, seeds, air borne fibres, sticky hydrocarbons before they reach the filter cartridges. Thus, they extend primary filter service life and add an extra stage of filtration on gas turbine air inlet static filter systems. The GENIUS pre-filter wraps are inexpensive, easy to change, can be installed and removed without shutting down the gas turbine.

the genius automatic viscous air filters are specially designed and developed for use in general ventilation, air conditioning plants and other industrial plants. They handle high volume of air flow and are suitable as pre-filter to fine filters and absolute (hepa) filters.

these filters are suitable where the dust concentration in the surrounding air is comparatively heavier such as cement industry, steel plants, coal and lignite mines, foundries and other similar industries. This filter utilizes a rotating endless metal screen as the filtering media whereby dust laden air passes through and leaves the dust particles on moving screens due to adhesion action, which is later removed by oil reservoir at the bottom of filter periodically. The dust so collected in the tank is discharged outside manually or automatically depending on the size of the filter.

Genius Panel Air Filters are systematically designed for use in HVAC systems, Air Handling units and as a pre filter to higher efficiency filters. GENIUS Panel Filter range includes.

HIGH EFFICIENCY AND HEAVY DUTY FILTER (DURACELL)
POCKET FILTERS
MINI PLEAT FILTERS
FINE FILTERS
PRE-FILTERS
MICROVEE FILTERS
PAINT BOOTH FILTERS etc.

Panel Filters frames are manufactured from MS / GI / Aluminium and Stainless Steel if required. M.S. Frames are spray painted with synthetic enamel paints. Filter media like pressed felt filter fabric / HDPE/ wire mesh etc. specially crimped and pleated to suit individual application basis are selected. Crimping the filter media into deep folds increases relative filtration area resulting in low differential pressure, dust holding capacity, high flow rate. The efficiency of these filters varies from 90% to 99.97% depending on the application and the media used. These filter units can be used under conditions of humidity upto and including 100% RELATIVE HUMIDITY. These filters can be tested as per BS-2831, BS-6540, ASHRAE 52-76, IS-7613 etc.

GENIUS HEPA Filter is the most efficient filter on the market and used in clean rooms all over the world. These Filters are designed for providing extremely high levels of ultra-clean air to the healthcare, pharmaceutical, food processing, nuclear, biological, electronics industries, Control rooms, Nuclear plants, Aero space industries etc. With the heightened awareness of dangerous airborne and negative biological, chemical, and nuclear contaminants, GFSPL has combined the proven HEPA technology and knowledge of positive pressure ventilation to develop specific products designed to protect occupants of commercial and public buildings from the risk of airborne contaminants including Anthrax spores until the airborne threat is eliminated.

GENIUS Filters are manufactured from the most suitable high quality Imported Glass Fibre filter media, pleated back and forth over corrugated Aluminium separators, housed in Anodized Aluminium or SS-304 casings. They are sealed to casing with specially developed rubber based adhesives to prevent fungal growth. Neoprene rubber gaskets are provided to facilitate leak proof installation. These filters are available without flange, one side flange and both side flange. All the filters are individually scan tested to ensure they meet rated efficiencies and resistance.

GENIUS Lube Oil Filters are designed to operate continuously and efficiently , reduces maintenance and increases system life. They remove moisture and particulate contamination from Lube Oil thus extending oil life.

Extending lube oil drains by the use of Lube Oil By-Pass filters shall streamline the lube oil maintenance operations, drastically reducing downtime, and show dramatic savings on new oil purchases and disposal cost of waste oil.

genius offers a wide range of water filtration products and services that meet the environmental and economic requirements of every sector. Genius has vast experience to treat water and wastewater using advanced technologies from conventional demineralizers for the power and petroleum sectors, to complex wastewater recycling treatment to producing pure water for boiler and process applications.

the cost of water is a key factor in manufacturing performance, and genius water systems helps optimise the bottom line through its range of recycling solutions offering the industrial and municipal consumers the lowest life cycle cost of treating water. Genius ensures that all customers have the most effective solutions that can remove bod and cod, suspended solids , ammonia , heavy metals , fats/oils/greases , colour, phosphates and nitrates.

genius range includes reverse osmosis plants for brackish water / sea water, filtration for surface waters and wastewater, fully automatic demineralizers for the power and chemical process industry, boilers / process condensate treatment, wastewater / sewage water recycling treatment for reuse as boiler feed, cooling tower make up, or as process water (zero liquid discharge), seawater desalination plants, nanofiltration and cdi™ (continuous electronic deionisation), which reduces the need for water treatment chemicals.

genius shall be able to offer the whole range of dust collecting, gas cleaning and energy recovery techniques to ensure the most cost efficient and technically optimum solution to our customer’s pollution problems. In order to meet stringent environmental regulations for a variety of particulate control applications, genius had developed pulse jet bag filters, pressure bag filters, suction-type bag filters, gravity separators, wet and dry type electrostatic precipitators, venturi washers, disintegrators etc.

genius fabric filter bags are designed to provide extended bag life, maximum filtration efficiency, dustcake release, durability and to minimize operating and maintenance costs while providing superior particulate control performance. Pulse-jet and plenum pulse baghouses collect dust on the outside of the filter. Dust laden gas floods the baghouse, and clean air exits through the inside of the bag while the dust particles collect on the outside filter surface. A support cage prevents bag collapse during filtration and aids in the re-distribution and cleaning of the dustcake. A wide variety of filter bags can be manufactured to meet specific application needs like snapband cuff, flange top, ring top, sleeve top, hem top , raw edge , disc bottom, tuffskirt, wearstrip etc.

for the majority of applications, non-woven polyacrylnitrile cloth is used, giving high filtration efficiency with low pressure drop. For dust with acid or alkaline properties, polypropylene and other synthetic fibres are available. Nomex, teflon & fibre glass media are used for high temperature applications. Different kinds of treatments are available to reduce the adhesion forces of dust, to improve the cleanability of the filter media, to improve water repellence and to improve the filtration efficiency.

in most of the fine chemicals processes, the genius filter leaves are fitted into vertical vessels whilst horizontal vessels are used in the heavier process industries such as the preparation of sulfur in phosphoric acid plants. The leaves inside horizontal tanks may be positioned either along the tank axis or perpendicular to the axis.

genius filter leafs has a centrally located neck at its bottom which is inserted into a manifold that collects the filtrate. The leaf is constructed with ribs on both sides to allow free flow of filtrate towards the neck and is covered with coarse mesh screens that support the finer woven metal screens or filter cloth that retain the cake. Replacement filter leaves are available for all original equipment filter designs; including bird, bowser, buffalo, delaval, dupps, eimco, enzinger, funda, goslin, hercules, idrex, industrial, keene, kelley, niagara, north-american, passavant, pronto, schenk, seitz, shriver sparkler etc.

genius is pleased to be able to manufacture replacement leaf filter for any of your specific filter design. The largest leaf filters in horizontal vessels have a filtration area of 300 m2 and vertical vessels 100 m2 both designed for an operating pressure of 6 bar.

Increasingly sophisticated Industrial processes and more demanding standards call for high levels of purity in fluids and gases that are ingredients in the process. Extreme care and caution needs to be exercised on the filter elements, filter housings, 'O' rings and gaskets with respect to materials of construction, pressure drops, compatibility to fluid in service etc.

GENIUS with its expertise to offer solutions and systems for process filtration, had designed process filters to help you reach the required levels of purity in your process demands.

GENIUS range of process filter elements include Sintered SS Mesh, pleated Sintered SS mesh, Sintered stainless steel, pleated polypropylene, Pleated Teflon membrane, Borosilicate fibre etc.

GENIUS Filters offers a complete line of original equipment elements. All elements meet or exceed the original equipment manufacturers’ specifications and are totally interchangeable with other filter manufacturers as well. GENIUS Filter Elements / Cartridges are suitable for depth filtration of a wide variety of industrial fluids, Liquids and gases including compressed air, lube oils, fuel oils, air intake/exhaust, high purity gas, oil mist elimination, vacuum inlet filtration etc in transport industry (Automobile), Heavy Industry, Process Industry, Power Plants, Fertilizer and Chemical Units, Natural Gas, Refineries, Petro Chemicals etc.

Filter elements / cartridges are made of variety of high efficiency filter media like Stainless Steel Mesh (SS-304,SS-316), Sintered Stainless Steel, Sintered Bronze, Ceramic, Glass Wool, Synthetic Fibre, Monel Metal, Brass, Bronze, Polypropylene, Paper etc. in honey comb, pleated and Sintered Construction as per the application requirements. The unique construction ensures large filtration area to allow flow through media at minimum resistance. Particles are trapped throughout the entire cross-section of the filter creating superior dirt holding capacity. These cartridges are tested as per IS-11509, IS-3351 and SAE J 806.

genius coalescing cartridges are employed as the first stage in filter/ separator vessels for hydrocarhon fluids. They perform two functions: 1) coalesce (combine) highly dispersed, emulsified water particles into large water droplets and 2) filter out particulate contaminants. Coalescing cartridges are primarily used in filtration of aviation jet fuel and also with other types of fuels, process streams in refineries and petrochemical plants and condensate streams, where natural gas is produced.

genius coalescing filters are constructed of three layers. The inner and outer layers made of rayon impregnated with phenolic resin act as built-in pre-filters, according to flow. These are also the drain and support layers. The middle layer - "binder free" borosilicate fiber/ microglass - is the coalescing portion of the filter. Pre-filtering removes dirt particles prior to coalescing thereby increasing filter life. Both liquids and gases are filtered throughout the entire depth of the filter and not just the outer layer. The convoluted design provides a much larger surface area than conventional elements which result in low pressure drop, high efficiency, high dust holding capacity and extended service life. Also, available in screw base design. Efficiencies range from 93% to 99. 99% at the 0. 3 micron range. The pre-filter can be constructed with microns from 1 to 75.

we will custom design for new applications or cross reference competitive filters for existing applications.

genius filter housings are available in vast range of quality materials as well as in mesh sizes as per national and international standards. Material of construction include carbon steel , stainless steel (ss-304, ss-316), cast iron, non-ferrous material ,i. E. Brass, gun metal, bronze depending up on each and every processing requirement. Housing can also be constructed as per asme, ansi b 16. 9, is, bs, din 2615 or similar codes.

genius strainers are manufactured with stainless steel mesh (ss-304,ss-316), sintered stainless steel, sintered bronze, ceramic, glass wool, synthetic fibre, monel metal, brass, bronze, polypropylene, paper etc. , as per the requirements and to suit the medium handled by these strainers. These strainers are manufactured up to one micron rating.

genius manufactures high quality filter elements that are dimensionally similar to other’s manufacturer’s elements and will fit interchangeability into their filter housings. The high beat ratios and leading dirt holding capacities of these elements extend service life and provide a greater price to maintenance cost ratio than elements from other manufacturers.

genius hydraulic filter elements will maintain the fluid cleanliness level required to give long, trouble free life of present day hydraulic systems. A variety of filter elements with various microns ratings are available. They include inline and tank top spin on, tank immersed, inline heavy duty, tank line mounted, fully immersed tank top, suction strainers, low, medium & high pressure filters, breathers etc. These filter elements are available in ratings from 3 to 50 microns as per iso-4572.

genius pipeline strainers main task is performed in continuous operation as straining protection against process-specific solid material impairment and against corrosion products. Standard t-strainers are filters in the vestment of pipeline parts. Strainers are bolted, screwed or welded into pipelines like valves. In fact, because of the similarity in materials of construction, pressure ratings, etc. , a strainer is installed in the same way as many valves. There are two fundamental types of pipeline strainers -- basket and y-type. Y-strainers are used with gases, and in cases where the necessity for cleaning is infrequent.

basket strainers are generally used with liquids, and where regular or frequent cleaning is needed. Basket strainers hold considerably more material than y-strainers, and they offer less pressure drop than y-strainers -- both factors of more importance in liquid flow than in gaseous flow, boiler manufacturing, food processing, compressor manufacturing. Standard baskets are available in any metallurgy with opening sizes as required. Wedge wire baskets are also available. Our in-house engineering facility is ready to serve you. Send your inquiry for any custom vessels. All code designs are available.

GENIUS Pulse Clean Intake Air Filter Systems are used for the supply of clean intake air for Gas Turbines, Compressors and other air using Machines. Designed to remove air borne contaminants such as dust, drysalt nuclei, fly-ash, un-burnt hydrocarbons etc they are manufactured in a wide variety of dimensions. Filter panels are assembled by the inserting the media pack into galvanized metal cell sides and sealing with a custom formulated fire retardant epoxy. Gaskets are added to the panel on air leaving face to provide the clean air mechanical sealing. Hence, they can operate at constant pressure drop, stabilizes even at the most severe of atmospheric dust load conditions thus eliminating the necessity of short-term filter changeout. The panel filter design permits higher air flow velocities than the circular cartridge concepts and provides a constant flow of filtered intake air to give high Filtration Efficiency upto 99.9% for fine dust and 99.6% for coarse dust and ensures excellent dust cake release with high air flow and low pressure drop.

Moreover, the air pressure used in the jet-pulse cleaning system for these filters can be minimized by 20% to 30% thus cutting energy costs while extending the durability of the filter elements. The main advantages shall be: (a) High Cleaning Efficiency, (b) Constant Pressure Drop, (c) Proven Pulse Cleaning Mechanism, (d) Completely Automatic Operation, (e) Unique filter panel, (f) Space saving Modular design, (e) Minimum Maintenance. The Pulse Clean filter elements are tested in house as per ARAMCO-32AMSS-008, ASHRAE, BS International Standards for rated Air Flow, Pressure Drop and Efficiency. Genius Filters & Systems (P) Ltd ensures that every filter is flawless with highest quality standard conforming to customer’s specification.