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March 11-13, 2001

Sullair Distributor Conference 2001

Compressed Air Filters


Objectives

 Why Use Filtration?


 Filtration Technology
 Sullair Product Range
 Applications
 Filter Sizing
Why Are Filters Needed ?
Answer

Filters are needed to remove contaminants that


are inherent within a compressed air system.

These contaminants are a result of the following


factors.
The Problem

In The Compressed Air System


By

Dirt + Water + Oil


Contamination
Contamination in Air

 Unburned hydrocarbons from


automotive & jet engines
 Industrial exhausts - Power
plants, refineries, general
industry
 Natural Pollution - Pollen,
bacteria etc
Atmospheric Contamination

Dust Particles 4 million per ft3

Water 50-80% R.H.

Industrial Pollution Acids, Hydrocarbons,

Natural Pollution Pollen, Bacteria, etc.

Compressor Oil n/a

Compressor Wear n/a


Particles
Atmospheric Dirt

80% < 2micron

4 Million Particles Compressor 3.2 Million Particles


Per Ft3 Intake Filter Per Ft3
Compressed Air

Compressed

8 x 1ft3 of Air
at 116 psia (8 bar a)

8 x 1ft3 of Air at 14.5 psi absolute (1 bar a)


Contamination After Compression
Dust Particles 3.2 million per ft3 26 million per ft3

Water 50-80% R.H. 100% Saturated

Industrial Pollution Acids, Hydrocarbons, 8 x Concentration

Natural Pollution Pollen, Bacteria, etc. 8 x Concentration

Compressor Oil n/a 2-200 ppm carryover

Dirt Particles n/a Wear & Corrosion


The Scale of the Problem

(Bacteria
(Bacteria 0.3 Micron)
0.3 micron) 0.01 0.1 1 10 100 microns
Defining a Micron

1 micron =

4 / 100,000 inch
1 / 1,000,000 metre
1 / 1,000 millimetre
Smallest Particle Which The Eye Can See

45 - 50 microns

i.e Coal Dust


Cement Dust
Effects of Dirty Compressed Air
 Undue wear & tear on
pneumatic equipment

 Increased maintenance &


spares costs

 Product spoilage

 Atmospheric pollution in the


work place
The Solution
The Solution
For which filtration can used to
remove
 Particles
 Oil & water aerosol
 Oil Vapour
Filtration Technology
Mechanisms of Filtration
Contaminated Air Clean Air
Filtration Technology
Mechanisms of Filtration
Contaminated Air Clean Air

Direct Interception (>1 micron)


Filtration Technology
Mechanisms of Filtration
Contaminated Air Clean Air

Direct Interception (>1 micron)


Inertial Impaction (1 - 0.3 micron)
Filtration Technology
Mechanisms of Filtration
Contaminated Air Clean Air

Direct Interception (>1 micron)


Inertial Impaction (1 - 0.3 micron)
Brownian Motion (0.3 - 0.01 micron)
Coalescing Filtration Technology

Flow in to out

Wet band
Activated Carbon
Oil vapour & odour adsorption
Maximum remaining Oil content <0.003ppm @ 70oF (21oC)
Typical Adsorption Element Life
Element Life (hours)

1000

100

50oF 75oF 100oF 125oF

20oC 30oC 40oC 50oC


Adsorption Temperature ( at Rated Flow )
High Performance
A range of 3 filtration grades to suit specific
application requirements

Grade Use Particle Oil Aerosol


(Micron) (ppm @700F)
MPF/PF General purpose pre- 1 0.5
filter
MPH/PH High efficiency 0.01 0.01
MPC/PC Oil Vapour removal --- 0.003
High Performance

Max operating pressure 232 psig


(290 psig manual drain)

Max.operating temperature 1500F

Max.recommended operating
temperature MPC/PC 860F
High Performance
Tailored solution for all
applications

Mini filters 1/4" to 3" ( 13 sizes )


Flow rates from 13 - 1315 scfm

New range of welded housings


Flow rates up to 3000 scfm
High Performance
Filter Element Design

Support media
For added strength &
Borosilicate microfibre with integral pre-filter
96% voids volume Stainless steel inner/outer
High dirt holding capacity with support sleeves
minimal pressure drop High dirt holding capacity
with minimal pressure drop

Anti re-entrainment
barrier
Chemical resistant.
Glass reinforced Nylon Prevents coalesced liquids
end caps from re-entering the air
Providing high corrosion stream
resistance
High Performance
Housing Design
Pressure Indicator (DPGL)
With high dp warning light

Pressure relief hole


Gives an audible warning if
an attempt is made to
remove filter bowl

Auto-drain
Removes collected
condensate
Sight Glass
Energy Efficient
Lowest operating pressure drop in
the market
• Typically 50% more energy
efficient than conventional
filters
Energy Efficient
Oleophobic filter media
 96% voids volume
 High dirt holding capacity
 Improved liquid drainage.
 Increase flow rates.
 Ultra low resistance to
flow.
Energy Efficient

12% On average 75% of total


operating cost is
10%
electricity.
3%

2 psi pressure drop = 1%


75% increase in consumed
Capital Cost compressor power
Maintenance
Installation
Electricity
Energy Efficient
Example
700 cfm (approx 1,200 m³/hr), 150 HP (121 KW) General
purpose compressed air system
$0.08/KWH
8760hrs/annum
Total annual compressed air generation cost
= $84,797

How much of this amount relates to filtration?


Energy Efficient

14 1.0 $4,155 (4.9%)


Pressure Drop ( dp )

psi bar
$2,119 (2.4%)
0.7 Typical Filter Element Replacement
10

$1,526 (1.8%)
6 0.34 Sullair Filter Element Replacement

2
$1,187 (1.4%)
0
12 months
Element Life
Low Maintenance

Filter element performance


guaranteed for 1 year

Annual element replacement


recommended for maximum
efficiency
Low Maintenance

Corrosion Resistant
 Alocrom treatment

 Epoxy powder paint


finish

 10 year housing
guarantee
ISO Standards & Applications
ISO 8573.1 Quality Classes
Quality Dirt Water Oil
Class Particle size Pressure Dewpoint 0F (including vapour)
in Micron (ppm. Vol.) at 100 psig ppm
1 0.1 -94 (0.3) 0.01

2 1 -40 (16) 0.1

3 5 -4 (128) 1.0

4 15 +37 (940) 5

5 40 +45 (1240) 25

6 -- +50 (1500) --
Typical Application Requirements
Typical Quality Classes
Typical Application Dirt Water Oil

General Purpose
Large air tools
Pre-filtration for dryers 2 -- 3
Low cost automation

“Oil Free” Air


Robotics
Spray painting 1 -- 2
Instrumentation

Critical Applications
Cosmetic Production
Foodstuffs 1 -- 1
Blow moulding

Reduced Dewpoint
System 1 4 1
General Purpose Protection

MPF
Oil-Lubricated or ‘Oil-free’
Compressor with Aftercooler
‘Oil-Free’ Air

MPF MPH
Oil-Lubricated or ‘Oil-free’
Compressor with Aftercooler
Critical Applications

MPF MPH MPC


Oil-Lubricated or ‘Oil-free’
Compressor with Aftercooler
Reduced Low Dew Point

MPF SR Refrigeration MPH MPC


Oil-Lubricated or ‘Oil-free’ Dryer
Compressor with Aftercooler
Filter Sizing
Obtain as much information as possible
 Pipe size, flow rates, working pressure/temp.
Select filter grade according to
application (Use ISO 8573.1)
Select size of filters by flow rate &
pressure
 Consider dp, do not undersize filters
 Select filters against highest air flow rate &
operational pressure
 General rule of thumb match filter to pipe size
Filter Sizing
To determine flow rates for filters at
various pressures
- Use correction factors from literature
OR
Q2 = Q1P2/P1
Q1 = Rated flow @ rated pressure
Q2 = New rated flow @ new pressure
P1 = Rated pressure
P2 = New pressure @ which flow is required
Filter Sizing
Example
MPF 300 filter
Rated flow (Q1) 300 scfm
Rated pressure (P1) 102 psig
Actual pressure (P2) 87 psig
New rated flow (Q2) = Q1P2/P1
Filter Sizing
Example
MPF 300 filter
Rated flow (Q1) 300 scfm
Rated pressure (P1) 102 psig
Actual pressure (P2) 87 psig
New rated flow (Q2) = Q1P2/P1
= 300 87/102
= 300 0.85
Q2 = 300 x 0.92 = 276 scfm
New Products - Coming Soon!
MPCR & PCR Combination Filters
 Flanged connections on welded housings
 Electronic level sensing drains as standard
PF, PH & PC Welded Housings
 Flanged connections

ME High Capacity Pre-filter


Summary
The Sullair range of high performance filters provide:
 Low cost of ownership
- Energy efficient
- Low maintenance
 High operational efficiency
 “OIL-FREE” Warranty
 Ease of installation
March 11-13, 2001
Sullair Distributor Conference 2001

Compressed Air Filters