Tag: 5 micron filter

Why are There so Many Compressed Air Filters?

Published on by Jordan T ShouseLeave a comment

Compressed Air Filters are a necessary thing in modern manufacturing, and here at EXAIR we provide them in most kits. But what filter do you use, cleanliness standards require a variety of impurities to be removed, including oil mist, vapors and particulate matter. Impurities can enter the compressed air stream in several different ways. Intake air can introduce dust or debris particulates, rusted pipes can introduce rust and scale particulates. Oil and liquid vapors are often a consequence of using oiled compressors and must be filtered out before the compressed air can be used. There are distinct cleanliness standards for different compressed air applications, but the presence of impurities can exceed those standards, leading to damaged products or unsafe air. Filters fall into three categories: coalescing filters, absorption filters and the dry particulate filters. While each type ultimately produces the same result, they each operate on different principles.

Particulate Filters

Dry particulate filters are commonly used to remove desiccant particles after an in process dryer. But here at EXAIR we recommend using them at the point of use also to remove any rust particles from the compressed air before It’s used to clean, dry or cool in your process. Dry particulate filters function similar to a coalescing filter, catching particles within the filter media / or element.

The particulate element captures solids larger than 5 microns, and the centrifugal element eliminates moisture.

Coalescing Filters

Coalescing filters are primarily used for removing liquids and aerosols, if used in line with a particulate filter is the coalescing filter should be second in line. Small condensations are caught in a filter media and merged into larger drops that are then taken out of the filter typically into a bowl.  Most of the liquid coalescing filters remove is water and oil. Coalescing filters remove most impurities, reducing particulate levels down to 0.1 micron in size and liquids down to 0.03 micron.

The coalescing element catches oil and very fine particulate

Adsorption Filters: Vapor removal filters are typically used to remove gaseous lubricants that will go through the coalescing filter. Because they use an adsorption process, vapor removal filters should not be used to capture lubricant aerosols. Aerosols will quickly saturate the filter, rendering it useless in a matter of hours. Sending air through a coalescing filter prior to the vapor removal filter will prevent this damage. The absorption process uses activated carbon granules, carbon cloth or paper to capture and remove contaminants. Activated charcoal is the most common filter media because it has a large open pore structure; a handful of activated charcoal has the surface area of a football field.

Knowing the needs of your compressed air system can help you chose the right filter. If your air needs a high level of filtration or basic contaminants removed, cleaning your air is an important step in the compressed air process. Check out EXAIRS filter options here!

Jordan Shouse
Application Engineer

Send me an Email
Find us on the Web 
Like us on Facebook
Twitter: @EXAIR_JS

Filtered Compressed Air is the Best Compressed Air: Three Filter Types

Published on by Jordan T Shouse1 Comment

When you are using compressed air to Clean, Cool, and or Dry products in production the quality of compressed air you are using is very important. You wouldn’t want to be blowing oil or condensation from your compressed air onto a surface you are trying to dry. Or blowing debris on a surface you are trying to clean.

The most common type of oil removal filter uses a coalescing element.  Oil entrained in pressurized gas flow isn’t as dense as water – so centrifugal elements won’t remove it – and it tends to act like particulate…but very fine particulate – so typical sintered particulate elements won’t remove it.  Coalescing elements, however, are made of a tight fiber mesh.  This not only catches any trace of oil in the air flow, but also much finer particulate than those sintered elements.  EXAIR Oil Removal Filters, like the Model 9027 , provide additional particulate filtration to 0.03 microns.  That’s some pretty clean air.

Dry Particulate Filters: Dry particulate filters are usually employed to remove desiccant particles after an adsorption dryer. They can also be implemented at point of use to remove any corrosion particles from the compressed air. Dry particulate filters operate in a similar manner as a coalescing filter, capturing and retaining particles within the filter media.

The particulate element captures solids larger than 5 microns, and the centrifugal element eliminates moisture.

Coalescing Filters: Coalescing filters are used for removing water and aerosols. Small droplets are caught in a filter media and merged into larger droplets that are then taken out of the filter. A re-entrainment barrier prevents these droplets from reentering the air. Most of the liquid coalescing filters remove is water and oil. These filters also remove particulates from compressed air, trapping them within the filter media, which can lead to pressure drops if not changed regularly. Coalescing filters remove most contaminants very well.

The coalescing element catches oil and very fine particulate

Adsorption Filters: Vapor removal filters are typically used to remove gaseous lubricants that will go through the coalescing filter. Because they use an adsorption process, vapor removal filters should not be used to capture lubricant aerosols. Aerosols will quickly saturate the filter, rendering it useless in a matter of hours. Sending air through a coalescing filter prior to the vapor removal filter will prevent this damage. The adsorption process uses activated carbon granules, carbon cloth or paper to capture and remove contaminants. Activated charcoal is the most common filter media because it has a large open pore structure; a handful of activated charcoal has the surface area of a football field.

Knowing the needs of your compressed air system can help you chose the right filter. If your air needs a high level of filtration or basic contaminants removed, cleaning your air is an important step in the compressed air process. Check out EXAIRS filter options here!

Jordan Shouse
Application Engineer

Send me an Email
Find us on the Web 
Like us on Facebook
Twitter: @EXAIR_JS

The Importance of Compressed Air Filters

Published on by EricKuhnash@EXAIR.comLeave a comment

The last home I purchased had an all-seasons room, but the sellers told me the air conditioner that controlled the room temperature wasn’t working. When I moved in and tested the unit, the sellers were correct that it did not run. I started breaking it down and thought that maybe it could use a good cleaning. During this I found the filter, black and covered with pet fur. It was a washable filter so I cleaned it and let it air dry as I continued to clean remaining areas of the unit. When I put the filter back in and tried running the unit it was a miracle, it was running and producing cool air. I did nothing other than clean and clear the filter, no replacement parts, no tweaking and no repairmen.

I tell this story to many people now as it also relates to appliances, cars, lawn mowers and now I emphasize filters for compressed air systems. Using auto drain filters and oil removal filters is imperative to keeping your air clean before it gets to your tooling and equipment. Keeping water condensate and particulates contained to your filters is critical to the operation and life of your tooling and equipment. Older compressed air lines can begin to rust or corrode inside, creating scale which can jam and cause inefficiencies. Sediment and other contaminants will build up and could cause damage to your compressed air systems.

Good engineering practice calls for point of use filtration and moisture removal, such as that provided by EXAIR Filter Separators.

EXAIR carries multiple sizes and types of compressed air filters available from stock. Our Particulate and Coalescing filters can be found in our catalog and online (use the link above). If you have an application and need help selecting and sizing the right filter for your needs please contact one of our application engineers by calling 800.903.9247.

Eric Kuhnash
Application Engineer
E-mail: EricKuhnash@exair.com
Twitter: Twitter: @EXAIR_EK

Issues and Problems with Pressure Drop

Published on by johnball2014Leave a comment

 

Super Air Knife Install Sheet

Pressure drop comes in different forms, and it causes inefficiencies within your pneumatic system.  EXAIR writes statements in the installation manuals to help find the correct pipe sizes to supply the different products.  (Reference Super Air Knife Installation Manual above).   But there are other areas that can affect the performance.  These can be fittings, tubing, valves, and accessories.  In this blog, I will cover some pitfalls that can minimize the potential of your EXAIR products.

Pressure drop by definition is a difference or loss in pressure.  A properly sized Filter Separator will typically have a pressure drop of 5 PSID (0.3 bar) at the rated conditions.  So, if you start with 100 PSIG (6.9 bar), the air pressure after the filter separator will be 95 PSIG (6.6 bar).  But what happens when a filter separator is undersized or too small?  The pressure drop will be much higher.  So, if the pressure drop is 30 PSID (2 bar), then the downstream air pressure will only be 70 PSIG (4.8 bar).  At that pressure, you may not be able to get the performance that is required to do the job.

The first thing in determining these potential issues is what I like to call forensics.  If you can install a pressure gage at the inlet of any EXAIR product, then you can deduce if a potential problem is within your setup.   For example, if the Pressure Regulator is at 100 PSIG (6.9 bar), and the pressure gauge at the inlet is reading only 60 PSIG (4.1 bar), then there is a pressure drop of 40 PSID (2.8 bar) between these two points.  You can look in this area for the problem or problems.  If the gauge on the Pressure Regulator goes down as well when you are operating, then the problem area is upstream of the Pressure Regulator.  This can be from the pipe size or the air compressor.

The most common issues are fittings and tubing.  With fittings, small openings may not allow enough air to pass through.  Above is a photo of some typical fittings.  You notice that the right side of the chart has large enough openings to decrease pressure drop.  In some instances, quick connect fittings are commonly used to easily connect or disconnect pneumatic devices; but if you use too small or too many of these fittings, they can cause a large pressure drop.

The other problem is with the inner diameter of tubing, hoses, or pipes that are not properly sized.  Russ Bowman, a colleague, created a video showing the issues with improperly sized plumbing.  It is a very interesting video that shows the effect on a Super Air Knife.

If you want to get the most from your EXAIR products, you will need to reduce the amount of pressure drop in your system.  Pressure drop is wasted energy and can affect your pneumatic system.  You can follow my recommendations above.  Or if you would like to discuss your setup with an Application Engineer, we will be happy to assist.

John Ball
Application Engineer

Email: johnball@exair.com
Twitter: @EXAIR_jb