STANDARDIZED FILTER TESTS OF METAL WORKING FLUID MIST SEPARATORS

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1 STANDARDIZED FILTER TESTS OF METAL WORKING FLUID MIST SEPARATORS Dipl.-Ing. Thomas Laminger Univ. Prof. Dr. Wilhelm Höflinger Mechanical Process Engineering and Clean Air Technology TEMPUS MEETING VIENNA th November 2010

2 CONTENT Introduction Background information about Metal Working Fluid Usage of mist separators in enclosed machine centers Proposal of a standardized test procedure for metal working fluid mist separators Analogies of standardized test procedures for dust filter media Filter test rig for mist separators Set up and main components Measurement device for metal working fluid mist emissions Liquid storage inside a mist filter Time evolution of the liquid storage and its effect on the pressure drop behavior Accelerated filter ageing procedure Determination of filtration specific properties of mist separators in a stationary condition Demonstrative measurement example Comparison of achieved results of different filter media Summary Outlook 2

3 INTRODUCTION Background In Germany about t per year of lubrication oil is used in the metal working industry. About 50% of the oil is used as oil/water emulsion which leads to t/a used metal working fluid (MWF) [1]. Mineral, synthetic or ester oil base Additives (emulsifier, stabilizer, biocides, fungicides, ) MWF mist emissions can cause skin disease (dermatitis, allergies, oil acne) disease of the respiratory path cancer, Measurement and monitoring of the working environment is necessary and regulated by law. (2010): cutting process Preventive measures Proper working process and adequate metal working fluid Scheduled metal working fluid care and maintenance Use of exhausts Total enclosed machines with filter system to reduce the emission (droplets and vapor) [1] Betrieblicher Umweltschutz in Baden Württenberg. bw.de (2010) (2010): full enclosed machining center 3

4 FULL ENCLOSED MACHINING CENTER: AIR VENTILATION material machining Fire protection Clean air exhaust Mist ventilation Mist separator Swarf capture air stream (2010): air ventilation system

5 MULTISTAGE MIST SEPARATOR State of the art filter systems use multistage mist separators: Clean gas 4 3 1)Pre-separator (Inlet) 2)1-stage filter 3)2-stage filter 4)HEPA filter 2 1 Raw gas Drainage (2010): OEL SOKE STOP

6 INTRODUCTION Types of mist separators Different separators can be distinguished by their filtration mechanism [2]: Filtering separators Electrostatic precipitators Centrifugal collectors Combinations 42% 52% 1% Types of mist separators[2] 5% Filtering separators Electrostatic precipitators Centrifugal collectors Combinations For MWF mist separators no standards or norms as they are available for cleanable dust filters or particulate air filters exist. Purpose of the work Development of a standardized test procedure for metal working fluid mist separators (filtering separators) with emulsion as test substance. Filtering separators [2] Riss, B.: Erfassung und Abscheidung von Kühlschmierstoff Emissionen: Erhebung zum Stand der Technik in Österreich. In: Zusammenfassung der Vorträger der Fachveranstaltung Kühlschmierstoffe der AUVA Österreich; Wien, 20. November

7 PROPOSAL OF A STANDARDIZED TEST PROCEDURE Analogies to norms and standards for dust filter DIN EN 1822: High Efficiency Particulate Air Filters (HEPA and ULPA) US Standard ANSI/ASHRAE Standard : Method of Testing General Ventilation Air Cleaning Devices for Removal Efficiency by Particle Size EN 779: Particulate air filters for general ventilation VDI 3926: Testing of cleanable filter media Content/object transferable for mist separators Filter test rig Filter test rig for mist separators Test substance (s) MWF emulsion (mineral oil, synthetic oil) Test condition of the filter Filtration specific parameters Classification and characterization Stationary liquid equilibrium steady state condition Pressure drop, total holdup, oil holdup, fractional separation efficiency respective MWF e.g. 10 stage classification system respective the fractional separation efficiency of several particle sizes 7

8 FILTER TEST RIG Components Aerosol generator generation of a test aerosol conditioning of the sucked off air Ageing nozzle Filter holder CYCL FID Measurement device Online detection of vapor and droplet concentration Measured and calculated values Pressure drop Drainage flow Oil concentration of the drainage flow and the emulsion tank Raw gas and clean gas concentration Total holdup (stored emulsion inside the filter) Oil holdup (stored oil inside the filter) Separation efficiency 8

9 CYCL FID MEASUREMENT DEVICE Online Measurement device for the detection of metal working fluid mist emission (concentration of droplet and vapor) Components and measurement principle Emission Droplets + Vapor Classifier (Cyclone) Droplets (Ø>Cut Off) Droplets (Ø<Cut Off) + Vapor Evaporator Vapor Measuremen t (FID) The variation of the Cut Off Diameter (0, µm) according to definitions of maximum workplace concentration values (zb. PM10, PM4, PM2,5, etc.) creates several emission fractions. The fraction with the smallest cut off diameter includes per definition the vapor fraction of the mist emission. Measuring the clean gas concentration of 4 fractions + Measuring the raw gas concentration of 4 fractions Fractional separation efficiency of 4 fractions Flame Ionization Detector (FID) 9

10 CYCL FID MEASUREMENT DEVICE: MEASUREMENT PRINCIPLE FID concentration [ppm propane equivalent] Raw gas <0,3 <1,0 <3,0 <10,0 Droplets Droplets Vapor Vapor FID concentration [ppm propane equivalent] Vapor Vapor and and Droplets Droplets <0,3 <0,3 µm µm <0,3 1,0 0,3 3,0 1,0 10,0 3,0 0,3 1,0 3,0 10,0 Cut Offdiameter [µm] 0,3 1,0 3,0 10,0 Cut Offdiameter [µm] FID Concentration [ppm propane equivalent] Clean gas <0,3 <1,0 <3,0 <10,0 FID concentration [ppm propane equivalent] <0,3 1,0 0,3 3,0 1,0 10,0 3,0 Cut Offdiameter 0,3 1,0 3,0 10,0 [µm] 0,3 1,0 3,0 10,0 Cut Offdiameter [µm] 10

11 CYCL FID MEASUREMENT DEVICE: MEASUREMENT PRINCIPLE Calculation of the fractional separation efficiency: Raw gas E i C = 1 C Clean Raw (i) * 100 (i) FID Concentration [ppm propane equivalent] <0,3 1,0 0,3 3,0 1,0 10,0 3,0 E i Fractional separation efficiency of the emission fraction i [%] C Clean (i)..clean gas concentration of the emission fraction i [mg/m³ or ppm] C Raw (i).raw gas concentration of the emission fraction i [mg/m³ or ppm] 0,3 1,0 3,0 10,0 Cut Offdiameter [µm] FID Concentration [ppm propane equivalent] <0,3 Clean gas 1,0 0,3 3,0 1,0 10,0 3,0 Fractional separation efficiency [%] Vapor Vapor and and Droplets Droplets <0,3 <0,3 µm µm 0,3 1,0 3,0 10,0 Cut Offdiameter [µm] <0,3 0,3 1,0 1,0 3,0 3,0 10,0 Cut Offdiameter [µm] 11

12 LIQUID STORAGE INSIDE A FILTER MEDIUM Balancing the emulsion mass flows of a filter medium allows the calculation of the total stored emulsion (total holdup). And from there including the oil concentration of the emulsion flows it is possible to calculate the stored oil mass (oil holdup). Filter medium Total emulsion balance With t=infinite: Stationary total holdup Raw gas Clean gas = & & & Water balance Stationary water holdup Holdup = & & & Drainage Oil balance Stationary oil holdup = & & & m & (t) = m(t) & drainage, oil m & (t) = m(t) & raw, oil m & (t) = m(t) & clean, oil raw,total drainage, total clean,total * c(t) * c(t) * c(t) raw,total clean,total drainage,oil 12

13 LIQUID STORAGE INSIDE A FILTER MEDIUM Results (Long time test run using only the aerosol generator) The pressure drop still increases although the drainage reaches quickly a stationary value. The oil concentration of the drainage emulsion is slightly lower as the oil concentration of the raw gas emulsion the oil holdup within the filter rises. Due to the separation of the oil/wateremulsion the oil holdup increases relative slowly compared to the total holdup. The growing oil holdup enhances the filtration resistance and therefore the pressure drop increases until the oil holdup reaches a steady state. 13

14 ACCELERATED FILTER AGEING: AGEING NOZZLE The development of the stationary pressure drop relies on the relative slowly forming oil holdup. To shorten the time to form the stationary oil holdup more oil is needed to be brought to the filter in a shorter time. Hence the time to reach a steady state pressure drop (=Ageing time) should be reduced by increasing the emulsion mass flow to the filter. Ageing nozzle up to 1g/( cm²/min) filter area specific mass flow (=filter loading) Ring with fine holes 200 Filter medium Top view 200x Side view Emulsion pump 14

15 ACCELERATED FILTER AGEING: TEST PROCEDURE A B 1) Accelerated Ageing transfer the filter in a stationary condition using the ageing nozzle and the aerosol generator 2) Stabilizing shut down of the ageing nozzle using only the aerosol generator 3) Measuring measuring the stationary raw and clean gas concentration with the CYCL FIDmeasurement device The same stationary pressure drop is achieved with (A) A accelerated and (B) B non accelerated filter ageing procedure. Ageing time filter loading 0,45g/(cm²/min) With high filter loading values the ageing time respectively the filter test Ageing time time can be reduced to a few hours. filter loading 0,05g/(cm²/min) 15

16 CORRELATION BETWEEN THE AGEING TIME AND THE FILTER LOADING Ageing time =timeto reach a stationary pressure drop Filter loading = filter area specific mass flow With increasing filter loading the ageing time decreases. The ageing time of the HEPAfilter depends mostly on the filter loading. For an optimal filter loading the finest filter can be used: Potential irreversible damage of the filter structure >1g/(cm²/min). For about 2 hours maximum test time 0,5g/(cm²/min) is sufficient. 16

17 DEMONSTRATIVE MEASUREMENT EXAMPLE Test filter Fine wire/glass fiber filter, 200x200x40mm Test parameters Filter face velocity: 5000m³/(m²h) Test substance: 10% emulsion, mineral oil Filter loading (ageing nozzle): 0,5g/(cm²/min) Test aerosol concentration: 56mg/m³ Test aerosol: Particle size distribution (PCS 2010, Palas ) Aerosol generator: 7500rpm; 1,2l/min emulsion flow 17

18 TIME DEVELOPMENT AND STATIONARY VALUES OF THE PRESSURE DROP, TOTAL HOLDUP AND OIL HOLDUP Pressure drop drop Total Total holdup holdup Oil Oil holdup holdup Accelerated Ageing Stabilizing Measuring Stationary pressure drop: 686Pa Stationary total holdup: 213g Stationary oil holdup: 125g 18

19 STATIONARY RAW GAS AND CLEN GAS CONCENTRATION AND THE FRACTIONAL SEPARATION EFFICIENCY IN FOUR FRACTIONS 19

20 COMPARISION: STATIONARY PRESSURE DROP, TOTAL HOLDP AND OIL HOLDUP OF DIFFERENT FILTER MEDIA Six filter media with different filter fineness were tested with the accelerated filter ageing procedure. Within 2 3 hours a steady state condition was reached and the stationary pressure drop, total holdup and oil holdup were determined. 1 st stage 2 nd stage 3 rd stage For economical reasons the 2 nd and 3 rd filter stage must be protected from large quantity of liquid mass. 20

21 COMPARISION: STATIONARY FRACTIONAL SEPARATION EFFICIENCY OF DIFFERENT FILTER MEDIA With increasing filter fineness the fractional separation efficiency increases. The largest differences of the fraction separation efficiencies are in the particle size range between 0,3 1µm. According to EN 779 Specified separation efficiency (solid particles) according to EN779: >99% CYCL FID Measurements includes also the vapour phase: Low vapour reduction! 21

22 SUMMARY In analogy to existing norms and standards for dust filters a standardized test procedure for metal working fluid mist filters was developed. A filter test rig with its main components was presented. The CYCL FID measurement device and the principle to measure the droplet and vapor concentration of a mist emission in several particle size fractions was shown. It was further presented that balancing the liquid mass flows of a filter medium allows the calculation of the total holdup, water holdup and oil holdup. Using an emulsion as test substance it was found out that the relative slow forming oil holdup limits the achievement of a stationary pressure drop of filter media (ageing time). Therefore an ageing nozzle was used to enhance the liquid mass flows to the filter respectively to shorten the ageing time. 22

23 SUMMARY A three step filter test procedure for an accelerated filter ageing was described which allows the determination of the stationary filtration specific parameters which are pressure drop, total holdup, oil holdup and the fractional separation efficiency in a relative short test time. The accelerated filter ageing procedure was tested using six different filters. With this accelerated ageing procedure the stationary filtration specific values could be determined within 2 3 hours test time. The pressure drop of 2 nd and 3 rd filter stage increase dramatically even with small liquid amounts and therefore pre stage filters should protect them. The stationary fractional separation efficiency in the particle size range <0,3µm of the tested filter media achieved with the CYCL FID measurement method were generally low. A comparison with specified fraction separation values according to EN 779 indicated a poor vapor reduction property of the filters. 23

24 OUTLOOK Development of a classification procedure using e.g. the stationary fractional separation efficiency in several particle size ranges. Implementation of a filter test norm or standard (e.g. ÖNORM).

25 THANK YOU FOR YOUR ATTENTION! 25

STANDARDIZED FILTER TESTS OF METAL WORKING FLUID MIST SEPARATORS

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