Air Filtration Parker

8/12/2019 Air Filtration Parker

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01 |02 Introduction

ENGINEERING YOURSUCCESS..

www.parker.com/dhfns

aerospaceclimate controlelectromechanicalfiltrationfluid & gas handlinghydraulicspneumaticsprocess controlsealing & shielding

High quality compressed airfrom generation to application


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ContentsFiltration, purification and separation is our business ........1Compressed air contamination is a real problem ................3Sources and types of contaminationin a compressed air system ..... .............................3Compressed air contaminants in detail ................................5Contaminant removal ............................................................7A solution for every contaminant ..........................................9Are all compressed air filters and dryers the same? .........11The Parker domnick hunter design philosophy ..................12After sales service ...............................................................13A dedicated solution for every application ..........................13


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01 |02 Introduction01 |02 Introduction

Filtration, purification and

separation is our businessParker domnick hunter is a world leader in the filtration,purification and separation of compressed air and gases.

Operating an efficient production facility allowsincreased volumes and better quality productsto be manufactured at a lower cost. Downtime

and unreliability are not acceptable.Fundamental to most modern productionenvironments is the compressed air network,often referred to as the 4th utility. This mustbe totally reliable and effective.

To guarantee maximum performance andreliability, Parker domnick hunter protects yourentire compressed air network, providing thebest quality compressed air, exactly whereit is needed.

These world class compressed air treatmentsolutions will improve production performanceand reliability whilst lowering energyconsumption, CO 2 emissions and operationalcosts to deliver 100% manufacturing uptime andtotal peace of mind.

Compressed Air - The 4th Utility Compressed air is a safe and reliable power source thatis widely used throughout industry. Known as the 4th

utility, approximately 90% of all companies usecompressed air in some aspect of their operations.Unlike gas, water & electricity which is supplied to siteby a utility supplier to strict tolerances and qualityspecifications, compressed air is generated on-siteby the user. The quality of the compressed air and thecost of producing this powerful utility is therefore theresponsibility of the user.


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Compressed air contamination

is a real problem for industryIn todays modern production facilities, the use of compressedair is often pivotal to manufacturing processes. Irrespective ofwhether the compressed air comes into direct contact with theproduct or is used to automate a process, provide motive power,packaging, or even to generate other gases on-site, a clean, dry,reliable compressed air supply is essential to maintain efficient

and cost effective production.

Sources and types of contaminationin a compressed air systemUnderstanding the sources of compressed air contamination andthe types of contaminants which must be reduced or eliminatedis a key factor in planning an efficient compressed air system. In atypical compressed air system, there are ten major contaminantsthat have to be removed or reduced to protect the consumerand provide a safe and cost effective production facility. Thesecontaminants come from four different sources.

Source 1 Atmospheric AirCompressors draw in huge amounts

of atmospheric air which continuouslyfills the system with invisiblecontaminants such as:

Water vapour

Atmospheric dirt

Oil vapour

Micro-organisms

Source 2The Air CompressorIn addition to the contaminants

drawn in from the atmosphere, oillubricated compressors will contributesmall amounts of oil from thecompression process. The oil will bein the form of:

Liquid oil

Oil aerosols

Oil vapour

After the compression stage,the after-cooler will cool the air,condensing water vapour andintroducing it into the compressed

air as: Liquid water

Water aerosols

Sources 3 & 4Compressed air storagedevices & distribution piping

As the air leaves the compressor it nowcontains eight different contaminants.The air receiver (storage device) andthe system piping that distribute thecompressed air around the facilitycan store large amounts of thiscontamination. Additionally, they coolthe warm, saturated compressed air which causes condensation on a largescale adding more liquid water into thesystem and promoting corrosion andmicrobiological growth: Rust

Pipescale


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Water vapour Water enters the compressed airsystem through the compressor intakeas a vapour (or gas). The ability of airto hold water vapour is dependentupon its pressure and its temperature.The higher the temperature, the more water vapour that can be held by the

air, the higher the pressure, a greateramount of water vapour is squeezedout. As large volumes of air are drawinto the compressor and compressed,the temperature of the air increasessignificantly. This allows the heated airto easily retain the water vapour in theatmospheric air.

Condensed liquid waterand water aerosols After compression, compressedair is normally cooled to a usabletemperature by an after-cooler. Thiscooling reduces the airs ability toretain water vapour, resulting in aproportion of the water vapour beingcondensed into liquid water. The liquid water is then removed by a condensatedrain fitted to the after-cooler waterseparator.The air leaving the after-cooler andentering the compressed air systemis now 100% saturated with water vapour. Any further cooling of thecompressed air will result in more water vapour condensing into liquid

Oil vapour Atmospheric air also contains oil ina gaseous form (oil vapour) whichcomes from inefficient industrialprocesses and car exhausts. As withother contaminants, oil vapour isdrawn into the compressor intake

and passes through the intakefilter. Typically concentrations can vary between 0.05 and 0.5mg percubic metre, but these can increasesignificantly should the compressor

be sited near highways and heavytraffic. Additionally, lubricantsused in the compression stage of acompressor can also be vaporisedand carried into the compressed airsystem. This oil vapour will then cool

and condense into a liquid. Oil vapourcan also taint products and packaging with an oily smell and / or make workers feel unwell.

Atmospheric contaminationentering the compressor Water Vapour Micro-organisms Atmospheric Dirt Oil Vapour

Contaminant SourceNo. 1

Ambient Air


The Air Compressor


The Air Receiver

Contaminants and sourcesin a compressed air system

water. Condensation occurs at variousstages throughout the system as the airis cooled further by the air receiver, thedistribution piping and the expansionof air in valves, cylinders, tools andmachinery.Saturated air, water aerosols andliquid water cause: Corrosion to the storage and

distribution system Damage to valves, cylinders, tools

and production equipment Damage to products and packaging

in direct contact with the air Increased microbiological

contamination Reduction in production efficiency Increased maintenance costs


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Liquid oil and oil aerosolsThe majority of air compressors in usetoday still use oil in their compressionstage for sealing, lubrication andcooling. The oil is in direct contact with the air as it is compressed,however due to the efficiency ofmodern air / oil separators builtinto the compressor, only a smallproportion of this lubricating oil iscarried over into the compressed

air system as a liquid, an aerosol(typically no more than 5mg/m 3 fora well maintained screw compressor)or as oil vapour. Liquid and aerosolsmix with water in the system to forma thick, acidic condensate.Compressor condensate causesdamage to the compressed air storageand distribution system, productionequipment, products and packaging.

Atmospheric dirt Atmospheric air in industrial andurban environments will typicallycontain 140 - 150 million dirt particlesin every cubic metre. As 80% of theseparticles are less than 2 microns in

size, they are therefore too small to becaptured by the compressor air intakefilter and will travel unristricted intothe compressed air system.

Micro-organisms Atmospheric air can contain up to 100

million micro-organisms per cubicmetre. Bacteria, viruses, fungi andspores are drawn into the intake ofthe air compressor and due to theirsize; will pass directly through thecompressor intake filters and into thecompressed air system. The warm,moist compressed air provides an idealenvironment for their growth.Many critical applications require

Rust and pipescaleRust and pipescale can be directlyattributed to the presence of water

in the compressed air system andis usually found in air receivers anddistribution piping. Over time, therust and pipescale breaks awayto cause damage or blockage in

production equipment which canalso contaminate final productand processes. Rust and pipescale

problems often increase for a periodof time after the installation of dryersinto older piping systems which werepreviously operated with inadequateor no purification equipment.

Contamination introducedby the compressor Water Aerosols Condensed Liquid Water Liquid Oil Oil Aerosols

Contamination introduced by the airreceiver and distribution piping Rust Pipescale

Total contamination entering thecompressed air distribution system Water Vapour Microorganisms Atmospheric Dirt Oil Vapour Water Aerosols Condensed Liquid Water Liquid Oil Oil Aerosols Rust Pipescale


The Distribution Piping

Compressor Room

sterility and if contaminated compressed aircan directly or indirectly contact products,packaging or production machinery, thensterility will be compromised.Loss of sterility can cause enormousfinancial damage for a company asmicro-organism can: Potentially harm the consumer Diminish product quality Render a product entirely unfit for use Lead to a product recall Cause legal action against a company


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Contaminant removalTo operate a safe and cost effective compressed air system,contamination must be removed or reduced to acceptable limits.

Microbiological contamination

Corrosion within storage vesselsand the distribution system

Damaged production equipment

Blocked or frozen valves, cylindersair motors and tools

Premature unplanned desiccantchanges for adsorption dryers

In addition to problems associated with thecompressed air system itself, allowing contaminationsuch as water, particulate, oil and microorganisms toexhaust from valves, cylinders, air motors and tools,can lead to an unhealthy working environment withthe potential for personal injury, staff absences andfinancial compensation claims.

Compressed air contamination will ultimately lead to:

Inefficient production processes Spoiled, damaged or reworked products

Reduced production efficiency

Increased manufacturing costs

Failure to remove contamination can cause numerous problems in the compressed air system, such as:

It is important to look at each contaminant in detail, as due to the diversity of the contamination present, a numberof purification technologies must be employed for its removal.

Compressed air contaminantsTo many compressed air users, the realisation that thereare ten major contaminants in a compressed air system issomewhat of a surprise. It is often thought that only threecontaminants are present (Dirt / Water / Oil), however,upon closer examination, these three contaminants canbe broken down further as:

Dirt Micro-organisms

Atmospheric Dirt & Solid Particulate

Rust

Pipescale

Water Water vapour

Condensed Liquid Water

Water Aerosols

Oil Oil Vap our

Liquid Oil

Oil Aerosols

Contamination Reduction / Removal

PurificationEquipmentTechnologies

BulkCondensed

WaterWater Vapour Water Aerosols

AtmosphericDirt & SolidParticulate

Micro-organisms Oil Vapour Liquid Oil &Oil AerosolsRust &

Pipescale

WaterSeparators

CoalescingFilters

AdsorptionFilters

AdsorptionDryers

RefrigerationDryers

Dust RemovalFilters

Microbiological

Filters*

* To ensure the highest level of food safety and shelf life, Parker domnick hunter recommends that all contact and non-contact high risk air is treatedwith a sterilising grade filter to remove all microbial contamination.


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Water separators Water separators provide bulkcondensed water and liquid oilremoval and are used to protectcoalescing filters against bulk liquid

contamination (for example whereexcessive cooling takes place in airreceivers and distribution pipinginstalled prior to purificationequipment).

Water separators will only removeliquids and will not remove wateror oil in either an aerosol or vapourphase.

Designs using centrifugal actionprovide the most efficient methodfor bulk liquid removal as they usea combination of directional change

and centrifugal action to optimiseseparation efficiency and reduceenergy costs.

Coalescing filters When considering purificationequipment, coalescing filters are vitalfor the cost effective operation of anycompressed air system, regardlessof the type of compressor installed. A purification system will normallyconsist of two coalescing filtersinstalled in series to remove water

aerosols, oil aerosols, atmosphericdirt, micro-organisms, rust andpipescale.

Suppliers of oil-free compressors willoften state that one of the coalescingfilters is a particulate filter andthe other is an oil removal filter,

therefore, in oil-free compressorinstallations, there is no need for theoil removal filter.

In reality, both filters removeexactly the same contaminants.The first filter is a general purposefilter which protects the second,high efficiency filter from bulkcontamination.

Omitting one of the filters in thebelief that it is an oil removal filter will result in poor air quality dueto contaminant bypass (carryover),

high operational costs due to thepressure loss across the filter andmore frequent filter elementchanges. Most importantly, omittingone of the filters will invalidateperformance guarantees.

The dual coalescing filter installationensures a continuous supply ofhigh quality compressed air withthe additional benefits of loweroperational costs and minimalmaintenance compared to a singlehigh efficiency filter.

Compressed air dryers Water vapour is water in a gaseousform and will pass through waterseparators and coalescing filters justas easy as the compressed air. Water

vapour is therefore removed fromcompressed air using a dryer. The water vapour removal efficiency of adryer (its performance) is expressedas a Pressure Dewpoint or PDP.

Dewpoint refers to thetemperature at whichcondensation will occur.

Pressure Dewpoint or PDPrefers to the dewpoint of air aboveatmospheric pressure.

Dewpoint is written as atemperature (but this is not the

airs temperature). Compressed air with a PDP

of -20C, would need thetemperature to drop below-20C for any water vapour tocondense into a liquid.

A PDP of -40C is recommendedfor all food applications where airis in direct or indirect contact withproduction equipment,ingredients, packaging orfinished products because aPDP better than -26C will notonly stop corrosion, it will also

inhibit the growth of micro-organisms.

Compressor Air Receiverand Drain

WaterSeparator

CoalescingFilters

Adsorption(Desiccant) Dryer

AdsorptionFilter

DustRemoval

FilterDustRemoval

Filter

A solution forevery contaminant

Compressor Room


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Adsorption dryers Water vapour is removed fromcompressed air using an adsorptiondryer. Adsorption dryers removemoisture by passing air over a

regenerative desiccant material which strips the moisture from theair. This type of dryer is extremelyefficient. A typical pressure dewpointspecified for an adsorption dryeris -40C as it not only preventscorrosion, but it also inhibits thegrowth of micro-organisms. Apressure dewpoint of -70C is oftenspecified for critical applications.

Refrigeration dryers (not shown)Refrigeration dryers work by coolingthe air, so are limited to positivepressure dewpoints to preventfreezing of the condensed liquid.Typically used for general purposeapplications, they provide pressuredewpoints of +3C, +7C or +10C.Refrigeration dryers are not suitablefor installations where piping isinstalled in ambient temperaturesbelow the dryer dewpoint i.e.systems with external piping, orcritical applications such as food,beverage or pharmaceuticals asthey do not inhibit microbiologicalgrowth.

DustRemoval

Filter

DustRemoval

Filter

DustRemoval

Filter

TransairPiping

SterileFilter

SterileFilter

Adsorption(Activated Carbon) filtersOil vapour is oil in a gaseous formand will pass through a coalescingfilter just as easily as the compressedair. Therefore, oil vapour removalfilters must be employed whichprovide a large bed of activatedcarbon adsorbent for the effectiveremoval of oil vapour, providing theultimate protection against oilcontamination.

Dust removal filtersDust removal filters are used for theremoval of dry particulates. Theyprovide identical particulate removalperformance to the equivalent

coalescing filter and use the samemechanical filtration techniquesto provide up to 99.9999% particleremoval efficiency.

Sterile filters Absolute removal of solidparticulates and micro-organismsis performed by a sieve retentionor membrane filter. They are oftenreferred to as sterile air filters as theyalso provide sterilised compressedair. Filter housings are manufacturedfrom stainless steel to allow forin-situ steam sterilisation of boththe filter housing and element. It isimportant to note that the pipingbetween the sterile filter and theapplication must also be cleanedand sterilised on a regular basis.

Important Note :As adsorption or refrigeration dryers are designed to remove onlywater vapour and not water in a liquid form, they require the useof coalescing filters to work efficiently.

Application


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Are all compressed air filters

and dryers the same?Compressed air purification equipment is essentialto all modern production facilities. It must deliveruncompromising performance and reliability whilstproviding the right balance of air quality with the lowestcost of operation. Many manufacturers offer productsfor the filtration and purification of contaminatedcompressed air, which are often selected only upon their

initial purchase cost, with little or no regard for the airquality they provide, the cost of operation throughouttheir life or their environmental impact. When selectingpurification equipment, the required air quality,the overall cost of ownership and the equipmentsenvironmental impact must always be considered.

Air Quality Parker domnick hunter has beeninstrumental in the developmentof both ISO8573 and ISO12500,the international standards forcompressed air quality and

compressed air filter testingrespectively. All Parker domnickhunter products are designed toprovide air quality in accordance with all editions of ISO8573-1, airquality standard.

Energy Efficiency In these times of increasing energycosts, an efficient and cost effectivemanufacturing process is a majorfactor in maintaining the profitability

and growth of your business. AllParker domnick hunter products are

designed to not only minimise theuse of compressed air and electricityin their operation, but also tosignificantly reduce the operational

costs of the compressor by minimisingpressure loss.

Low Lifetime Costs Equipment with a low purchase costmay turn out to be a poor investmentin the long term. By guaranteeingair quality and ensuring energyconsumption is kept to a minimum,

Parker domnick hunter purificationproducts can reduce the total costof ownership and help improveprofitability through improvedmanufacturing efficiencies.

The Parker domnick hunterdesign philosophyParker domnick hunter has beensupplying industry with highefficiency filtration and purificationproducts since 1963. Our philosophyDesigned for Air Quality & Energy

Efficiency ensures products thatnot only provide the user with clean,high quality compressed air, but also with low lifetime costs and reducedcarbon dioxide (CO 2) emissions.

Reduced CO 2 Emissions Many countries worldwide arelooking closely at their manufacturingindustries in an effort to reduce theamount of harmful greenhouse gasesreleased into the atmosphere. The useof electricity has a direct impact on

the generation and release of CO 2.By significantly reducing the energyconsumption of its products, Parkerdomnick hunter can help you toreduce your carbon footprint andprotect the environment.


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After sales serviceCompressed air equipment users demand much more than the supplyof high quality products in order to maintain a competitive edge.

Modern production technology is increasingly demanding theprovision of a higher purity and more reliable compressed airsupply. Products and solutions that are manufactured by Parkerdomnick hunter are designed to provide air quality that meets withand often exceeds international standards. As well as the requirement for air purity and reliability, there areadditional factors to consider when choosing the right serviceprovider for your compressed air and gas purification system.For example, knowledge of the many regulations regarding themanagement of industrial waste, energy efficiency improvementprograms and consideration of any environmental impact. It isanticipated that future legislations will demand further in-depthtechnical and knowledge based support from service providers.

Our commitment to industry does not stop with the supply ofhigh quality products. We are also committed to ensuring that ourequipment provides high performance by providing a trouble-freeservice from a bespoke maintenance and verification package alltailored to your own specific requirements.

We offer a wide range of valuable services that will impact positivelyon your drive towards improved production efficiency and productquality with reduced production rejections and operational costs.

From initial selection to installation, commissioning, preventativemaintenance and extended services, Parker domnick hunter isredefining customer service.

A dedicated solution for every applicationThe quality of air required throughout a typical compressed airsystem will vary depending upon the application for which it is used.Treatment of the compressed air at only one point alone, forexample the compressor room; is not enough. Compressed airshould be treated prior to entry into the distribution system (to aquality level suitable for protecting air receivers and distributionpiping) and then at the point of use, with specific attention beingplaced on the application and the level of air quality required.This approach to system design ensures that air is not overtreated and provides the most cost effective solution to highquality compressed air.

The use of the ISO8573-1:2010 Air Quality Standard provides thesystem engineer with a simple method of specifying the air purityrequired at each point in the compressed air system. Using thisstandard allows Parker domnick hunter to quickly and easilyselect products from its comprehensive range of purificationproducts to exactly match your system requirements and toensure that both capital and operational costs are kept to aminimum.

Critical ApplicationsPharmaceutical products

Silicon wafer manufacturing

TFT / LCD Screen manufacturing

Memory device manufacturingOptical storage devices (CD, CD/RW,DVD, DVD/RW)

Optical disk manufacturing (CDs/ DVDs)

Hard disk manufacturing

Foodstuffs

Dairies

Breweries

CDA systems for electronicsmanufacturing

High Quality Oil-Free AirBlow Moulding of Plastics e.g. P.E.T.Bottles

Film processing

Critical instrumentation

Advanced pneumatics

Air blast circuit breakers

Decompression chambers

Cosmetic production

Medical air

Dental air

Lasers and optics

Robotics

Spray Painting

Air bearings

Pipeline purging

Measuring equipment

Blanketing

Modified Atmosphere Packaging

Pre-treatment for on-site gasgeneration

General Purpose Oil-Free AirGeneral ring main protection

Pre-filtration to point of use adsorptionair dryers

Plant automation

Air Logistics

Pneumatic tools

General instrumentation

Metal stamping

Forging

General industrial assembly(no external pipework)

Air conveying

Air motors

Workshop (Tools)

Garage (Tyre filling)

Temperature control systems

Blow guns

Gauging equipment

Raw material mixing

Sand / bead blasting


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Catalogue: 174004401_04_EN 11/112011 Parker Hannin Corporation. All rights reserved. Parker Hannifin Manufacturing Limiteddomnick hunter Filtration and Separation Division

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