E7700 10 10 13 - Prozesstechnik - Web
E7700 10 10 13 - Prozesstechnik - Web
E7700 10 10 13 - Prozesstechnik - Web
13
Filtration in
Industrial Processing.
Contents
Introduction
Your Partner in the Filtration of Process Media
Industries and Applications
Page
3
6
7
9
10
Product Overview
Automatic Back-flushing Filters AutoFilt
Inline and Screen Basket Filters
Gas Filters
System Solutions
Clogging Indicators
11
12
14
15
16
Know-how
Process Media
Selecting the Correct Process Filter
17
21
Appendix
Filter Specification Questionnaire
ATEX Check List
E 7.700.10 / 10.13
Note
22
23
E 7.700.10 / 10.13
H
3
Leading
by Filtration
You too can benefit by installing
HYDAC process filters!
Improvement of the quality of the medium
Poor product quality
No interruption to operation
The HYDAC
FluidCareCenter
You can count on top quality
and innovation.
Development at HYDAC is characterised
by designs based on test results from
our research and test laboratories as
well as field analyses. These designs
are incorporated into applicationorientated filtration systems and take
the requirement profiles of users and
providers into account.
E 7.700.10 / 10.13
Inspection Classification
Certification
Collaboration with inspection,
classification and certification bodies
is part of our daily business.
Our products are developed and
manufactured according to their
specification, as required.
Additional certification can of course
be undertaken on request.
ATEX Products
HYDAC also has products which are
suitable for use in potentially explosive
atmospheres.
We will be pleased to send you our
ATEX specification questionnaire.
Customized Solutions
Flexible flange connections
(JIS, DIN, ANSI)
Various design pressures available
Wide range of power supplies
Digital or analogue signals
to customer interfaces
E 7.700.10 / 10.13
Industries
and Applications
Steel industry
Filtration of the process water to
protect the nozzles and pumps in
high pressure descaling
Water conditioning for cooling
blast furnaces and rolling mills
Emulsion filtration in cold rolling mills
Paper industry
Protection of all types of
nozzles on paper machines.
Treatment of fresh water (e.g. river
water) to be used for cooling
Seal water filtration for vacuum
pumps
Power plants
Conditioning of industrial water
for generator cooling
Filtration of seal water to increase the
service life of the turbine shaft rotary
seals in hydropower stations
Protection of heat exchangers
in thermal power plants
Automotive industry
Filtration of cooling lubricants and
washing fluids to extend service
intervals
Treatment of cooling and process
water for different applications
Machine tools
Improving the quality of cooling
lubricants
Extension of service lifetimes
Protection of tools, consistent quality
of the manufactured parts
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Mining
Marine
Pre-filtration for ballast water
treatment systems
Chemical industry
Cooling water and
waste water filtration
Filtration of a wide variety
of chemicals
Plastics industry
Polymer melt filtration
Further applications
Water pre-filtration for snow-making
equipment
... and much more
Filter Materials
The core of each filter is the filter element. To a large extent, they determine the efficiency. For this reason, HYDAC filters
are made using only the best filter materials which meet the highest standards in respect of stability, long life and cleanability.
Filter materials
Characteristics
Retention rate
Surface filtration:
Nominal:
Particle are separated primarily at the surface of the filter material.
Once a pre-set pressure drop is achieved or according to fixed intervals,
the filter materials are cleaned and the filtration process can continue
continuously or intermittently.
Depth filtration:
Absolute:
The operating fluid being cleaned penetrates the filter structure.
The contaminating particles become trapped in the deeper layers
of the filter. The flow resistance increases as the media becomes
more and more clogged, which means that the filter element
must be replaced.
Retention rate
Surface
Description
Material
Depth
Filtration
rating in m
Nominal
Absolute
Temperature
in C
Used in
following
HYDAC filters
400
Inline filter
400
Automatic
back-flushing
filters
400
Automatic
back-flushing
filters
Automatic
back-flushing
filters
1 to 100
Chemicron
metal fibre
Stainless
steel
Wire mesh
(Dutch weave)
Stainless
steel
Wire mesh
Square mesh
Stainless
steel
Slotted tube
Stainless
steel
50 to 3,000
400
Perforated
plate
Stainless
steel
3,000 to 10,000
400
0.5 to 25
for gases
Inline filter
25 to 60
Inline filter
100 to 500
Inline filter
Screen basket
filter
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Material
Filter Materials
Non-cleanable Filter Materials
Filtration
Retention rate
Surface
Material
Description
Material
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Depth
Filtration
rating in m
Nominal
Absolute
Temperature
in C
Used in
following
HYDAC filter
Betamicron
Glass fibre
3 to 20
95
Inline filter
Synthetic
non-woven
material
PP / PES /
Nylon
1 to 100
95
Inline filter
Filter bag
PP / PE /
Nylon
1 to 1,000
80
Inline filter
Filter Elements
Description
Features
Type
Filtration rating
in m
50 3,000
SuperMesh, conical
25, 40, 60
50 3,000
SuperMesh, conical,
SuperFlush coating
25, 40, 60
50 3,000
Filter elements
for gas filters
Chemicron
Wire mesh
3 20 (absolute)
25 500
Flexmicron
1 90
Betamicron
3 20 (absolute)
Chemicron
0.5 25
(absolute)
Wire mesh
25 1,000
Slotted tube
50 3,000
Screen basket
filter elements
PELF
Inline filter elements
Perforated plate
3,000
Polyester, pleated
1 90
Flexmicron Economy
1 90
Flexmicron Standard
1 90
Flexmicron Premium
1 90
Betamicron
Inline filter elements
Filter bag
Betamicron
3 20 (absolute)
Filter bag
PP/PE/Nylon
1 1,000
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Flexmicron
Inline filter elements
Special Features of
Filter Element Technology
Description
Features
Efficiency of back-flushing
low
high
SuperFlush coating
with
without
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Increased efficiency
10
Automatic
Back-flushing Filter AutoFilt
HYDAC automatic back-flushing filters AutoFilt are designed for continuous or intermittent filtration in all areas of industry
and in water treatment. HYDAC AutoFilt automatic back-flushing filters are self-cleaning systems for the removal of solid
particles from fluids. They make a great contribution to operational reliability and reduce operating and maintenance costs.
Temperatures up to 90 C
Pressures up to 350 bar
Filtration ratings from 15 to 10,000 m
Flow rates up to 10,000 m3/h
Flow rate
Q max
Operating pressure
P max
Filtration ratings
10,000 m3/h
100 bar
25 to 3,000 m
220 l/min
16 bar
25 to 1,000 m
4,200 m3/h
10 bar
200 to 3,000 m
25 to 3,000 m
AutoFilt RF3
AutoFilt RF4
AutoFilt RF5
AutoFilt RF7
7,500 m /h
3
10 bar
AutoFilt RF10
3,000 m3/h
6 bar
40 to 3,000 m
400 m3/h
16 bar
200 to 3,000 m
800 l/min
350 bar
25 to 500 m
AutoFilt ATF
AutoFilt RFH
Slotted tube
Wire mesh
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11
Inline and
Screen Basket Filters
HYDAC inline filters are designed for the toughest applications in process technology.
They provide effective filtration of all types of solid contamination. Numerous designs and
filter materials ensure the best fit to the filtration task and the given process conditions.
Temperatures up to 400 C
Pressures up to 1,000 bar
Filtration ratings from 1 (absolute) to 10,000 m
Flow rates up to 3,600 m3/h
Flow rate
Q max
Operating pressure
P max
Filtration ratings
3,600 m3/h
64 bar
3 to 3,000 m
Betamicron,
Chemicron, Wire mesh,
Slotted tube
3,600 m3/h
16 bar
25 to 3,000 m
Wire mesh,
Slotted tube,
Perforated sheet
1,200 m3/h
40 bar
1 to 90 m
Flexmicron Economy,
Flexmicron Standard,
Flexmicron Premium
120 l/min
100 bar
1 to 2,000 m
Chemicron,
Wire mesh,
Slotted tube
PRFL / PRFLD
PRFS / PRFSD
PMRF / PMRFD
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PFM / PFH /
PFMD / PFHD
12
Inline and
Screen Basket Filters
Flow rate
Q max
Operating pressure
P max
Filtration ratings
300 l/min
400 bar
3 to 250 m
Betamicron,
Chemicron,
Wire mesh
500 l/min
10 bar
1 to 1,000 m
Filter bag
1,440 l/min
16 bar
1 to 90 m
PELF
EDF
PBF
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PLF1
13
Gas Filters
Operating pressure
P max
Operating temperature
Filtration ratings
Filter material
up to 500 bar
- 35 C to + 225 C
0.5 to 25 m
Chemicron
up to 500 bar
- 35 C to + 225 C
0.5 to 25 m
Chemicron
up to 500 bar
- 35 C to + 225 C
0.5 to 25 m
Chemicron
up to 500 bar
- 35 C to + 225 C
0.5 to 25 m
Chemicron
up to 250 bar
- 35 C to + 225 C
> 15 mm*
Stainless steel
up to 250 bar
- 35 C to + 225 C
700 bar
- 40 C to + 85 C
1 to 25 m
Chemicron
GCF
Gas Coalescer Filter
GCF
with cyclone
GCF
Double Block & Bleed
GPF
Gas Particulate Filter
GDS
Gas Demister Filter
GCS
Gas Cyclone Separator
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GF1
High Pressure Filter
14
System Solutions
Type
Description
Process Booster
Block PBB
Technical Details
Process monitoring
Pressure control
Pressure boost
AutoFilt TwistFlow
Strainer ATF Skid
Example:
Flow velocity: approx. 600 m3/h
Filtration rating: 200 to 3,000 m
Materials: stainless steel, carbon steel
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BTU Backflush
Treatment Unit
15
Clogging Indicators
HYDAC clogging indicators are designed to indicate visually and/or electrically
when the filter elements must be changed or cleaned.
Pressure setting
[ bar]
420
1, 1.5, 2, 3, 5, 8
420
1, 1.5, 2, 3, 5, 8
420
1, 1.5, 2, 3, 5, 8
160
25,
40 on request
0 - 1.6, 0 - 4
25
0.5, 1, 1.5, 2, 3, 5
on request
on request
PVD x B.x
PVD x C.x
PVD x D.x/-L
V01 x VZ.x
DS11
PVL x GW
HDA 4xxx
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16
Process Media
Water
Many industrial companies require different types of process and service water
for their production and manufacturing processes. These include, for example,
water for cooling purposes, washing and flushing water, seal water for rotary seals,
service water to prepare chemical solutions etc. The use of drinking or mains water
for such applications is too expensive as a rule and so ground or surface water
is utilised for these purposes. Depending on the application and the quality of the
raw water, more or less complex treatment is required for the water to obtain
the required water quality.
Invariably in all water treatment processes, filtration of the solid particles
suspended in the untreated water is required to guarantee operationally safe
recovery of process and service water. Owing to its broad product range
of automatic back-flushing filters as well as inline and screen basket filters,
HYDAC can provide the correct process filter for virtually all areas of application
and industries.
Ballast Water
Water is required to provide ballast depending on the load condition of the ship.
Up to now, there has been the risk of sea-life being transported to areas causing
damage to the ecosystem as a result of the exchange of ballast water.
For this reason, so-called ballast water treatment systems are to be installed on
ships in future. By using mostly two-stage systems which consist initially
of a pre-filtration stage followed secondly by disinfection (such as electrolysis,
UV irradiation or ozonation systems) harmful microorganisms and viruses are killed.
The automatic back-flushing filter AutoFilt series from HYDAC is ideally suited to
pre-filtration and already has a proven track-record in numerous installations.
Disinfection
To the ballast
tanks
Sea-chest
Sea-chest
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Back-flush line
17
Process Media
Cooling Lubricant
ip a
tio
rt
He
at
d
iss
Chip handling
po
Increases
cutting speed
ns
Tra
Flushing
contamination away
Lubrication
Reduced friction between
tool / workpiece
tool / chip
The relative importance and emphasis of the individual criteria are dependent
on the particular machining process. In addition, all cooling lubricants for metal
machining are optimally tailored to numerous secondary requirements which
also have positive implications for the user:
Consistent stability for long term use due to perfect filtration
Excellent corrosion protection
Neutrality towards compatible elastomers, machine coatings
Reduced outlay for machine failures and
maintenance due to continuous conditioning
Easy disposal
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18
Process Media
Filtration of cooling lubricant
Even the best cooling lubricant will not function without conditioning!
In order to be able to obtain maximum usage from the cooling lubricant
over a long time period, effective filtration is essential.
All contamination which enters the system must also be removed
from the system by filtration.
Tramp oils
Abrasion products
Salts
Waste
Polymer Melts
A specialist area of fluid filtration is in the production and processing of plastics.
In addition to the impurities brought in from outside and caused by the
manufacture of raw materials, the presence of gels and specks often causes
further problems in production quality assurance.
Filtration using special filter elements in Chemicron (metal fibre), in filtration
ratings of between 1 and 100 m absolute, has proven most effective in this
field. The filter elements are supplied in pleated form as standard or customised
elements.
Pellets
Reactor
Granulator
Gear pump
Filter
Pellets
Fibres
Filter
Spinnerets
Plastic extruder
Fibres
Films
Filter
Nozzles
Plastic extruder
Films
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19
Process Media
Seal Gas
HYDAC gas filters have been specially developed for use
in dry gas seal systems for turbo compressors.
Dry gas seals of turbo machines are very complex systems and extremely
sensitive to contamination by solid particles, aerosols and condensates.
As the shaft rotates, a tiny gap of just 3 m forms on the seal through which
the seal gas flows. To protect these seals, the seal gases must be filtered
appropriately to ensure the seal has as long a service life as possible.
Filter elements with a coalescing action (coalescer elements) are invariably
used in all HYDAC seal gas filters.
All the elements consist of pleated filter materials which define the micron
rating and the contamination retention capacity, and coalescer materials which
cause the fluid phase to coalesce.
The design criteria for HYDAC seal gas filters are clearly described in the API.
The customer requirements take precedence, and these can be different to the API.
HYDAC has developed special design software for sizing and matching the filter
to the particular application.
H2
Hydrogen
The European Union has committed itself to converting its transport
and energy systems, by 2050, into low-carbon systems and to decoupling
economic growth from resource and energy consumption.
In combination with a fuel cell, hydrogen can provide a safe energy source
which is flexible, decentralized and without emissions. It therefore represents
a key technology to achieve these objectives.
Particularly in the automotive industry, hydrogen is gaining increasing importance
as an alternative fuel. The cleanliness of the hydrogen is vitally important here for
the lifetime of the fuel cell powered vehicles.
Following the launch of the PSA-H70 (HYDAC Accessories), which is a measuring
cell for monitoring the H2 cleanliness on 700 bar hydrogen fuel pumps,
remarkably high levels of particle contamination could be detected irrespective
of the compressor design or fuel pump manufacturer.
E 7.700.10 / 10.13
With the gas filter GF1, specially developed by HYDAC Process Technology
for hydrogen fuel pumps up to 1,000 bar , it has been possible to draw on the
knowledge and experience gained in the dry gas seal filtration sector.
All filter elements consist of pleated filter materials which define the filtration
rating and the contamination retention capacity and thus fulfil the requirements
of hydrogen fuel pumps for the first time.
20
Selecting the
Correct Process Filter
The Nature of the Medium
being Filtered
Unlike hydraulic media the solid
contamination of process media
is not classified according to ISO.
No two applications requiring
process media filtration are alike.
Nevertheless, various parameters
can be identified from which it is
possible to make the best selection
to match the filter to the particular
process.
In addition to having an exact
description of the application,
one of the first steps in selecting
the correct filter is the classification
and analysis of the intended medium.
Type of contamination
Medium
Viscosity (cSt.)
Particle distribution
Chemicron
Wire mesh -
Square mesh
Wire mesh
(Dutch weave)
Betamicron
Filter bag
Filter material
Slotted tube
Perforated plate
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21
Filter
Specification Questionnaire
Company:
Telephone:
Name:
Fax:
Address:
Mobile:
E-mail:
Medium:
Medium
Viscosity
cSt.
Type of contamination
Contamination load
mg/l
Group 1
(hazardous)
Group 2
(non-hazardous)
(only if applicable)
Operating data:
P1: Operating pressure /
Pressure at inlet
bar
bar
bar
Operating temperature*
Flow velocity
m/h
Design data:
Design pressure
bar
Design
temperature
Flow velocity
m/h
Filtration rating
Connection inlet/outlet
Materials
Single filter
Duplex filter
Filter material
Single use
Cleanable
Clogging indicator**
Visual
Visualelectrical
Electrical
Type of control***
Electropneumatic
Electrical only
Pneumatic only
Compressed air***
Yes
If yes, please
indicate pressure:
No
V
Automatic filter
Hz
Neutral wire
bar
Yes
Required approvals/Certificates
E 7.700.10 / 10.13
Quantity
22
* If the maximum operating temperature of the fluid exceeds its boiling point, please contact Head Office
** Not required when using an automatic back-flushing filter
*** This information is only required when using an automatic back-flushing filter
No
Group II
(Mines, methane
and / or combustible dust)
Category M
Category 1
Equipment
designed to
ensure a very
high level
of safety.
Operation
guaranteed
even in the
event of a rare
malfunction.
Equipment
designed to
ensure a high
level of safety.
Intended to be
de-energized
in event of
explosive
atmosphere.
G
(Gas)
(Zone 0)
Category 2
D
(Dust)
(Zone 20)
Equipment designed to
ensure a very high level
of safety. Designed for
environments where a
potentially explosive
atmosphere is to be
expected frequently or for
long periods.
G
(Gas)
(Zone 1)
D
(Dust)
(Zone 21)
Equipment designed
to ensure a high level
of safety. Designed for
environments where a
potentially explosive
atmosphere is to be
expected.
Category 3
G
(Gas)
(Zone 2)
D
(Dust)
(Zone 22)
Equipment designed to
ensure a normal level
of safety. Designed for
environments where a
potentially explosive
atmosphere is rarely
expected and then only for
a short time.
Medium
Explosion group
Medium
II A
II B
Flash point
II C
Ambient temperature
Temperature class
T1
450
T2
300
T3
200
T4
135
T5
100
T6
85
Pressurisation
Constructional safety
Flameproof enclosure
Liquid immersion
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23
Speichertechnik 30.000
Head Office
HYDAC Process Technology
GmbH
Electronics 180.000
Accessories 61.000
Global Presence.
Local Expertise.
www.hydac.com