Energy efficient exhaust air filter and heat recovery systems in die casting foundries

Clean air. Save energy.

During the casting process often occur greasy, oily and pasty smokes, which can quickly clog the filter when using unsuitable filter material and thus could result in high follow-up and exchange costs.

With the modular ULTRAVENT® System KMA Umwelttechnik GmbH offers an exhaust air filtration system especially developed for the foundry, which allows due to its cleverly harmonized elements the exact adaptation of the filter system to the needs of the foundry. In this way, dust, smoke, but also sticky or greasy aerosoles and various odours can be high efficiently filtered. Exhaust air filter systems of the brand ULTRAVENT® can be manufactured as decentralized filters (stand-alone solution) or centralized filters (connecting several machines to one filter station).

For a good fume capture the extraction devices are adapted to the machine dimensions and are delivered also according to the modular principle. ULTRAVENT® exhaust air filtration systems are guided by the high requirements of the German legislation concerning occupational safety (BG) and environmental protection (BImSchG).

Contact our expert team on air filtration for die casting machines


Kerem Kartal

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Less energy consumption means less costs.

Individual filter solutions for different requirements

The KMA ULTRAVENT® exhaust air filtration system is suitable for an operation in a circulating air as well as exhaust air mode. The question of which system is used, is decided by the individual needs of the company. The key is: Whether in the circulating air or exhaust air mode, KMA ULTRAVENT® filter systems reduce energy consumption for air purification in foundries by up to 85 percent and protect effectively the environment.

KMA ULTRAVENT® in air circulation mode with closed air extraction hood

Energy saving circulating air mode

ULTRAVENT® exhaust air filter systems enable the cleaning of hall exhaust air in energy-saving recirculation mode. Exhaust fans and high heat losses in the winter months are largely avoided in this way. The total energy consumption of conventional air handling systems is reduced by up to 85 % when using ULTRAVENT® air filtration systems.
ULTRAVENT® air filtration systems ensure clean air. This keeps buildings and machines cleaner – maintenance and cleaning costs are reduced. Since in many cases the filtered air is returned to the hall, there is often no need for cleaning-intensive exhaust pipes to the outside. At the same time, the heating costs of the building are significantly reduced.

KMA Ultravent® in exhaust air mode at the exterior of a building

Exhaust air mode with integrated heat recovery

If the filtered exhaust air is to be ducted into the open air the filter system can be expanded by a high efficient heat recovery system with integrated heat exchanger and if necessary with heat pump. The Filter System consists of demister and electrostatic filter. The electrostatic filter is really important in this case, because it ensures the high-grade separation of oily and greasy emissions as smoke, dust and mist and simultaneously the efficiency level of the heat exchanger. By means of the heat exchanger the energy is withdrawn from the warm exhaust air and transferred to the incoming ambient supply air. Improve your foundry’s carbon footprint by using a heat exchanger for highly efficient heat recovery.

Efficient smoke collection systems

The smoke collection near the emission source is decisive for the air quality in the production hall. In case of waste air extraction at the hall roof the waste air is first diffused inside the hall and could then be extracted only by the collection of a much larger exhaust air volume. The larger the exhaust air volume, the higher the energy consumption and thus the operating costs. Therefore the classic KMA method provides the selective smoke collection at the source.

For the selective collection of the smoke tailor-made hoods above the die casting machines are the rule, which is especially an advantage in case of large machine places. As the production processes must not be hindered, KMA extraction hoods can be moved aside, so that the area above the production machine is completely accessible. After the waste air extraction follows the waste air filtration. KMA offers as an alternative air curtain systems as well.

KMA Smoke collection bonnet and exhaust air filter system via pressure casting machine

Highly efficient smoke detection

For heavy-duty machines ULTRAVENT® extraction hoods are available in one and two-piece versions. If required, the regular or space-saving telescopic hoods can be moved aside, sliding on rails. The movement is carried out either manually or by a hood motor drive.

KMA Ultravent Air curtain system above die casting machine

Space-saving smoke detectors

Air curtain systems are used where limited space or other obstructions at the workstation will hinder the installation of extraction hoods. The KMA air curtain system consists of two elements: the blower unit that is attached to one end of the machine, generating an entirely adjustable horizontal air current above the source of emission. The second element is the extraction unit placed at the opposite end, receiving the air current including the contaminated air stream from the machine.
Air curtain systems usually require a higher extraction capacity than a comparable hood, because they do not have the possibility of buffering thermally rising fumes. However air curtains offer the advantage that the working area is not covered or obstructed by a suction device.

ULTRAVENT® exhaust air filter system – flexible and economic

KMA ULTRAVENT® electrostatic filter collectors extract impurities from the exhaust air stream.

ULTRAVENT® electrostatic filter cells assure the highly effective separation of smoke, dust, and fine mist. “Blue haze” caused by the use of release agents gets separated effectively as well. The filter cells are characterized by the particularly robust design: frame and carrying bars made of stainless steel, insulators in oil-resistant ceramics, optimized design for the separation of liquid or viscous substances. These features make sure that the electrostatic filter is an economical and durable filter medium for many applications. Often two categories of contaminants are captured in the electrostatic collection cell. One kind of the filtered substances is liquid, drips off the collection plates, and is collected in a recuperation tank. The oil separated here can often be reused. The second type forms a greasy, oily or encrusted deposit on the filter surface. Unsuitable filter types can quickly plug and become ineffective, leading to excessive costs associated with filter replacement and disposal. However, electrostatic precipitators never obstruct the air flow through the exhaust system.

An automatic filter cleaning system is available for many types of ULTRAVENT® emission control systems. It is suitable for cleaning all washable filter media such as demisters, electrostatic collection cells or UV light oxidation units. The automatic ULTRAVENT® washing system is unmatched in terms of comfort and cleaning results – due to its movable nozzle bar that moves back and forth above the collection cells during the filter washing process. It allows the regular and labour-saving cleaning of the filter cells and thus ensures minimal maintenance requirements. The intelligent control of the washing system simultaneously reduces the consumption of water and of purifying agents.

KMA ULTRAVENT® demister cells remove impurities from exhaust air

The ULTRAVENT® demister units consist of robust 50 mm thick stainless steel mesh wire elements. This wire is held in position by expanded metal mesh, both on the incoming and outgoing side of the gas flow. The special shaping of the wire allows for a high separating capacity for aerosols, droplets and mist. The units can be washed for cleaning. Changing the demister elements is not necessary.

Synchronisation of the spray cycle

Air conveying is one of the most significant energy consumers in production. Fans without frequency converters (FU) run permanently at 100 % power and are thus designed for the highest possible power requirement. In practice, however, only 70 – 90 % power is usually required, and even less if the load fluctuates.

KMA offers an alternative and, on request, synchronises the spray cycle of your die casting machine with the fans of our systems. This means that the speed can always be optimally adjusted, because even a small reduction in speed results in significant energy savings. The result is an additional energy cost saving potential of up to 40%.

KMA ULTRAVENT® Filters are characterized by the following features:

  • Cost-effective operation through wear-resistant filters and low energy consumption (usually the cleaned air flows back into the work area)
  • Minimised maintenance due to highly effective automatic filter cleaning
  • Flexibility through a modular system with many different sizes
  • Durability: filter housing and collection cells are made of stainless steel or aluminum

Due to the wide choice of filter media the KMA ULTRAVENT® System is very flexibly to use and is also suitable for high filter loading.

The KMA ULTRAVENT® exhaust system allows the highly efficient collection and separation of emissions like mist from release agents, oil mist, plasticizer fumes, and emulsion mist. Due to the special filter design liquid components (oil, emulsion, etc.) get discharged during operation. Adhesive substances can easily be removed by the optional automatic filter cleaning system.

In case of application in large scale machines (die casting machines, forging presses, etc.) extraction hoods, supports, and service platforms are available. A customised solution can be provided for any kind of machine.

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