Exhaust air filtration systems for forging presses
Clean air. Save energy.
The extremely high friction within the forming process imply the common use of cooling lubricants (KSS). As a result, oil mist driblets develop during the cold and hot forming operation due to the evaporation of the cooling lubricants (KSS). In order to reduce this oil mist in the exhaust air effective smoke extraction measures and air filter systems are necessary.
Energy efficient air purification of oil mist is essential for the purpose of achieving the relevant emission limits for forging presses.
The KMA ULTRAVENT® filter system has been developed to address the challenges of forges and presses which emit greasy, oily and pasty smokes and oil mists during production.
The ULTRAVENT® air filter system is available in individual modules with capacities of 1.000 m³/h to 20.000 m³/h. Thanks to its modular design there are also large filters cells with over 100.000 m³/ h capacity ready for application.
The functional concept of KMA air filter systems is based on the energy efficient electrostatic filter cells. This is the economic alternative to mechanical filters since it reduces the energy costs of forging presses and convinces with high grade separation of exhaust air emissions.
KMA ULTRAVENT® air filter systems operate – depending on the actual construction – with a 2 or 3-step filter structure. The functional principle of the KMA filter and the different available filter operating modes are explained below. In addition to that our air filter systems are equipped with an automatic filter cleaning system which minimises the maintenance effort and expenditure.
Lower energy consumption means lower costs.
Oil smoke in forging, hardening plants, oil baths and metal forming
- Forging hammers
- Oil hardening plants
- Hot-Air Leveling Machinery
- Soldering units
- Welding systems
- Laser cutting units
- Other originators of fine oil mist or other air pollution
Exhaust air mode or circulating air mode?
The KMA ULTRAVENT® exhaust air filtration system for forging presses is suitable for an operation in a circulating air mode as well as exhaust air mode. During the circulating air mode the filtered air is redirected in the production hall. Here the high separation efficiency of the electrostatic filter cells is mandatory. During the exhaust air mode the filtered air is directed outside. By means of a heat exchanger the exhaust heat can be recovered and used for subsequent processes. To increase the energy efficiency of the heat recovery system a combination with an additional Ambitherm® Heat Pump is possible.
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 forging presses by up to 80 percent and protect effectively the environment.
ULTRAVENT® exhaust air filter system – flexible and economic.
Filter modules for the separation of smoke, dust, mist and vapours at forging presses and forming machinery.
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.
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.
The ULTRAVENT® modular system offers a wide range of mechanical filter cells for almost any application. They are available as a pre-filter (filter class G), as a powerful main filter (filter class F), and as a HEPA filter (filter class H) with enormous precipitation performance. Special filter cells (e.g. with drainage fabric for emulsion separation) are available for many applications.
Please ask our consultants for the suitable KMA cell for your appliance.
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® 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.