High-grade separation of oil and emulsion mists on CNC machining for metal processing
Oil and emulsion mist filter for CNC machinery
On modern processing machinery the pollution in form of oil smoke and emulsion mist is substantial.
Due to the high rotation speeds and the associate strong heat development on the processing machinery (such as drilling, milling, turning, honing and grinding machines) the intensive application of cooling lubricants (cutting fluid) is common which have to be separated.
The associated dispersed aerosols, oil and emulsion mist – resulting from evaporation of the cooling lubricants (cutting fluid) – pose a severe challenge to the industrial safety:
- Micro-fog remains in the processing hall and contaminates the machinery equipment and commodities
- Increased fire risk
- Increased risk of slippages
- Health risk to employees
In order to reduce this air pollution effective smoke extraction measures and air filter systems are necessary. Energy efficient air purification is essential for the purpose of achieving the relevant emission limits for processing machinery.
The solution: KMA ULTRAVENT® air filter system for seperation of oil smoke and emulsion mist
ULTRAVENT® is the modular waste air filtration system by KMA. Its sensibly adapted elements allow for accurate adjustment of the filter system to meet requirements of your processing machinery facilities.
KMA ULTRAVENT® is characterised by high grade separation performance, energy efficiency and durability. Even extreme applications such as sticky, oily or greasy smoke can or continuous use in a three-shift-operation is mastered effortlessly by KMA air filter systems.
Thanks to the low energy consumption as well as the low-wear operation not only the operating costs are diminished but also the carbon footprint of the company is substantially improved.
Lower energy consumption means lower costs.
Central or decentral?
ULTRAVENT® air filter systems enable the central or decentral smoke extraction from the processing machinery.
KMA offers decentral solutions for an exhaust air volume of 1.000 m3/h to 5.000 m3/h or central solution concepts for processing CNC centres with an air volume flow of 5.000 m3/h to over 100.000 m3/h.
Large central smoke extraction systems offer various advantages for big air volumes: Thanks to the integrated fully-automatic KMA filter cleaning system (CIP) and the highly efficient heat recovery system, the efficiency of the filter modules is assured while maintenance effort and energy consumption of the processing machinery is minimised.
Exhaust air mode or circulating air mode?
The KMA ULTRAVENT® exhaust air filtration system for processing machinery 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 processing halls by up to 80 percent and protect effectively the environment.
KMA ULTRAVENT® air filter systems can – thanks to its flexible 2- to 3-step filter structure – be configured with electrostatic precipitator and/or demister or mechanical filter according to the client’s requirements. Based on its unique construction and the air flow optimised design of the filter cells KMA electrostatic precipitators are particularly suited for the separation of dripping filtrates.
Filter systems with air volume capacity of 5.000 m3/h can be optionally equipped with an automatic filter cleaning system in order to minimise the maintenance effort. In light of the increased exposure to fire hazard during the extraction of oil smoke all KMA systems are available with fire sensors and fire extinguishing systems as an option.
ULTRAVENT® exhaust air filter system – flexible and economic
The KMA filter module for separation of oil and emulsion mist
The KMA ULTRAVENT® air filter system enables the highly effective collection and separation of emissions such as release agents, oil smoke, softener vapours and emulsion mist. There are three different types of filter modules available which can be combined with each other.
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.
When using KMA exhaust air filtration systems at machines with fire potential, all KMA systems are optionally available with fire detectors and fire extinguishing system. In the case of fire the system is flooded with extinguishing gas and further damages can be avoided.
KMA ULTRAVENT® Filters are characterized by 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.