Nanofiber Coating - Elmarco · Performance benchmarking Nanofiber composite media provides higher...
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HVAC reference filter multi-layered nanofiber composite media with gradient density Properties Nominal face velocity Initial pressure drop Efficiency rating per ASHRAE 52.2: 2007 Efficiency rating per ASHRAE 52.2: 2007 App. J Dust holding capacity Media area Nominal dimensions (H x W x D) Filter type English 492 fpm 0.33 in wg MERV 15 @ 1968 cfm >95% MERV 15A @ 1968 cfm >95% 300 g @ 1.5 in wg 172 ft 2 24 x 24 x 12 inches High efficiency mini-pleat V-bank filter Metric 10 m/s 82 Pa F9 F9 300 g @ 375 Pa 16 m 2 610 x 610 x 305 mm High efficiency mini-pleat V-bank filter Elmarco works with its focus supply chains to take nanofiber products from concept to reality. By doing so we create reference designs and demonstrate perfor- mance of new products that make use of nanofibers from Elmarco’s best-in-class Nanospider™ machinery. Nanofibers in multi-layer composite media
Transcript of Nanofiber Coating - Elmarco · Performance benchmarking Nanofiber composite media provides higher...
Nanofiber CoatingPolymer selection based on application conditions
Solution and process optimization tomaximize production throughput
Tuning of fiber diameter and basisweight to meet performance targets
Scalable production of discharge durable nanofibers
Optimization of adhesion treatmentbased on final properties
.
.
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Composite MediaMaterial selection based on fiber properties, pore structure, basis weightand stiffness
Rapid prototyping of media to confirmperformance
Selection and optimization of the lamination and bonding processes
.
.
.
Final FilterDesign parameters of self supportedmedia
Selection and optimization of the ple-ating process
Media pleati design
.
.
.
Design parametres – potential for final product optimizationThe multilayer composite media concept offers designers by numerous design parameters to optimize their final filter design. Tomeet required performance, design parameters are can be optimized in all three main manufacturing stages:
HVAC reference filtermulti-layered nanofiber composite media with gradient density
Properties
Nominal face velocity
Initial pressure drop
Efficiency rating per ASHRAE 52.2: 2007
Efficiency rating per ASHRAE 52.2: 2007 App. J
Dust holding capacity
Media area
Nominal dimensions (H x W x D)
Filter type
English
492 fpm
0.33 in wg
MERV 15 @ 1968 cfm >95%
MERV 15A @ 1968 cfm >95%
300 g @ 1.5 in wg
172 ft2
24 x 24 x 12 inches
High efficiency mini-pleat V-bank filter
Metric
10 m/s
82 Pa
F9
F9
300 g @ 375 Pa
16 m2
610 x 610 x 305 mm
High efficiency mini-pleat V-bank filter
Elmarco works with its focus supply chains to take nanofiber products from concept to reality. By doing sowe create reference designs and demonstrate perfor-mance of new products that make use of nanofibersfrom Elmarco’s best-in-class Nanospider™ machinery.
Nanofibers in multi-layer composite media
Elmarco’s reference design demonstrates how nanofibers can be utilized within a composite structure to achieve optimium targets for pressure drop, efficiency, and capacity in gradient air filtration.Third party tests confirm that the filter media shows no impact from discharge for ASHRAE 52.2J or EN779 – the nanofiber layer survives an IPA and KCLchallenge and demonstrates mechanical filtration at pressure drop levels thatmatch electrets type media.The MERV 15 / F9 reference product demonstrates superior pressure drop and dust holding and outlines a path for media makers and filter manufacturers to further improve upon these results. The reference filter was made with commercially available materials using commonly used manufacturing processes.Typical applications of given HVAC filter: commercial buildings, hospitals, educational facilities, manufacturing and research facilities, airports, etc.
Polymer selection based on application conditions
Solution and process optimization to maximize production throughput
Tuning of fiber diameter and basisweight to meet performance targets
Optimization of adhesion treatmentbased on final properties
Nanofiber coating.
.
.
.
.
Material selection based on fiber properties, pore structure, basis weightand stiffness
Rapid prototyping of media to confirmperformance
Selection and optimization of the lamination and bonding processes
Composite media.
.
.
Design parameters of self supported media
Selection and optimization of the pleating process
Media pleat design
Final filter.
.
.
SUMMARY.
.
.
.
.
Design parameters – potential for final product optimizationThe multi-layer composite media concept offers designers numerous design levers to optimize their final filter design. To meet required performance, design levers can be optimized in all three main manufacturing stages:
CONTACT US: Europe: [email protected], Americas: [email protected], Asia: [email protected], www.elmarco.com
Elmarco © 2013. All rights reserved. The information in this document is subject to change without prior notice.
Key layer determining: Fine filtration (small particulates) High filtration efficiency and low pressure dropPrepared on needle-free NanospiderTM electrospinning technology
Capacity layer: Pre-filtration (large particulates), high dust holding capacity, prevents clogging Nanofiber layer: Fine filtration (small particulates), high filtration efficiency and low pressure dropStiffenning layer: Protects nanofibers and provides added rigidity and increases the stiffness of the composite media to be pleated and retain their pleats
Made of commercially available materials Using common pleating and lamination technologiesNo damage of nanofibers after pleating Discharge durable composite media that works on mechanical filtration principles
Performance benchmarkingNanofiber composite media provides higher dust holding capacity with better mechanical filtration efficiency atlower pressure drop.
Effect of nanofibers on operating costThe high specific surface area and porosity of the nanofiber structure provides low pressure drop with high filtration efficiency. Thus at $0.13 kWh cost, a filter user would save $50 / filter / year in operating cost.
ASHRAE 52.2 KCL
No efficiency drop after discharge procedureProven durability of nanofibers
Stiffenning layer: PET spunbond
Nanofiber coating: Nanospider™ Production Line NS 8S1600U
Lamination: Spray adhesive lamination
Pleating:Adhesive bead separator mini pleat
Assembling: Custom build
Capacity layer: PP meltblown
EXAMPLE PRODUCTION FLOW
Proven concept Feasibility of the concept is proven byreference filter project in all necessarydesign and manufacturing steps. Themulti-layer composite media concept offers designers by numerous designparameters to optimize their final filterdesign.
The information in this document is related to reference filter prototype only. The information in this document is related to reference filter prototype only.
High mechanical filter efficiencyIndustry leading low pressure drop
NANOFIBER COATING...
COMPOSITE MEDIA...
FINAL FILTER....
Discharge durable nanofibers..
.
.
0,60
0,50
0,40
0,30
0,20
0,10
0,00
300
250
200
150
100
50
00 500 1000 1500 2000 2500 3000
Airflow rate (cfm)
Annual operating cost per filter (USD)
Resistance (in WG)
Elmarco (reference)
Benchmark - 1
Benchmark - 2
Benchmark - 3
0,00 0,20 0,40 0,60 0,80
Initial resistance @ 2460 cfm
Resistance (in wg)
Elmarco (reference)
Benchmark - 1
Benchmark - 2
0 100 200 300 400
Dust holding capacity
DHC (gram)
Improvementup to 30%
Improvementup to 48%
Elmarco (reference) Benchmark - 1 Benchmark - 2
Air flow vs. Resistance @ 498 fpm
Particle size (micron)
Removal efficiency (%)
Elmarco (reference)
Benchmark - 1
Benchmark - 2
Benchmark - 3
0,00 0,10 0,20 0,30 0,40 0,50
Initial resistance @ 1968 cfm
Resistance (in wg)
100
95
90
85
80
Removal efficiency (%)
100
95
90
85
800 1 2 3 4 5 6 7 8 9 10
Particle size (micron)0,0 0,5 1,0 1,5 2,0 2,5 3,0
Efficiency vs. Particle size @ 492 fpm
EN779IPA
Efficiency vs. Particle size @ 5,3 cm/s
Improvementup to 18%
ASHRAE 52.2.: 2007ASHRAE 52.2.: 2007 Appendix J
Baseline mediaIPA liquid bath 1 min / 24 h
Key layer determining: Fine filtration (small particulates) High filtration efficiency and low pressure dropPrepared on needle-free NanospiderTM electrospinning technology
Capacity layer: Pre-filtration (large particulates), high dust holding capacity, prevents clogging Nanofiber layer: Fine filtration (small particulates), high filtration efficiency and low pressure dropStiffenning layer: Protects nanofibers and provides added rigidity and increases the stiffness of the composite media to be pleated and retain their pleats
Made of commercially available materials Using common pleating and lamination technologiesNo damage of nanofibers after pleating Discharge durable composite media that works on mechanical filtration principles
Performance benchmarkingNanofiber composite media provides higher dust holding capacity with better mechanical filtration efficiency atlower pressure drop.
Effect of nanofibers on operating costThe high specific surface area and porosity of the nanofiber structure provides low pressure drop with high filtration efficiency. Thus at $0.13 kWh cost, a filter user would save $50 / filter / year in operating cost.
ASHRAE 52.2 KCL
No efficiency drop after discharge procedureProven durability of nanofibers
Stiffenning layer: PET spunbond
Nanofiber coating: Nanospider™ Production Line NS 8S1600U
Lamination: Spray adhesive lamination
Pleating:Adhesive bead separator mini pleat
Assembling: Custom build
Capacity layer: PP meltblown
EXAMPLE PRODUCTION FLOW
Proven concept Feasibility of the concept is proven byreference filter project in all necessarydesign and manufacturing steps. Themulti-layer composite media concept offers designers by numerous designparameters to optimize their final filterdesign.
The information in this document is related to reference filter prototype only. The information in this document is related to reference filter prototype only.
High mechanical filter efficiencyIndustry leading low pressure drop
NANOFIBER COATING...
COMPOSITE MEDIA...
FINAL FILTER....
Discharge durable nanofibers..
.
.
0,60
0,50
0,40
0,30
0,20
0,10
0,00
300
250
200
150
100
50
00 500 1000 1500 2000 2500 3000
Airflow rate (cfm)
Annual operating cost per filter (USD)
Resistance (in WG)
Elmarco (reference)
Benchmark - 1
Benchmark - 2
Benchmark - 3
0,00 0,20 0,40 0,60 0,80
Initial resistance @ 2460 cfm
Resistance (in wg)
Elmarco (reference)
Benchmark - 1
Benchmark - 2
0 100 200 300 400
Dust holding capacity
DHC (gram)
Improvementup to 30%
Improvementup to 48%
Elmarco (reference) Benchmark - 1 Benchmark - 2
Air flow vs. Resistance @ 498 fpm
Particle size (micron)
Removal efficiency (%)
Elmarco (reference)
Benchmark - 1
Benchmark - 2
Benchmark - 3
0,00 0,10 0,20 0,30 0,40 0,50
Initial resistance @ 1968 cfm
Resistance (in wg)
100
95
90
85
80
Removal efficiency (%)
100
95
90
85
800 1 2 3 4 5 6 7 8 9 10
Particle size (micron)0,0 0,5 1,0 1,5 2,0 2,5 3,0
Efficiency vs. Particle size @ 492 fpm
EN779IPA
Efficiency vs. Particle size @ 5,3 cm/s
Improvementup to 18%
ASHRAE 52.2.: 2007ASHRAE 52.2.: 2007 Appendix J
Baseline mediaIPA liquid bath 1 min / 24 h
Nanofiber CoatingPolymer selection based on application conditions
Solution and process optimization tomaximize production throughput
Tuning of fiber diameter and basisweight to meet performance targets
Scalable production of discharge durable nanofibers
Optimization of adhesion treatmentbased on final properties
.
.
.
.
.
Composite MediaMaterial selection based on fiber properties, pore structure, basis weightand stiffness
Rapid prototyping of media to confirmperformance
Selection and optimization of the lamination and bonding processes
.
.
.
Final FilterDesign parameters of self supportedmedia
Selection and optimization of the ple-ating process
Media pleati design
.
.
.
Design parametres – potential for final product optimizationThe multilayer composite media concept offers designers by numerous design parameters to optimize their final filter design. Tomeet required performance, design parameters are can be optimized in all three main manufacturing stages:
HVAC reference filtermulti-layered nanofiber composite media with gradient density
Properties
Nominal face velocity
Initial pressure drop
Efficiency rating per ASHRAE 52.2: 2007
Efficiency rating per ASHRAE 52.2: 2007 App. J
Dust holding capacity
Media area
Nominal dimensions (H x W x D)
Filter type
English
492 fpm
0.33 in wg
MERV 15 @ 1968 cfm >95%
MERV 15A @ 1968 cfm >95%
300 g @ 1.5 in wg
172 ft2
24 x 24 x 12 inches
High efficiency mini-pleat V-bank filter
Metric
10 m/s
82 Pa
F9
F9
300 g @ 375 Pa
16 m2
610 x 610 x 305 mm
High efficiency mini-pleat V-bank filter
Elmarco works with its focus supply chains to take nanofiber products from concept to reality. By doing sowe create reference designs and demonstrate perfor-mance of new products that make use of nanofibersfrom Elmarco’s best-in-class Nanospider™ machinery.
Nanofibers in multi-layer composite media
Elmarco’s reference design demonstrates how nanofibers can be utilized within a composite structure to achieve optimium targets for pressure drop, efficiency, and capacity in gradient air filtration.Third party tests confirm that the filter media shows no impact from discharge for ASHRAE 52.2J or EN779 – the nanofiber layer survives an IPA and KCLchallenge and demonstrates mechanical filtration at pressure drop levels thatmatch electrets type media.The MERV 15 / F9 reference product demonstrates superior pressure drop and dust holding and outlines a path for media makers and filter manufacturers to further improve upon these results. The reference filter was made with commercially available materials using commonly used manufacturing processes.Typical applications of given HVAC filter: commercial buildings, hospitals, educational facilities, manufacturing and research facilities, airports, etc.
Polymer selection based on application conditions
Solution and process optimization to maximize production throughput
Tuning of fiber diameter and basisweight to meet performance targets
Optimization of adhesion treatmentbased on final properties
Nanofiber coating.
.
.
.
.
Material selection based on fiber properties, pore structure, basis weightand stiffness
Rapid prototyping of media to confirmperformance
Selection and optimization of the lamination and bonding processes
Composite media.
.
.
Design parameters of self supported media
Selection and optimization of the pleating process
Media pleat design
Final filter.
.
.
SUMMARY.
.
.
.
.
Design parameters – potential for final product optimizationThe multi-layer composite media concept offers designers numerous design levers to optimize their final filter design. To meet required performance, design levers can be optimized in all three main manufacturing stages:
CONTACT US: Europe: [email protected], Americas: [email protected], Asia: [email protected], www.elmarco.com
Elmarco © 2013. All rights reserved. The information in this document is subject to change without prior notice.
