High bulk coalescing filter media and use thereof

Abstract

A coalescence filter for purifying a fluid which contains a carrier and at least one liquid contaminant by coalescing of the at least one contaminant, where the coalescence filter includes an inlet for supplying the fluid to a filter element present in the coalescence filter, where the filter element includes a primary coalescence medium which is provided for coalescing of the at least one contaminant in the primary coalescence medium during the displacement of the fluid through the primary coalescence medium. The coalescence filter further includes an outlet for discharging the coalesced contaminant from the filter element, where the primary coalescence medium comprises at least one layer of a porous material, where the primary coalescence medium has a total thickness of at least 3.5 mm.

Claims

1. A coalescence filter for purifying a fluid which contains a carrier and at least one liquid contaminant by coalescing of the at least one contaminant, wherein the coalescence filter includes an inlet for supplying the fluid to a filter element present in the coalescence filter, wherein the filter element includes a primary coalescence medium which is provided for coalescing of the at least one contaminant in the primary coalescence medium during the displacement of the fluid through the primary coalescence medium, wherein the coalescence filter further includes an outlet for discharging the coalesced contaminant from the filter element, wherein the primary coalescence medium comprises at least one layer of a porous material, wherein the primary coalescence medium has a total thickness of at least 3.5 mm, measured at a pressure of 2N/cm.sup.2, and wherein the primary coalescence medium has a density of between 0.08 and 0.50 g/cm.sup.3.

2. The coalescence filter according to claim 1, wherein the primary coalescence medium has a thickness of 50 mm at a maximum.

3. The coalescence filter according to claim 1, wherein the pores in the primary coalescence material have an average pore diameter of between 2 and 100 μm.

4. The coalescence filter according to claim 1, wherein the primary coalescence medium has an air permeability of at least 30 l/m.sup.2.s.

5. The coalescence filter according to claim 1, wherein the primary coalescence medium has an air permeability of 20001 l/m.sup.2.s at a maximum.

6. The coalescence filter according to claim 1, wherein the primary coalescence medium includes a plurality of layers of a same porous material.

7. The coalescence filter according to claim 1, wherein the primary coalescence medium includes one or more layers of a first coalescence medium and one or more layers of a second coalescence medium, which is different from the first coalescence medium.

8. The coalescence filter according to claim 7, wherein the first coalescence medium is wetting with respect to the contaminant to be coalesced, and the second coalescence medium is non-wetting with respect to the contaminant to be coalesced.

9. The coalescence filter according to claim 1, wherein the primary coalescence medium is made of one or more layers of a porous fibrous material, which substantially includes fibers of an average diameter of 0.25-20 μm.

10. The coalescence filter according to claim 1, wherein the coalescence filter includes a layer of a drainage material, preferably adjacent to and along a downstream surface of the primary coalescence medium along which coalesced contaminant exits the primary coalescence medium, for receiving and draining the coalesced contaminant.

11. The coalescence filter according to claim 10, wherein the drainage layer is manufactured of a thermoplastic or thermosetting plastic, an organic or inorganic material, a metallic material or a metal alloy, or a blend of two or more of said materials and chemically modified forms thereof.

12. The coalescence filter according to claim 1, wherein the coalescence filter includes a layer of a protective material, adjacent to and along an upstream surface of the primary coalescence medium along which the fluid is supplied to the primary coalescence medium.

13. The coalescence filter according to claim 1, wherein the primary coalescence medium is manufactured from a material chosen from the group of wetting or non-wetting, hydrophobic, hydrophilic, oleophobic or oleophilic fibrous materials or a blend of two or more thereof.

14. The coalescence filter according to claim 1, wherein the primary coalescence medium is manufactured from an oleophilic or an oleophobic fibrous material or a blend thereof.

15. A coalescence medium for use in a coalescence filter according to claim 1.

16. A method for purifying a fluid which contains a carrier and at least one contaminant, wherein the fluid is conducted through a coalescence filter according to claim 1, for reducing the concentration of the at least one contaminant by coalescing of this contaminant in the coalescence filter.

17. The method according to claim 16, wherein the fluid is chosen from the group of compressed air contaminated with one or more hydrocarbons, contaminated water or contaminated hydrocarbons.

18. The method according to claim 16, wherein the at least one contaminant belongs to the group of liquids, aerosols, macro drops or mixtures of two or more of these materials.

19. The method according to claim 16, wherein the supply of fluid to the coalescence filter is continuous and wherein at least a fraction of said fluid is supplied to the coalescence medium at an angle of 1 to 90°.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The invention is further elucidated below in the appended figures and the description of these figures.

(2) FIG. 1 shows a view of the inner volume of a representative coalescence filter for compressed gas.

(3) FIG. 2a is a schematic cross section of a primary coalescence medium, relative to a drainage layer, with a carrier fluid (CF) being supplied at an angle of 90° and the coalescence medium and the drainage layer arranged adjacently.

(4) FIG. 2b is a schematic representation of a primary coalescence medium, relative to a drainage layer, with a carrier fluid (CF) being supplied at an angle of between 1° and 90° and the coalescence medium and the drainage layer arranged adjacently.

(5) FIG. 3 shows a cross section of a quasi-continuous channel formed in the primary coalescence medium, as is shown by a higher concentration of deposited liquid.

(6) FIG. 4 shows an isometric view of a plurality of quasi-continuous channels formed in the primary coalescence medium, as is shown by regional areas exhibiting a higher concentration of deposited liquid.

(7) FIG. 5 is a graphic representation of the pressure drop of a carrier fluid through a coalescence medium including wetting (oleophilic) fibers according to this invention, given a carrier fluid flow with deposition of a liquid, oil-containing contaminant, as a function of time.

(8) FIG. 6 is a graphic representation of the pressure drop of a carrier fluid through a coalescence medium including oleophobic fibers according to this invention, given a carrier fluid flow with deposition of a liquid contaminant, as a function of time.

DETAILED DESCRIPTION OF THE INVENTION

(9) The coalescence filter 10 shown in FIG. 1 includes a closed housing 24 with a filter head 12 at the top. Filter head 12 includes an inlet 16 via which a fluid containing a carrier liquid and at least one contaminant is introduced into the coalescence filter. The housing 24 includes an outlet 18 for discharging a fluid and/or carrier liquid which has flowed through the filter element. Filter head 12 is detachably connected with housing 24, so that the inner space of the coalescence filter is accessible for replacement of the filter element if necessary. The detachable connection can be effected in any manner considered suitable by the skilled person, for instance, by means of a threaded connection, by means of pressure, friction, clamping, etc. Inlet 16 is connected with a filter element in such a manner that a fluid can be passed to the filter element. The filter element is preferably detachably connected with the filter head 12, so that the filter element can be replaced periodically, or can be replaced if necessary.

(10) The coalescence filter shown in FIG. 1 is intended for coalescing one or more liquid contaminants present in a liquid or gaseous carrier of a fluid. The one or more contaminants can be, for instance, an inert or reactive substance. The one or more contaminants may, for instance, belong to the group of liquids, aerosols, macrodrops or mixtures of two or more of these materials. An example of a fluid suitable for use with the coalescence filter of this invention is compressed air, contaminated with an oil aerosol.

(11) The filter element includes at least one primary coalescence medium 22, for coalescing in the coalescence medium one or more liquid contaminants present in the fluid and separating these contaminants from a carrier present in the fluid. Depending on the intended application, especially if coalescence of a plurality of contaminants is intended, it may be chosen to install two or more different primary coalescence media, each with a desired affinity for the contaminant to be removed.

(12) In a preferred embodiment, the filter element additionally includes, adjacent to the coalescence medium 22 and downstream from the coalescence medium 22, at least one porous drainage layer 30. This drainage layer is positioned adjacent to a surface of the coalescence medium, with or without a layer of air or other physical separation between the two media, preferably without a layer of air. Purpose is to enable an energy-efficient flow of fluid, carrier and/or contaminant from the coalescence medium to the drainage layer. This is shown in FIGS. 2a and 2b. The drainage layer is mostly arranged downstream of the primary coalescence medium.

(13) A drainage layer 30 positioned downstream is intended to maximize the transfer and delivery/discharge of the contaminant separated from the fluid by the primary coalescence medium due to the motive force of the fluid and/or the carrier present therein which is conveyed through the filter, on the one hand. Materials that enable this are known to the skilled person. The material of the drainage layer 30 preferably also provides a barrier to resist reflux of the coalesced contaminant back to the primary coalescence medium 22 but, in particular, to the carrier. Without wishing to be bound by this, it is supposed that the drainage layer 30 provides a boundary or transitional zone for the adjacent surface of the coalescence medium 22, which counteracts any build-up of coalesced contaminant on this contact surface in that it stimulates the formation of macroscopic drops of the contaminant liquid. These drops are thereupon driven off the drainage layer 30 by an additional motive force, such as gravity, and, for instance, deposited or precipitated in the housing and discharged from the filter. If desired, two or more drainage layers 30 may be provided. An example of a suitable material is an open cell polymeric foam.

(14) If desired, upstream but also downstream of the primary coalescence medium 22, a protective layer 25 may be provided. This protective layer 25 can also serve as a drainage layer, or direct the fluid flow in a desired direction. An example of a suitable material for use as a protective layer 25 is an open polypropylene layer, but other materials can also be used. Preferably, the filter element also includes a core 20. The at least one primary coalescence medium 22 is arranged downstream of the filter core 20.

(15) The coalescence filter 10 preferably includes one or more internal support structures 26, which support integration of the filter element into one mechanical whole, which minimize the risk of mechanical deformation of the filter materials including the coalescence medium 22, under the influence of loading by the fluid, and protect same against the action of unexpected or momentary impact.

(16) The housing 24 may further include a drainage mechanism 32. A suitable drainage mechanism 32 can include automatically, semiautomatically or manually operated valves, via which a coalesced and drained contaminant retained in the housing is removed.

(17) The coalescence filter 10 can further include optional components, which further improve the use and the yield of the filter. Filter head 12 can include, for instance, a status indicator 14, which gives an indication about the status of the coalescence filter, including the potential necessity for a periodic replacement. The status indicator 14 may be provided for directly or indirectly measuring the yield of the coalescence filter and may include an indicator providing indicia of the condition of the coalescence filter 10, by means of, for instance, a visual, auditory or electronic signal or a combination thereof. The indicator 14 may work pneumatically or electrically or according to any principle considered suitable by the skilled person.

(18) The primary coalescence medium 22 used in the coalescence filter of this invention has a porous structure, which can induce aggregation or coalescence of one or more contaminants present in the fluid. The surface of the pores present in the porous structure of the primary coalescence medium may be wetting with respect to one or more of the contaminants to be coalesced, or non-wetting. The surface may be, for instance, oleophobic or hydrophobic, or oleophilic or hydrophilic. In applications where removal of oil from a liquid or gas stream is intended, the coalescence medium can be oleophilic or oleophobic. The material for the primary coalescence medium 22 is preferably so chosen as to have a high affinity for the impurity to be removed.

(19) To make it possible for contaminants of a various nature to be removed in succession, the coalescence filter of this invention can include two or more primary coalescence media 22 of different affinity selective for the contaminant to be removed. Preferably, however, to keep the capillary pressure as low as possible, the coalescence filter includes just one primary coalescence medium.

(20) The primary coalescence medium is a porous material which can include one or more layers of a porous material, and is preferably layered. The primary coalescence medium is preferably made up of one or more layers of a same layer-form fibrous material. In an alternative embodiment, the coalescence filter includes two or more filter elements with different coalescence media, i.e., a plurality of coalescence media of different affinity selective for the contaminant to be removed.

(21) Suitable layer-form materials for use as primary coalescence medium 22 comprise substrates or materials comprised of finite length fibers, continuous filaments and combinations thereof. The primary coalescence medium preferably includes suitable materials which are resistant to the pressure applied to enable displacement of the fluid through the primary coalescence medium, to the liquid contaminants present in the fluid, and to the static and dynamic loads to which the material is exposed during the manufacture of the filter, assembly thereof, and use thereof. Examples of suitable layer-form fibrous materials include woven or nonwoven fibrous materials, knitted materials, plaiting, films, and combinations of these materials or laminates or composites thereof.

(22) The primary coalescence medium is preferably a multilayered material, which preferably includes at least 4 layers, more preferably at least 6 layers, most preferably at least 10 layers. Mostly, the number of layers of fibrous material will not be higher than 20. The thickness of the individual layers of the coalescence medium is not critical for this invention and may vary within wide limits. The thickness of a layer can be, for instance, a thickness of 0.4 mm, 0.5 mm, 0.6 mm, 0.75 mm or 1 mm. On the other hand, the primary coalescence medium may also be made up of one layer of the desired material, in the desired thickness.

(23) A multi-layered primary coalescence medium can be produced in different ways, for instance, by stacking, pleating, rolling or wrapping a plurality of layers of a fibrous material, so that the desired number of layers is obtained. However, any other method can be suitably used. The layers of the fibrous material are preferably arranged adjacently relative to each other, such that a layer of air of a least possible layer thickness is present between adjacent layers. Preferably, adjacent layers are so arranged that no layer of air is present between them. This can be obtained, for instance, by pressing a plurality of stacked layers together or clamping them, for instance along one or more sides of the fibrous material. Preferably, however, the fibrous material is wrapped, to keep the risk of damage minimal.

(24) Examples of fibrous materials that are particularly suitable for manufacturing a layered material for use in the primary coalescence medium of this invention comprise thermoplastic materials, thermosetting materials, organic or inorganic materials, metallic materials or alloys, admixtures, blends and chemically modified materials, for instance manufactured by drawing, spinning, needling, hydroentanglement, melt spinning (for instance, spin bonding, nanofibers, melt blowing), wet-laying, electro-spinning, solvent spinning, point bonding, adhesive bonding, continuous weave/knit, casting, co-extrusion, etc. Materials of particular preference comprise glass fibers, silicate-based wet-laid thermosetting adhesive bond nonwoven fabrics, for instance, a borosilicate glass fiber of finite length, because of their thermal and hydrothermal resistance to loading by the fluid, the carrier liquid and the contaminant, without the need of chemical modification, for instance by a fluorocarbon surface treatment.

(25) Primary coalescence media suitable for use in this invention have a density which preferably varies between 0.05-0.90 g/cm.sup.3, more preferably 0.05-0.75 g/cm.sup.3, most preferably 0.08-0.50 g/cm.sup.3. Materials having a density of between 0.10-0.25 g/cm.sup.3 or 0.12-0.17 g/cm.sup.3 can also be suitable and be preferred for well-defined fluids and/or contaminants.

(26) The average diameter of the pores present in the material which the primary coalescence medium is made up of (measured with microscopy) is preferably in the range of 2 to 100 μm, preferably between 3 and 70 μm, more preferably between 5 and 50 μm, most preferably between 5 and 35 μm, in particular between 5 and 30 μm.

(27) Materials for use in the drainage layer 30 can be, for instance, woven or nonwoven materials, knitted materials, films, open cell foams, cast or spun scrims, open meshes and combinations of laminates or composites of the aforementioned materials. Materials for use in the drainage layer 30 may be chosen, for instance, from the group of thermoplastic or thermosetting plastics, organic or inorganic substances, metallic materials or alloys, blends of the aforementioned materials and chemically modified forms thereof. The aforementioned materials can be manufactured in any manner considered suitable by the skilled person, for instance by drawing, spinning, needling, hydroentanglement, melt spinning (for instance, spin bonding, nanofibers, melt blowing), wet-laying, electro-spinning, solvent spinning, point bonding, through-air bonding, adhesive bonding, continuous weave/knit, casting, coextrusion, expansion, solvent cast and the like. Particularly preferred are polyurethane foams, since they are well resistant to thermal loading by the fluid and/or the carrier and contaminant liquid present in the fluid, but at the same time counteract return of the contaminants, for instance hydrocarbon-based contaminants, to the coalescence medium, without the necessity of pretreating one or more parts of the coalescence filter or the drainage layer with fluorine-containing substances.

(28) The primary coalescence medium 22, the drainage layer 30 and the barrier layer can be assembled in the coalescence filter 10 as separate layer-form materials. It is also possible, however, to unite the aforementioned materials in a laminate, so that they form a whole, and optimum contact between adjacent layers is ensured and optimum flow of fluid from one layer to the next can take place.

(29) This invention provides the advantage that the primary coalescence medium is made up of one or more porous layered materials or structures having a high bulk volume and low density, with a large pore volume, the pores having a relatively great average pore diameter. Such an open structure makes it possible to keep low both the capillary pressure and the channel pressure in the transport of the fluid and the coalesced contaminant through the primary coalescence medium and to keep the pressure drop across the coalescence filter low. Capillary pressure is understood to refer to the resistance that a contaminant must overcome to enter a non-wetting coalescence medium, but also the resistance that a contaminant must overcome upon exiting a wetting coalescence medium. Channel pressure is understood to refer to the resistance that a coalesced contaminant must overcome in its displacement through the pore system of the coalescence medium.

(30) The coalesced fractions of the liquid contaminant typically appear in the coalescence medium as quasi-continuous channels with an increased concentration of coalesced liquid. These channels form discrete, perceptible areas which extend through the thickness of the filter material as is shown in FIG. 4. The motive force of the carrier which is forcibly transported through the coalescence filter, for instance by pumping, takes care of the transport of the contaminants through the coalescence medium towards the outlet or the rear, downstream outer surface of the primary coalescence medium, where the contaminants as a liquid fraction have reached a sufficient aggregation to leave the carrier as macroscopic drops under the influence of gravity. It is supposed that the relatively large pores, the low density and high air permeability of the primary coalescence medium of this invention cooperate to enable a dynamic development of quasi-continuous channels during the useful life of the filter and to minimize the pressure drop across the filter.

(31) Without wishing to be bound by this theory, it is supposed that it is possible that upon a first contact of a fluid, for instance compressed gas, with the primary coalescence medium 22, a first population of distinct quasi-continuous channels 50 is formed. As additional fluid is supplied, the accessibility of one or more of the quasi-continuous channels 50 may lessen due to the formation of aggregates or immiscible complexes, gelling, and occlusion by solids and/or particles in these channels. Upon continued inflow of fluid, it is possible that a quasi-continuous channel 50 develops in a different direction of the primary coalescence medium 22, along a pathway of lesser resistance. Thus, new quasi-continuous channels may form. Without wishing to be bound by this hypothetical model, it is supposed that upon transport of a compressed flow of, for instance, air containing oil aerosol as contaminant, through a primary coalescence medium, transport proceeds through one or more quasi-continuous channels 50. In these channels 50 an effective reduction of the amount of oil in the air is brought about by coalescing of the oil in these channels 50.

(32) FIG. 5 shows a practical situation for a coalescence medium made up of an oleophilic fibrous structure. The inventors have established that coalescence of a liquid contaminant from the fluid proceeds according to a stepwise process, with at least a first and second discrete step, each discrete step being associated with a decrease of the pressure across the coalescence medium. A second discrete step was observed when the contaminant leaves the coalescence medium and is associated with an energy barrier which must be overcome upon leaving the coalescence medium for overcoming a force of attraction. A first discrete step was observed upon the movement of the contaminant through the coalescence medium in the form of one or more quasi-continuous channels in that the liquid must be pumped through the coalescence medium.

(33) FIG. 6 shows a practical situation for a coalescence medium made up of an oleophobic fibrous structure. The inventors have established that coalescence of the liquid contaminant from the fluid is accompanied by a stepwise pressure decrease across the coalescence medium, with at least a first and second discrete step. A first discrete step occurs upon the contaminant flowing into the coalescence medium for overcoming the repulsive force. A second small discrete step occurs upon the transport of the contaminant through the coalescence medium through one or more quasi-continuous channels.

(34) This invention thus provides a coalescence filter with a coalescence medium comprising a plurality of layers of a fibrous material with pores of a relatively great average diameter, through which the fluid with carrier and at least one contaminant move. The fibrous material has a high air permeability, a low density and contains a pore system whose pores have a relatively great diameter. This makes it possible to provide a primary coalescence medium that ensures a higher separation yield of a contaminant present in the fluid. This higher separation yield is accompanied by a considerable reduction of the capillary pressure that is to be overcome by the fluid upon flowing into or exiting from the coalescence medium, but also by a considerable decrease of the channel pressure, that is, the pressure to be overcome in the transport of the fluid and the coalesced contaminant through the pore system of the primary coalescence medium. As the pressure drop across the coalescence medium can be reduced, the energy requirement of the filter system can be improved considerably. This invention thus provides a coalescence filter having an improved separation yield in combination with a reduced energy requirement. This is surprising since in the prior art systems an improved separation yield adversely affects the energy requirement.

(35) With the coalescence filter of this invention, in particular when employed as coalescence filter for a compressed air stream, a separation yield for contaminant liquid present in the air can be obtained of at least 40 μg liquid per m.sup.3 carrier fluid or carrier gas per 1.0 mbar pressure difference, preferably at least 44 μg, more preferably at least 46 μg.

(36) The invention is further elucidated in and by the examples below.

(37) The fibrous materials specified below were tested as coalescence filter for purifying oil-contaminated air, as described in ISO 12500-1 and ISO 8573-2. The initial oil concentration was 10 mg/m.sup.3.

(38) Comparative experiments A-B

(39) A filter material was used comprising the specified number of layers of a conventional, commercially available oleophobic filter material with properties as specified in Table 1.

(40) TABLE-US-00001 Average Total Wet Maximum pore thickness Air pressure oil Number diameter coalescence permeability drop transfer of layers (μm) medium (l/m.sup.2.Math. s) (mbar) (mg/m.sup.3) Efficiency A 5, 4.7   4 mm 43 283 0.023 92 flat layers, oleophilic B 5, 8.2 2.75 mm 109 133 0.12 77.5 flat layers, oleophobic

Examples 1-2

(41) A coalescence medium was used comprising 14 and 8 layers, respectively, of oleophilic and oleophobic glass fiber material, respectively, having the material properties as specified below. The permeability to air was determined according to DIN EN ISO 9237.

(42) TABLE-US-00002 TABLE 2 Average Total Wet Maximum pore thickness Air pressure oil Number diameter coalescence permeability drop transfer of layers (μm) medium (l/m.sup.2.Math. s) (mbar) (mg/m.sup.3) Efficiency 1 14, 8.2 7.70 mm 109 212 0.008 98.9 flat layers, oleophilic 2 8, 15.9 5.12 mm 210 110 0.203 79.6 flat layers, oleophobic

(43) From the comparison of Example 1 with Comparative experiment A it appears that the filter efficiency of a thick, open package of filter material is better than that of a thin, closely stacked package. The pressure drop across the thick open package even appears to be lower.

(44) The comparison of Comparative experiment B with Example 2 shows that the filter efficiency is similar for a thick, open package and a thin, densely packed package. However, the pressure drop across the thick open package is lower than the pressure drop across the thin densely packed package