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Oil & Mist Collectors
An industrial mist collector filters out harmful oil mist that is the byproduct of a manufacturing processe. A good example is oil mist that comes from CNC machines. That being said, water mist, oil and coolant mist can also be collected and filtered as well.
A coolant is necessary when milling or grinding metalwork. This is to reduce friction, which in turn improves the life cycle of machine tools. When a coolant is applied oil mist is created. When the temperatures are high the oil transforms to smoke.
Types of Mist Collectors?
There are (3) acceptable methods of mist collection. Understanding how each mist collector functions will help determine which one is best for the application.
- Media Based
- Electrostatic Precipitators
- Centrifugal Separators
Media Based Collectors
Media based collectors consist of a physical filter material. Whether it be metal, paper, synthetic, or some other material a physical barrier is involved. There are a variety of designs offering single stage and multi-stage solutions to best fit your needs.
Common types of media filters are drum, vee and cartridge. This is because they are typically of simple design, maintenance is equally simple. Media based collectors are an excellent choice for oil & coolant mist as well as light smoke.
Electrostatic Precipitators (ESP)
Electrostatic Precipitators are an electronic form mist and smoke collection. The system draws contaminated air across an arrangement of ionizers and collection plates. The ionizer section places a positive charge to anything coming across it and is then introduced to a series of negatively charged plates.
The combination acts like a dust / mist / smoke magnet. The true benefit to this method is that it does not care about particle sizes, it will place the positive charge to anything conductive that crosses its path and collect it accordingly.
The filters used are permanent filters and are cleaned and reused. Maintenance of this method is typically a bit more labor intensive to keep the system operating at a high level. Electrostatic Precipitators are an excellent choice for oil based mist and smoke.
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Centrifugal Separators
Centrifugal Separators utilize centrifugal force to separate the mist from an airstream. The contaminated air is drawn into the separator and introduced to a fast moving blade or cage. Once the mist has coalesced it is forced to the exterior walls of the housing pushed to a drain point. Initial maintenance of this system is simple and infrequent but does increase over time. Centrifugal separators are an excellent choice for oil based coolant mists. This system will not capture smoke. These (3) styles of collection offer a variety of designs with varying levels of efficiency. It is important that you choose a collector based on your application, byproduct and loading. This criteria will dictate the style and configuration of the collector you require.Methods of Capturing Mist
Source Capture
Anyone with any sense will tell you that source capture should always be your first choice. This allows you to capture the mist at the source, before it has had a chance to contaminate any other spaces. Equipment can be unit mounted, remote mounted, hooded or tapped directly into the machine allowing collection to take place where the mist is originated. Source capture allows you to accomplish more with less and should be used anytime that it is feasible.Ambient Capture
When the equipment does not allow for source capture another solution is ambient collection. A collector would be hung in the general space around a mist generating piece of equipment. The air moving through the collector would then draw a vacuum and remove the mist from the air.
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Why You Need a Mist Collector
A mist collector is used to save you money. It has several important tasks that result in a significant return on investment.
- Stop mist from becoming airborne
- Eliminate the buildup of oil, smoke and dirt on the walls, ceiling, floor
- Increased Employee safety
- Reduced maintenance
- Reduced fire risk
- Improved employee health
Mist collection is truly spending a dime to get a dollar. The benefits of a mist and smoke collector will provide you with a return on investment throughout its life.
By removing the mist and smoke from your facility you gain an increased indoor air quality providing a safe and healthy work environment (OSHA.gov source). Additionally you remove the oil from the building surfaces reducing the risk of accidents and damage to other expensive equipment.
Mist collection is truly spending a dime to get a dollar. The benefits of a mist and smoke collector will provide you with a return on investment throughout its life.
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Equipment that Generates Mist
There are many industrial machines that generate mist. Once you understand what type of machine you’re working with, how much mist and at what size particles it produces then you’ll be able to get a better idea of what is the best mist collector for your application.
Mist Collection for Metal Cutting Operations
Mills
Mills are typically used for drilling operations, such as boring, hobbing and honing. Mills use oil lubricants or water-soluble coolants that produce a mist 20 microns or less.
Turning
Metal applications such as turning are comprised of lathes, turning centers and screw machines. When the manufactured part rotates an oil or water-soluble coolant is sprayed on it. Not only does this lubricate the part being manufactured, but it also keeps it from overheating, removes debris and reduces defects. Turning mist is 20 microns or less.
Some turning mills run hot and produce smoke when using oil. Therefore a smoke rated filter is recommended.
Metal Grinding
Metal grinding mainly consists of surface, profile, centerless, and cylindrical grinding. Grinding metal generates heat and dust. Therefore water-soluble coolants keep it cool, provide lubrication and flushing the debris and dust. Metal grinding produces mist larger than 2 microns.
Heading & Stamping
Using metal to repeatedly hit another piece of metal using immense pressure results in a lot of heat, mist and smoke. Therefore a mist collector and other filters are necessary for heating and stamping metal operations. The typical size is .07 to 2 microns of oily mist and smoke.
Casting
When pouring molten metal into a die mold a lot of steam and fumes are generated. The fumes are necessary to control. The steam creates a lubricant that is half water and half paraffin wax. This steam becomes sludge like. Therefore, several filters are necessary for mist collecting metal casting. The water-soluble with wax is 2 to 50 microns. The metal fumes are much finer and less than 1 micron.
Mist Collection for Heat Treating
Heat treating, quenching, and annealing use a combination of heat and cool metal parts to reach the desired material asset. Water, brine and oil, are typically used to reduce the temperature of the metal parts. When cooling metal smoke, steam, metal scale and mist are emitted.
To collect these various mists, several filtration systems are necessary to manage solids or metal scales. The mist and smoke need a seperate filter. The water, brine and oil emit 0.8 to 5 microns of mist. Smoke is .07 to 1 micron. The metal scale and fumes are .5 to 2 microns.
Drawing Operations
Drawing operations produce heat and typically use water-soluble, soap-based, wax-based or straight oil. The water-based lubricant generates mist. The mist collectors require a decent holding capacity for solids.
Prefilters are recommended to remove the soaps and wax, which reduce the life cycle of the primary filter. The water-soluble mist is 1 to 20 microns. Oil is .5 to 2 microns and smoke is .07 to 1 micron.
Part Washing
Washing parts require steam, water mist & water vapor to remove lubricants, oils and greases. A substantial amount of water vapor and steam. Unfortunately, mist collectors cannot filter vapors, therefore a separate filter & media is required to collect that.
There are some part washing applications that use a rust inhibitor to prevent rust. These applications require a filter with depth-loading features. Not having one will reduce the life of the filter. The water mist from the vapor, steam and dropels emit up to 10 microns. The rust inhibitors emit 1 to 5 microns.
CNC Mist Collectors
CNC machining is a very common application requiring mist collection. CNC machines are used for a variety of metal cutting operations including mills, drills, grinding, lathes, plasma cutters, wet jet cutters and more. Additionally, because they are so versatile they are available in a variety of cabinet sizes and designs ranging from totally open to totally enclosed. One common factor across all of designs is that they are using some form of coolant and require mist extraction. The most common is a totally enclosed machine that bellows out a plume of mist and smoke when the main access door is opened. The mist collector selection considers the type of CNC machine being used, the style and speed of the cutting head, the type of oil or coolant the machine is using and the size of the machine and the open spaces. Knowing these details provides the information necessary to select a successful CNC mist collector. SHARE
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Mist Collector Installation Options
Machine-Mounted Systems
A machine mounted mist collector is the most common type of installation. The mist collector is installed right on to the machine that is generating the mist.
Ducted Single Machine Center
The mist collector can be mounted on the floor, mounted on to another object such as a wall or beam, or hung from the ceiling.Ducted Group Systems
Ducted Group Systems are a practical mist collection solution if there are several machines in a group or cell. A larger collector can service multiple machines utilizing the same type of coolant.
Ambient Mist Filtration System
When a plant, factory, warehouse, or any type of facility that produces mist that cannot be directly collected, an ambient mist filtration system is used. They are commonly used in combination with another mist filtration system to further purify the indoor air quality. They are a viable option when trying to meet federal, state or union air quality standards.
Mist Collector Installation Methods
When choosing a mist collector that best suits your needs, you should evaluate all factors to determine which system and technology to use.
Indoors vs Outdoors
Typically mist collectors are installed indoors. However, if you are considering installing it outdoors you should factor in some variables such as:
- Does the temperature outside ever drop below 32 degrees? If so, how often and when?
- Are you located in a residential area?
- Do you have a skilled maintenance worker on hand to care for the mist collector in case of weather damaging the electrical connections, seems, seals, pressure taps, etc?
Mist Collection Hooding Designs
There are some mist-collectors that require a hood. The design of the hood is important and depends on application it is being use for in order to properly filter the mist.
Hood Sizes
The hood size of the mist collector requires calculations by a skilled professional in order to collect as much mist as possible in an efficient manner.
Mist Collector Media Filters
Synthetic Filers
A commonly used material in media based mist collection is polyester. Polyester provides the most bang for the buck. Providing a moderate collection efficiency rate, high loading capacity with good drainage properties at a very reasonable cost.
Another commonly used material in media based mist collection is fiberglass. Providing a high collection efficiency rate, moderate loading capacity and moderate drainage properties at a very reasonable cost.
An upgraded synthetic media based filter option is a combination of polyester and fiberglass. This combination provides the best of both worlds offering high collection efficiency rates, high loading capacity and good drainage. These filters carry a higher cost than the other options but are well worth the investment.
HEPA & DOP Filters
A HEPA filter is commonly used as the final filter. HEPA is an acronym for High Efficiency Particle Air and is 99.97% @ 0.3 micron particle size (EPA Source).
95% DOP Filter is also used as a final filter. DOP stands for Dioctyl Phthalate. It is 95% efficient @ 0.3 microns. Larger particles can be more than 99% effective.
Both of these filters are very efficient and are the standard filters used to meet federal, state, local, corporate and union air standards. You can check out our complete line of filters here.
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