The Value of Specialty Manufacturing Equipment in ... - Filtration News

I N T E R N A T I O N A LFILTRATIONNEWSSeptember/October 2010Volume 29 No. 5www.filtnews.comYour Global SourceThe Value of Specialty ManufacturingEquipment in a Competitive MarketA Special Report from Chase Machine & EngineeringIn MemoriamWells Shoemaker 1922-2010A Special Tribute to an Industry LeaderIndustry NewsChina’s Filtration andSeparation IndustryStrongly GrowingFiltration | MediaPlasma ProcessingChanging Filtration

Editorial Advisory BoardEditorial Board ChairmanEdward C. Gregor, ChairmanE.C. Gregor & Assoc. LLCTel: 1 704 442 1940Fax: 1 704 442 1778ecg@egregor.comM&A, Filtration MediaHaluk Alper, PresidentMyCelx Technologies Corp.Tel: 770.534.3118Fax: 770.534.3117alper@mycelx.comOil Removal – Water and AirPeter S. Cartwright, PECartwright Consulting Co.cartwrightconsul@cs.comMembranes, RO,UltrafiltrationWu ChenThe Dow Chemical CompanyTel: 1 979 238 9943Fax: 1 979 238 0651Process Filtration (liquid/gas)Equipment and MediaPeter R. Johnston, PETel/Fax: 1 919 942 9092ddandp3@aol.comTest proceduresJim JosephJoseph MarketingTel/Fax: 1 757 565 1549josephmarketing@verizon.netCoolant FiltrationGerard J. Lynch, PESigma Design Co., LLCTel: 1 973 912 7922Fax: 1 973 912 5244gjlynch@sigmadesign.netFiltration Machinery &Product DesignDr. Ernest MayerDuPont Co.Tel: 1 302 368 0021Fax: 1 302 368 1474ernest.mayer@usa.dupont.comGeneral Solid/Liquid Separationsin All AreasRobert W. McilvaineTel: 1 847 272 0010Fax: 1 847 272 9673mcilvaine@mcilvainecompany.comwww.mcilvainecompany.comMkt. Research & Tech. AnalysisHenry Nowicki, Ph.D. MBATel: 1 724 457 6576Fax: 1 724 457 1214Henry@pacslabs.comwww.pacslabs.comAbsorbent Testingand TrainingBrandon Ost, CEOFiltration GroupHigh Purity Prod. Div.Tel: 1 630 723 2900bost@filtrationgroup.comAir Filters, Pharmaceuticaland Micro-ElectronicDr. Graham RidealWhitehouse Scientific Ltd.Tel: +44 1244 33 26 26Fax: +44 1244 33 50 98rideal@whitehousescientific.comFilter and Media ValidationAndy RosolGlobal Filtration Products Mgr.FLSmidth Mineralsandy.rosol@flsmidth.comTel: 1 800 826 6461/1 801 526 2005Precoat/Bodyfeed Filter AidsGregg PoppeThe Dow Chemical CompanyTel: 1 952 897 4317Fax: 1 942 835 4996poppeg@dow.comIndustrial Water, Power,and Membrane TechnologyTony ShucoskyPall MicroelectronicsTel: 1 410 252-0800Fax: 1 410 252-6027tony_shucosky@pall.comCartridges, Filter Media,MembranesScott P. YaegerFiltration and SeparationTechnology LLCTel/Fax: 219-324-3786Mobile: 805-377-5082spyaeger@msn.comMembranes, New Techn.Wells ShoemakerAdvisory BoardMember EmeritusDr. Bob BaumannAdvisory BoardMember Emerituswww.filtnews.com • October 2010 • 3

Industry | EventsWorld-Leading Lineup forFiltration Society Conference in U.K.By Ken Norberg, EditorPore size measurement of a filter using glass calibration microspheres.The Filtration Society’s 2010(U.K.) annual conference andexhibition has once again attractedan impressive array of speakerswho are world leaders in their fields. “FilterTesting 5 – millimeter to nanometer”takes place October 13, 2010 in Chester,U.K., and will be preceded by a short4 • October 2010 • www.filtnews.comcourse and workshop on October 12 forthose new to filter testing, or who wishto further develop their knowledge inthis field.Conference organizer Dr. GrahamRideal of Whitehouse Scientific is particularlypleased with the enthusiasticresponse he has received from those invitedto present. “The Filter Testing seriesof conferences has been runningfor more than 10 years and continuesto grow,” he said. “Once again I am delightedthat we have been able to attracta great line up of speakers. What’smore, a number of those presenting themain conference sessions are alsoteaching the pre-conference shortcourse, providing attendees with aunique learning opportunity.”The main conference begins withtwo plenary presentations in whichMark Crooks of TSI, U.K., will present“A review of ISO standards in relationto the dry testing of filter media – theenvironmental driving force,” andChristope Peucheot of IFTS, Francewill discuss “Validation of liquid filtertest methods and equipment.” Havingset the scene, the rest of the conferenceis largely focused on the latest testmethods and equipment. The remainderof the morning will be devoted toadvances in pore size distributionanalysis (Danny Pattyn, Benelux Scien-

tific) and analysis of surface area andpore size in the nanometre range (MikeTucker, Quantachrome).After lunch there is a look at filtertesting by nanoparticle tracking analysis(Bob Carr, Nanosight), real-timemeasurement of the available absorptioncapacity of activated carbon cloth(Andrea Smith, Chemviron Carbon),the use of microsphere standards to determinefilter cut points and pore sizedistributions (Graham Rideal, WhitehouseScientific), and essential improvementsfor a reliable fractionalefficiency test of filter media and filters(Sven Schutz, Palas).A trade exhibition running alongsidethe conference will also feature a“technology burst” session in which exhibitorsare given the opportunity tomake 5-10 minute presentations abouttheir products or services – an efficientmeans of introducing delegates to allthat is available at the trade show.In summing up the significance ofthe conference, Dr. Rideal noted, “Recentenvironmental issues have reallybrought a wider recognition of theimportance of filter technology,whether we’re talking about protectingaircraft from volcanic ash or filteringsand from deep sea oil wells.Much has also been spoken about thereal or potential effects of nanoparticleson the environment and the importanceof filtration. Our focus onfilter testing provides insight into theperformance of filter media and helpsguide people in correctly specifyingproducts that are appropriate for theirapplications.”ABOUT WHITEHOUSE SCIENTIFICWhitehouse Scientific is a leadingproducer of glass microspheres for calibrationand is the highest-ranking Europeancertification laboratory forprimary methods of particle size analysis.The company’s standards cover allparticle-sizing techniques includinglaser diffraction, Coulter methods, opticalsizing, sieve calibration and imageanalysis. Most of these reference materialsare NIST-traceable. They range insize from 0.1 micron to 5.0 millimetersand are available as single sizes orbroad distribution standards. In addition,Whitehouse offers a unique calibrationprocedure for NIST-traceablemeasurement of filter apertures between3 and 1000 microns, and alsoproduces general-purpose researchgrade microspheres.Whitehouse Scientific has been producingcalibration microspheres formore than 25 years. Founder and managingdirector Dr. Graham Rideal is apast chairman of The Filtration Society,and is now active as its Science Correspondent.He is also a member of theEditorial Advisory Board of InternationalFiltrationFNNews.For more conference information visit:www.filtsoc.orgFor company information contact:Dr. Graham RidealTel: +44 (0) 1244 332626Fax: +44 (0) 1244 335098Email: info@whitehousescientific.comWebsite: www.whitehousescientific.comwww.filtnews.com • October 2010 • 5

In MemoriamWells Shoemaker1922 - 2010A Personal Tributefrom Ed Gregor6 • October 2010 • www.filtnews.comIcannot think of anyone, who is more highlyadmired or has done more for the Americanfiltration industry than Wells Shoemaker whopassed away July 25, 2010. When consideringthe names of giants in filtration, Wells ranks withthe best of them, even though he never ran a filtrationmanufacturing company or invented anyfiltration media, filter or system. What separatedWells were his persona, exceptional industryleadership and organizational abilities, but whattruly set him apart was he made everyone whomet him feel important. You appreciated his easyway, the warmth of his personality, and his abilitywith a few words or a nod to convince you tohelp him with whatever filtration endeavor hewas pursuing at the time. I learned this first handwhen I met Wells for the first time. He and HarrySandsteadt walked into my office at Gelman Sciencesin 1983. Within 15 minutes I found myselfagreeing to give a presentation at a filtration conferencebeing held in three weeks, and much tomy surprise volunteered to be on a committee ofthe American Program Committee, the predecessorto the American Filtration & Separations Society.It didn’t seem to matter that I had apending trip to Europe and was reorganizing afaltering business unit that occupied all my time.I’ve since learned, when Wells had an idea, anyidea, somehow everyone wanted to be part of it,and I was no exception.After graduating from Cornell University with achemical engineering degree, Wells served in theU. S. Navy for 4 years. Following World War II,Lieutenant Shoemaker’s career began with early employmentat American Enka and Johnson and Johnsonwhere he was first exposed to filtration. Hislifelong devotion and enthusiasm for filtration wascemented when he joined Eaton-Dikeman (nowAhlstrom Filtration) in Mt. Holly Springs, PA in

1965. From his position in technical sales and responsibilitiesto sell filtration media, his natural abilitiesblossomed and begin what would be fourdecades of leadership, planning skills, passion anddedication in organizing countless filtration Conferencesand Filtration Days across the United States.In 1981 Wells left Eaton-Dikeman to form his ownconsulting company, Filterex, Inc. Now on this own,Wells really went to town, promoting industry educationwhile building a wide following of active participants,individuals, companies and competitorsalike at a torrid pace throughout all of Filterdom, aterm he coined and liked to use. He organized numerousevents, Conferences and Filtration Days inMonterey, Williamsburg, Princeton, Valley Forge,Hersey, Flint, Ocean City and many other locations,as many of us fondly recall. His Membrane Conferencesin conjunction with the BCC began in 1982and, under his guidance for almost 20 years, was theforemost membrane conference of the industry.Wells always was ready to plow new ground. In 1991he ran a conference titled “The Pore” with FrankTiller and Ted Meltzer contributing. Consider hisimagination. Who would ever think to organize aConference to discuss the Pore…not the media, butonly the hole and get over 120 people to attend. Beginningin the early 1960s through the mid-1980sWells organized many Filtration Society regionalchapters under the American Program Committeeon behalf of the Filtration Society in the U.K. Chaptersgrew like mushrooms as leading filter expertswere recruited or “co-opted” to manage new chaptersfrom New England, the Mid-Atlantic, Chicagoand Dixie and then on to California, with 11 activechapters – all this while managing his filtration mediaconsulting business, which flourished in spite of allthe time he devoted to his passion of bringing the industrytogether. You always saw the light side ofWells at every conference, including his talk on thewww.filtnews.com • October 2010 • 7

“The Filtration Pill,” and what good it does for youif you swallow it. He organized and sang barbershopas part of the “Un-Filterable Four” at many a conference,and once Wells even arranged a local highschoolband to parade in with trumpets anddrummers filling the room with march music duringa networking reception. Something new and unexpectedalways provided a lasting memory.For his skills, the Filtration Society in the U.K.elected Wells as the first of only two [ever] InternationalFiltration Society Chairmen. Followinghis exemplary leadership as Chairman, the FiltrationSociety awarded him the first World FiltrationCongress to the United States, held inDowningtown, PA in 1982. Again, Wells steppedforward to organize the event, which still remainsthe standard by which all World Congresses arejudged. However, in the mid-1980s relations betweenthe Filtration Society and the AmericanProgram Committee began to deteriorate to thepoint of ultimately culminating in the foundingof the American Filtration & Separations Society(AFS) in 1987 as a separate stand-alone Society. Iclearly recall the day wefounded the Society andI suggested we considercreating CorporateSponsorships. Immediately,Wells took out hispen and wrote somethingon his businesscard and handed it tome, which I still keeptoday. It read: “OneCorporate Membership.I.O.U. $1,000.” Len Ortinowas sitting to myleft and said, “Count mein as well.” Before the

day was out, I had corporate promises of $5,000!Wells never sought credit or held any office in theAFS, but was always there as a contributor, evenat the age of 85. Wells and Don Olds teamed up inNovember 2007 to run a Conference in Knoxville,where he drew the who’s who of the industry asspeakers. Wells still had that same old magic andreceived a stellar Conference review and as usualand most importantly, his lovely wife of 66 years,Sara, was at his side as she has been for over theyears at virtually every industry event. Even inretirement, Wells organized. It was just part of hisDNA. As Scott Yaeger said recently, “Wells undoubtedlyis organizing the Heaven Filtration Societyat this time.” When he and Sara moved toSparta, NC from Fairfield, PA in early 2007, at theage of 85 and shortly after heart surgery, Wellsfounded the Sparta Newcomers Club, and helpedwrite and participated in several plays as part ofthe local community theater group. His organizationalskills were honed with many years workingwith local church groups, and the Rotary Clubwherever he and Sara lived over the years.Wells Shoemaker is the Father of the AmericanFiltration and Separations Society. He fostered moreinterest in filtration and separations at any level thanany individual I know. Today, filtration and separationsis a true growth industry with annual growthat 4-6 percent per year above GDP, whether theeconomy is up, down or sideways. The steady handof Wells Shoemaker has surely played a role in helpingto achieve this success. Wells was an idea manarmed with charm, wit and an innate ability to bringpeople together for a common cause and have funwhile doing it––everything about him was quality.Wells left all of us with a great industrylegacy and he will forever be remembered in theannals of Filterdom. We all salute him and extendour sympathies to his wife Sara and all theShoemaker Family.FN

Filtration | MediaPlasma Processing Changing FiltrationBy Stephen Coulson, Ph.D., Chief Technical Officer, P2iPlasma processing of filtration media can increase oil and water repellency while maintaining pore size distribution and airflow.Membrane and nonwovenfilters are widely used bythe industry to separatesolids from liquids or gases. Filterscan range from the conventional,such as simple dust filters for air intakes,to the critical,such asdialysis filters toprevent kidneyfailure. In fact,there are morethan 50 filters in asingle car. Theworldwide filterindustry is expectedto expand5.6% through2010 to a value of$45 billion.Filtrationmedia is generallyselected based onreasons of cost,ease of processingand performancerequirements.Many differentmaterials can beused, but wherefilters are intendedfor repeateduse, it isvitally importantthat integrity and10 • October 2010 • www.filtnews.comconsistency of pore size is retainedthroughout a product’s lifetime despitethe often harsh environmentsthey are exposed to, including cleaningprocesses.In order to achieve this level of reliability,reusable filtration mediahave traditionally been made fromhighly resistant and rigid polymers,such as polyvinylidene fluoride(PVDF) and polytetrafluoroethylene(PTFE). However, these materialstend to be fairly costly and wouldstill benefit from complex chemicalfinishes to add further performancebenefits. A more desirable scenario,therefore, would be to use cheaper,easily formed filter media and thenmodify the surface using an additionalprocess to impart the desiredliquid resistance.Thanks to the pioneering work ofP2i and its revolutionary liquid repellentnano-coating, it is now possibleto enhance alternative, moresustainable filtration media – such ascellulose or nylon – to a level thatmatches, or exceeds, the performanceof traditional, more expensivematerials that are more difficult towork with. Indeed, using the widelyaccepted American Association of

Filtration | MediaP2i’s technology can enhance the performance of a wide range of filter media andcomplete filtration systems.Textile Chemists and Colorists conventions,P2i’s nano-coating has beenshown to create filters with the maximumlevels of liquid repellency inboth the AATCC 193-2007 water repellencytest (resisting 100% isopropylalcohol) and the AATCC118-2007 oil repellency test (resistingn-heptane).Using a special pulsed ionized gas(plasma), which is created within avacuum chamber, the patented P2itechnology attaches a nanometerthinpolymer layer over the entiresurface of a product. This dramaticallylowers the product’s surface energy,so that when liquids come intocontact with it, they form beads andsimply run off.In filtration media, the P2i nanocoatingincreases oil and water repellencywithout affecting the material’sbulk properties or pore size distribu-12 • October 2010 • www.filtnews.com

Filtration | Mediation and, therefore, airflow. It hasalso been shown to exhibit improvedcake release, no pressure drop or decreasein water entry pressure and alower replacement frequency, meaningless waste. This allows productsto perform at a much higher level ina wide range of application sectors,including biosciences, industrial processing,laboratory testing, food &beverage, electronics and water treatment,as well as opening up new applicationsaltogether.A PROBLEM SOLVEDP2i’s technology is genuinely revolutionaryfor filtration because itsolves so many of the industry’s traditionalchallenges. For example, untilnow the choice of filter material hasusually been dictated principally bydesirable bulk physical properties andease of processing. In many cases,however, this has led to a compromisein material surface properties, whichmay not be ideal for the intended use,requiring treatment with complexchemical formulations and high curingtemperatures. In turn that has ledto manufacturing processes that arepower hungry, time consuming, andlimited to specific materials that willwithstand the chemicals and high curingtemperatures involved. Theseprocesses are expensive and can havesignificant environmental impacts.P2i’s technology, by contrast, islow-energy, solvent-free and usesonly tiny quantities of protectivemonomer, resulting in minimal wasteand no adverse impact on the environment.Plus, because the nanocoatingis applied within a vacuumchamber, there is no release to theenvironment during processing and,since the nano-coating is molecularlybonded to the product, there is nowash off, leachables or extractables.COMPONENTS TO ASSEMBLIESIn addition to enhancing filtrationmedia, P2i’s technology is alsoequally effective at treating the oftencomplex structures they are formedinto. For example, filter media aregenerally manufactured in 2D formthough rarely used in this format.The sections required are cut into thedesired shapes and configured into elementscontained in housings. Thesecan be used to form a larger system inorder for the filter element or systemto perform the desired function.Because P2i’s protective polymer isformed in a gas plasma, it permeatesevery exposed surface of finished filterstructures, meaning that the membranemay be treated while sealed ina permanent housing. It also meansthat the same chemistry can be impartedto a wider range of media, includingsurface and depth filtermedia, woven and nonwoven textiles,14 • October 2010 • www.filtnews.com

membranes and media combinationscreated to form a filter medium, elementor system format. Other associatedbenefits are increased liquidprotection and greater working efficienciesin harsh environments,which in turn translates into benefitssuch as longer filtration life, higherperformance (in terms of reducedpressure drop and higher particle captureefficiency), and pleatability.COST-EFFECTIVEIncreasing environmental concerns,demands for product cleanlinessand the growing need forcontaminant reduction in sectorssuch as electronics, and medical andbiological industries means the marketfor filters is growing rapidly.P2i’s liquid repellent nano-coatingtechnology allows reusable filtrationproducts to perform at a much higherlevel in their intended applicationthrough increased oil and water repellencywithout affecting airflow,porosity or other crucial indicators,such as cake release. Furthermore,this multi-patented innovation iscost-effective and environmentallyfriendly for enhancing cheaper filtermediums, such as cellulose or nylon,without compromising performance.Both the wide variety of filtermedia and the complex structures involvedmake the P2i enhancementprocess highly sought after. The companyis already working with some ofthe world’s leading filtration manufacturersand has been providingprocessed media into the marketFNplace for more than six years.About the AuthorStephen Coulson, Ph.D., is the Chief TechnicalOfficer of P2i. Mr. Coulson invented theP2i technology while carrying out his Ph.D.at Durham University on ‘Liquid repellentsurfaces’. He was consequently employedby the MoD to set up a plasma capabilityand further scale-up the patented technologyfor industrial applications. In 2001, Mr.Coulson moved into project managing theUK Nuclear Biological and Chemical clothingprogram, but continued to exploit theplasma technology for a range of commercialapplications. Mr. Coulson was thefounding member of P2i when it was formedin January 2004 and has more than adecade’s experience in advanced materialsciences and plasma processing.Visit us online: www.filtnews.comBack Your Filters BetterExtensive Range of Expanded Metals & Polymers Perfect for membrane support & backing Assures media integrity & pleatspacing even under dynamic flow Materials laminate for co-expansion/contraction/flex Openings down to25 micron Thickness: 0.001”to 0.2”Dexmet Engineerswelcome the challengeof your unique materialsand applicationsCustom-ExpandedMaterials from203 294 4440 www.dexmetfilter.comwww.filtnews.com • October 2010 • 15

Cover Story | Chase Machine & EngineeringThe Value of Specialty ManufacturingEquipment in a Competitive MarketHVAC Pocket Filter Line improves quality and reduces defects with ultrasonic bonding.Modular design allows customers immediate market entrance at a reduced cost.Every equipment supplier hasspecial capabilities and ChaseMachine & Engineering Inc. isno exception. Equipment is traditionallyof a commodity nature or speciallydesigned to accommodate particularmanufacturing needs. Specialty equipmentsuppliers such as Chase Machineare often asked to suggest better conceptsto enable lower processing costsor the manufacture of products withunique capabilities. Experience andknowledge of the industry and customermanufacturing processes are importantaspects in bringing suchconcepts to reality.DIFFERENTIATION IS THE KEYWithout question, product differentiationis the most important offering acompany can provide to its customers.Chase Machine differentiates itself in anumber of ways beyond simply offeringcompetitive pricing. They include:•All products are made in ChaseMachine’s manufacturing plant in theUnited States.•In-house engineering capabilitiesemploying state-of-the-art 3-D solidmodeling software, combined withweb handling and pick and placeautomation expertise, sets thecompany apart in most cases.•Filtration product design concepts,which allow customers to successfully sell against competition – that’swhat 56 years of business experienceand talented employees can provide.•Custom engineered equipment andmanufacturing processes that permitcustomers to gain market sharethrough manufacturing efficiencyand low-cost production.•Vertical integration, includingelectrical panel building and PLCprogramming, machining, weldingfabrication, painting and finalmachine assembly ensures fullcontrol from both a quality anddelivery standpoint.•Process filtration equipment maderight the first time.•Reliable and superior processes onthe shop floor – as only an operationmanager and the CFO can truly16 • October 2010 • www.filtnews.comappreciate, sometimes “good enough”is not good enough.EQUIPMENT NEEDS HAVE SHIFTEDThe shift from conventional glassand cellulose filtration media to syntheticnonwoven meltblown, spunbondand needlepunch fabrics hasopened the door for the introductionof new and exciting assembly methods.Technologies such as ultrasonics,hot air, band sealing, RF andimpulse welding are becoming commonpractices within the industry.Engineers now select media not onlybased on filtration performance criteria,but also on assembly preference.Needle and threads combinedwith adhesives are slowly beingphased out – why incorporate anothercomponent (and expense) intothe final product, especially whenthere are safer and more environmentallyfriendly alternatives?

Liquid Filter Bag Machine produces awide range of products for varying filtrationneeds, including needle punchand spunbound/meltblown filter media.Single Position Ultrasonic Ring Welderallows maximum operator efficiency withergonomic engineering practices, and isdesigned to be safe and operator-friendly.SYNTHETIC NONWOVENS - GROWTHChase Machine & Engineering hasembraced the move from conventionalfiltration media to synthetic nonwovens.Heat sealing technologies, whenincorporated into a continuous process,can reduce labor and maintenance expensessince consumables such as adhesivesor sewing supplies are nolonger required. While it is understoodthat some filter requirements call forthe use of cellulose and glass fibers thatrequire adhesives and/or sewing, applicationsthat lend themselves to the useof synthetic media have generated excitingnew assembly alternatives.The liquid filter bag market presentsan excellent example of multiple technologiescombining within the sameprocess to improve manufacturing performance.Employing hot air welding,Chase Machine joined the two edges ofa needlepunch fabric to create a tube ona continuous basis. At the same time,the company integrated Ultrasonics tocut and seal the bottom of the filter,freeing the end product of loose fibersand contaminants. The process gavethe end user complete control whilecutting labor expenses by more than50% and eliminating the need for ancillaryconsumables. What’s more, thefinished bag could be joined to a plasticring using ultrasonic plunge weldersand eliminating the conventionalsewing method for attachment.Ultrasonics is also commonly usedin the synthetic HVAC filtration market.Chase Machine was instrumentalin this transition with the developmentof the extended HVAC pocket filter machine,which was designed, built andpatented incorporating ultrasonic technologyinto the continuous assemblyprocess. Nonwovens manufacturers realizedthe importance of designingmedia for use with Ultrasonics. In theearly years of development, consistencyand uniformity across wide meltblownand spunbond lines was a challenge.The finished product, while suitable forthe filtration application, varied in itsdistribution of fiber. Although thisnever became an issue when sewing,ultrasonic welding required greateruniformity and consistency.In the membrane market, nonwovensare chosen for their strength as a supportsubstrate. The synthetic component ofthe nonwovens affords the end user theability to splice membranes together oreven attach multiple layers to improvefiltration characteristics. Ultrasonics, impulsewelding, or even simple bar sealingtechnologies may be incorporatedinto a process line. Chase Machine’s experiencewith membrane casting andhollow fiber process lines helps customersdecide which technology suitstheir specific application best. Then theysubstantiate their conclusions in theChase Materials Applications Lab.CUSTOMER TESTING LABIn response to this need, Chase Machineestablished a Materials ApplicationsLab, which enables companies totest materials and assembly methods beforecommitting to full production.Working with some of the largest filtrationmedia manufacturers in the world,Chase Machine has run thousands ofwww.filtnews.com • October 2010 • 17Chase Machine’s Materials ApplicationLab allows customers to test materialsand assembly methods.feet of media to verify process improvements.Many of these improvementshave gone on to benefit the marketplace.MEMBRANE AND HOLLOW FIBERSChase Machine is an important supplierin the rapidly growing area of hollowfibers and flat sheet membranes,building equipment ranging from singlefiber lab scale pilot lines, to large-scaleproduction systems. Hollow fibers andflat sheet membranes are highly efficient,offering greater flow rates, andlower differential pressure and energyrequirements. Chase works hand inhand with customers to understand thestrict design and manufacturing specificationsrequired to make their particularmachinery. Like its nonwoven filtermanufacturing equipment, Chase Machine’shollow fiber and flat sheet membraneprocess capabilities rely uponmany years of building equipment andprocesses confidential to each customer.CONCLUSIONToday’s filtration industry is constantlyevolving. Ongoing improvements tochemistry and manufacturing processesoffer infinite possibilities for new productdevelopment. With companies such asChase Machine offering testing, prototypingand full-scale process solutions, thetransition from concept to final product isFNnow faster than ever before.For more information contact:Chase Machine & Engineering, Inc.324 Washington StreetWest Warwick, RI 02893Tel: 401-821-8879 Fax: 401-823-5543Website: www.chasemachine.comMADE IN USA

Industry | NewsChina’s Filtration and Separation Industryto Grow as Country Cleans up EnvironmentBy Jason Chen, China CorrespondentChina faces serious environmentalproblems due to thefast growing economy. It isthe largest carbon dioxide (CO 2 ) emitterin the world and its emissions ofsulfur dioxide (SO 2 ) and chemical oxygendemand (COD) reached, respectively,23 million and 30 million metrictons in 2007.To reduce pollution and protectthe environment, China has set targetsto reduce 10% of its SO 2 emissionsand COD emissions by 2010from 2005, and reduce CO 2 intensityby 40% to 45% from 2005 to 2020. Atthe same time, the Chinese economywill keep on growing over the nextdecade. As a result, the Chinese filtrationand separation industry is enteringa sizeable growth-period.FILTRATION AND SEPARATION INDUSTRYAccording to Professor WangYanxi and Dr. Yao Gongbi of CFS(Chinese Filtration Society), China’sfiltration and separation industry hasa total market scale of more than 150billion Yuan ($22 billion): more than60 billion Yuan for air pollution control,more than 50 billion Yuan forwater purification and waste waterdisposal, and approximately 25 billionYuan for solid-liquid separationof industrial production.China’s filtration and separation industrycan satisfy more than 90% of thedemand from the domestic market. Theremaining 10% are mainly importedfrom the United States, West Europeand Japan.There are more than 2,000 companiesin the Chinese filtration and separationindustry. Most of thecompanies are based in the YangtzeDelta Area (Shanghai, JiangsuProvince, Zhejiang Province andAnhui Province), Pearl River Delta(Guangdong Province), and BohaiGulf Area (Beijing, Tianjin, LiaoningProvince and Hebei Province).18 • October 2010 • www.filtnews.com

Market details for the Chinese filtrationand separation industry:1. Filtration machinery market.This market amounts to 20 billionYuan. Chinese companies’ mainproducts include –Pressure filter: Chinesemanufacturers can produce plateand frame filter, recessed platefilter, pressure leaf filter, automaticpressure filter, and candle filter.Currently they don’t produce rotarypressure filter (BHS); Vacuumfilter: Chinese manufacturers canproduce horizontal belt filter,tilting pan filter, table filter, drumfilter, and disc filter; Chinesecompanies also produce beltpressure filter for mining selectionand silt dewatering.2. Separation machinery market.This market amounts to 19 billionYuan. Chinese companies’ mainproducts include –Solid-gas separation machines suchas cyclone separator; Solid-liquidseparation: Chinese manufacturerscan produce horizontal pushercentrifuge, siphonicscraper-unloaded centrifuge,vertical axis basket centrifuge withautomatic discharge, horizontalscroll discharge decantercentrifuge, top-suspensory-basketcentrifuge, tubular centrifuge, discseparator, centrifugal extractor, andhydrocyclone.3. Bag filtration.This market amounts to 14 billionYuan – more them 4 billion Yuan forfilter media. The growth rate ofhigh-temperature resistant bag filterwill exceed 20% each year. Chinacan produce sintered metal net,metal fiber felt and ceramic filtermedia (tube, plate or other forms).Currently there are more than 100nonwoven producers engaging in theproduction of filter media in China.4. Membrane filtration products.This market amounts to more than10 billion Yuan. Currently China stillneeds to import a lot of membranefrom the United States and othercountries.5. Filters & cartridges.This market amounts to morethan 10 billion Yuan. China is thelargest filters & cartridgesmanufacturing center in the world.6. Filter media. This marketamounts to more than 10 billionYuan. The processing measuresinclude: woven, nonwoven,wet-laid (paper-making), metalsintering, and composite(lamination, coating, andimpregnation).Visit us online:www.filtnews.comFNwww.filtnews.com • October 2010 • 19

FiltrationMergers, Acquisitionsand DivesturesGL Capital, LLCPreview | FILTECH 2011FILTECH 2011 Expecting anIncrease in Exhibitors and VisitorsWe understand the nuances ofthe domestic and internationalfiltration industry and bringover 70 years of combinedbusiness, technical and financialexpertise. The current economicclimate is an ideal timefor sellers to locate buyersseeking to diversify and forbuyers to identify growth opportunitiesthrough acquisition.Rhein-Main-Hallen in Wiesbaden, Germany, is once again the location forFILTECH 2011. Among the international exhibitors are A2Z FiltrationSpecialists (top left) from Gurgaon, India.For a confidential conversation contact:Edward C. Gregor704-442-1940ecg@egregor.comP. John Lovell719-375-1564glcapital@comcast.netWith all five halls of morethan 7,400 square metersfilling up the FILTECH2011 tradeshow in the Rhein-Main-Hallen in Wiesbaden, Germany, it isonce again becoming a guaranteed successfor the vast Filtration and SeparationIndustry in Europe. The FILTECHshow expects a 40 percent increase inexhibitors and 25 percent more visitors.Besides this, the scheduled FILTECH2011 Conference, which takes place atthe same location, is currently ready topresent 200 technical papers.In short, it seems that from March22 – 24, the beautiful town of Wiesbadenwill once again become the centerpoint for all European filtration andseparation experts.European machinery and equipmentproducers will provide the largestnational group of exhibitors at theshow, however, ample participation ofcompanies from both Asia and theAmericas will ensure that visitors willbe offered a growing international perspectiveon technical innovationsacross the entire filtration and separationprocessing sequence.The FILTECH 2011 CONFERENCEis promising to becoming the educational20 • October 2010 • www.filtnews.complatform of the year for the industry.Once again there will be a strong focuson the latest advances and techniques inliquid/solid and gas/particle separation(dust, gas & air filtration) over a 3-dayperiod. At this moment the organizers ofthe conference are still inviting engineers,managers, researchers and scientists tojoin them in Wiesbaden to present theirlatest findings to the worldwide Filtrationand Separation Community. The topicsare fundamentals, equipment and strategiesto “Solid-Liquid-Separation” by filtrationand sedimentation, as well as “Airand Gas Cleaning” by filtration, settling,electrostatic precipitation, scrubbing and“Membrane Separation Technology”.International Filtration News’ upcomingNovember/December issuewill further preview this importantEuropean event.FNTo discuss your attendance atFILTECH contact:Filtech Exhibitions GermanyPO Box 12 2540637 Meerbusch - GermanyTel: +49 2132 9357 60Fax: +49 2132 9357 62Email: info@filtech.deWebsite: www.filtech.de

Product | NewsGlobal Filter Launches New GTCHBSeries Band Clamp Cartridge Vessel LineEarly in 2009 Global Filter,LLC began a broad marketstudy to understand thetrends and needs for various filter vesselsin both the North American andEuropean Marketplaces. Global Filterhad already begun making marketshare gains with the launch of itsASME designed bag and cartridge vessels.However, with the addition of a30,000 square foot vessel facility inCedar Rapids, Iowa, there was amplespace and capacity to evaluate the potentialof other stainless vessel lines.In late 2009 Global Filter realizedthat there was a real market demandfor an improved version of the existingband clamp style vessels beingmarketed by Watts Flowmatic, Shelco,and several other companies. With thegoal of offering an improved “drop-inreplacement”for these units, GlobalFilter launched its GTCHB SeriesBand Clamp Vessel Line.While looking to improve thequality and durability of the “bandclamp” style vessels, the companyknew it was essential to keep anidentical footprint to what was alreadybeing sold in the marketplace.In addition, after discussions withmany OEM buyers of band clampstyle units, they learned of severalimprovements that were needed. Indeveloping the GTCHB Vessel Line,Global Filter listened to what themarketplace was saying and incorporatedthe following features into theirnew GTCHB line:•Heavier wall thickness for amore robust unit•Improved lid sealing by using theoptimum lid profile•DOE/222 Universal Cups arestandard on all GTCHB Vessels•All units accept 2.5” wound andmeltblown cartridges in addition to2.7” pleated cartridges•Legs are standard on all unitsWith the state of today’s economyand pressure on many OEM’s to limitinventory costs, Global Filter determinedthat a key to success with theGTCHB Vessel Line would be rapidshipment from inventory. With thisgoal in mind, Global purchased a30,000 square foot vessel and trainingfacility and now maintains astock of over 300 vessels ready forFNsame day shipment.For more information contact:Global Filter, LLCTel: 1-877-603-1003Website: www.globalfiltercorp.comGlobal Filter’s new GTCHB series band clamp vessel line22 • October 2010 • www.filtnews.com

Filter Press | TechnologyCake Blowing Considerations in Filter PressesBy Reuben G. Neumann, Global Product Manager, Filter Press Technologies – FLSmidthCake air* blowing of filter cakesis not new technology. The useof air and sometimes othergases to sweep out liquids from interstitialgaps in formed filter cakes hasbeen used for many years. Air is by farthe most prevalent medium used forporous filter press cake blowing but isnot the only medium used. Many applicationsrequire alternate compressedgases such as nitrogen.*For the purposes of this article theterm “air” will be used generically andassumes the reader is basically familiarwith filter press operating principles.Some contend that the basic principleof drawing air through a filter cakefor dewatering comes primarily fromvacuum filtration technology. Conventionalvacuum filters such as Drum,Disc, and Horizontal Pan or HorizontalBelt types relyon atmosphericconditions toproduce thedriving forceneeded to formand dry the filtercake. Atmosphericconditions arevariable mostlydue to altitudebut also due toother factorssuch as temperatureand humidityall ofwhich have impacton the design of the equipmentand the long-term effectiveness of theinstalled dewatering device.Figure 1.0The use of an enclosed chamber asfound in the typical filter press technologyallows the dewatering impact of24 • October 2010 • www.filtnews.com

Figure 2.0variable atmospheric conditions to bemitigated by isolating the filter cake inthe chamber. If the cake is porousenough to pass air through, the isolatedcake can now be dewatered by usingcompressed air, which can be ideallyconditioned to achieve the desired result.Enclosed chambers also allowcake-dewatering forces during cake formationto be mechanically produced bypumping and/or membrane squeezing.Figure 1.0 illustrates a cross sectionof the typical recessed chamber configurationshowing cake formation insidethe chamber and will help familiarizeus with a filter press chamber. For purposesof this article, only vertically orientedchambers are considered.For porous filter cakes, air can be introducedinto one side of the chamber,which is then forced through the filtercake carrying interstitial liquid with itto the other side of the chamber, whichthen exits the filter through portingprovided. The direction of feed, filtrateand air is controlled by piping andvalves similarly shown in Figure 2.0.There are different ways to configurefilter plate porting in order to allow thepassage of air through the cake. Figure2.0 illustrates just one typical way.CONSIDERATIONSThe impact of air consumption bothon filter plant operating and capitalcosts can be enormous. In any filterplant design, careful consideration ofhow filter configurations impact air demandis required to keep costs down.There are two phases to blowing afilter cake. Phase I is simply the applicationof air pressure, which then26 • October 2010 • www.filtnews.com

pushes the liquid through the cake. Inthis phase the rate of airflow is controlledby the rate at which the liquidwill pass through the cake. Phase II isthe “air sweep” phase. This occurs afterthe liquid is completely pushedthrough the saturated cake. At thispoint air “break through” is achievedand the airflow begins to “sweep” surfacemoisture from the solid particles.Phase II will account for the maximumair demand. Phase II is where we willfocus the remainder of this discussion.Some of the variables that can impactair consumption include:1. Filtration area of filters requiredby the various filter pressconfigurations. This is often variablefrom manufacturer to manufacturerand can be impacted by:A. Pumping methods and timerequired to form the filter cake.B. Mechanical time needed forcake discharge.C. Frequency and timerequired for cloth washing.2. Permeability of the filter cake,which is impacted by particle sizeand shape.3. Homogeneity of the filter cake4. Filter cake cross sectional profile.5.Viscosity of the liquid to beremoved.For the purposes of considering theabove variables, let’s take a look at atypical copper concentrate application.The material releases water freely andwhen formed into a filter cake is porousalmost always, requiring air blow toachieve desired moisture levels.Specifications:• Production rate: 50 mtph• Cake form time: 3.0 minutes• Cake thickness: 50 mm• Measured airflow rate from testing:18.3 Nm3/h/m2• Required air blow time: 8.0 minutes• Cake moisture: 8.0 wt%1. Filtration area required:For this evaluation, let’s compare twodifferent filter types. One that employshigh-speed mechanical functions for dischargingthe filter cakes vs. one that usesmore conventional methods. In the caseof FLSmidth we might use our AFP IV TMAutomatic Filter Press vs. our Shriver®filter press. In the case of the AFP, mechanicalfunctions associated with cakedischarge are performed in about 2 minutes.In the case of the Shriver filter itmight take about 5 minutes. The resultsshown in Table 1.0 indicate that theShriver filter would require 1.23 times thefiltration area to process the same amountof tonnage as the AFP option. Aside fromother implications such as larger feedpumps, valve, piping, etc., the installedcompressed air system would need to produce23% more instantaneous air flow asderived from the total time comparison16/13. This is perhaps a simplistic viewbut it provides an idea of the impact ofequipment type selection. Other factorssuch as cloth washing frequency, avail-28 • October 2010 • www.filtnews.com

Figure 3.0 Figure 3.1ability and hours per day of operation cangreatly exacerbate the issue.2. Permeability of the filter cake:Experience has shown that cake airblow dewatering can be considered amass for mass function (“it takes somany kg of air to remove so many kg ofwater”). The values of this relationshipcan only be determined by testing the individualapplication. If we can acceptthat, we can assume; “provided that thesolid particles are similarly formed andcompacted, the volume of air required toachieve any given moisture level is thesame per ton of solids regardless of cakethickness or plate type. The power required/tonis also the same.”The impact of cake permeability on airconsumption becomes more significantwhen we consider the next two points.3. Homogeneity of the filter cake:A filter cake that is not homogeneousmeans the existence of particle stratificationand/or non-uniform particle compactionand the development of cracksdue to the shrinkage of the cake during theblowing process. Both of these will havesignificant impact on air consumption.The homogeneous formation of filtercake inside a filter press chambercan be affected by a number of factorssome less obvious than others. Thesecan include: feed port location (top,center, and bottom), feed pumping athigher vs. lower rates, terminal fillingpressure and whether or not membranesqueezing is utilized.Feed Port Location can have significantimpact on cake homogeneity in applicationswhere solids densities arehigh, like the copper concentrate example.In that case it typically means thatthe slurry when placed in contact withthe filter cloth will release water rapidlyeven by gravity.www.filtnews.com • October 2010 • 29

To achieve true homogeneity, it is importantthat the chamber is fed in such away as to promote the formation of thecake in layers over the entire filtrationsurface simultaneously. This will ensureFigure 4.0that particles are evenly distributed andcompacted. To accomplish this usuallymeans that the chamber needs to be fedat a fairly high rate in order to create sufficientturbulence to prevent stratificationof particles.Feeding a filter chamber from an elevatedposition can promote cake, whichis non-uniformly formed and compactedwith stratified particles creating a nonhomogeneousfilter cake. Figure 3.0 providesa cross sectional view of how cakeformation might look. As the cake developsfrom the bottom up and pressurebuilds inside the chamber, it is evidenthow the lower sections of the cakewould not experience the pressurespresent in the upper portions and consequentlywould not exhibit the sameconsolidation properties. The final cakeprofile shows evidence as to how air bypassingwould occur. Some manufacturersusing this upper eye technologyattempt to mitigate the problem byadding membranes to compress the particlesmore tightly. Membranes also tendto eliminate cracks that may haveformed. The use of membranes themselvescan have air flow implications,which will be discussed later.Figure 3.1 provides a cross sectionalview of how cake formation looks in achamber that is feed from a lower center30 • October 2010 • www.filtnews.com

position. The lower extremities of thechamber are kept turbulent and cake isformed more uniformly over the entirefiltration surface. The center core of thecake remains in slurry form so pressureincreases are applied over the entire surfaceuniformly.Full-scale, side-by-side field testingof this configuration by a prominentcopper producer in South Americashowed an increase of air demand in excessof 50% over the alternate lowercenter feed system.Figure 4.1 (689.5 kpag)4. Filter Cake Cross Sectional Profile:Air flow at any given pressure increasesas (T/t) 2 (where “T” is thethickest section of the cake and “t” isthe thinner section). Figure 4.0 showsa typical recessed chamber filter cakecross section. Figure 4.1 illustrates theair-flow factors associated with thecross sectional change.Likewise, variable air pressure increasesor decreases the air flow as(P/p) 2 (where “P” is the base pressureand “p” is the desired pressure). If weincreased the air pressure to 827 kpagfrom 689 kpag, the average design airflow would increase by (827/689) 2 orfrom 18.28 Nm 3 h/m 2 to18.28(827/689)2 = 26.33 Nm 3 h/m 2 , asignificant jump. Since velocity increasesas the pressure drop squared,the time to blow the cake will similarlydecrease. Naturally a reduction in airpressure will decrease the instantaneousflow but also will increase the requiredblow time, commensurately.With respect to the edge thinning ofthe cake around the perimeter of theplate, many manufacturers will coat thefilter cloth on one side of the chamberin the tapered zone. This does not significantlyeffect cake formation butblinds the cloth to prevent air from travelingthrough horizontally, which mitigatesthe spike in airflow factor in thiszone. Coated filter cloths do come withan increased cost. It is recommendedthat an evaluation be made to determinethe lesser-cost impact between that anda higher average air demand.Use of membranes will also have anaffect on filter cake profile. Membranewww.filtnews.com • October 2010 • 31

Figure 5.0 Figure 5.1filter plate manufacturers typicallylimit the cake formation pressure to689 kpag at 20-30 deg C. Higher temperaturesreduce this allowable pressure.The increased time requirementto inflate and deflate membranes in afilter press drives the filter size up tomaintain any given throughput. Figure5.0 illustrates the differences inprocessing time between high pressurefeeding vs. low pressure withmembranes in a minerals applicationas it relates to time.To control this overall processingtime, chambers are not filled completely.The result is that the final filtercake thickness is less than thenominal chamber depth and may evenhave irregular thickness over the entirearea of the cake. Figure 5.1 illustratesthe cross sectional effect ofmembrane squeezing. Normally thedry cake densities have very little variation.The use of membranes can increasethe variability of airflow due tofinal cake thickness variations in anygiven filter cake.CONCLUSIONThe impact of air consumptionduring cake blow can have critical impacton plant capital and operatingcosts. Careful consideration must begiven to the selection of filter pressconfigurations to avoid excessive airconsumption.For the most efficient air demandthe filter system should incorporate asystem that provides:• High-speed mechanical functionsto help minimize filtration surfacearea.• Feed systems and filter platedesigns that promote uniform andhomogenous formation of the filtercake inside the chamber.• Uniform compression of the filtercake where membranes are used. FNFor more information contact:Filter Press Technologies – FLSmidth7158 South FLSmidth DriveMidvale, UT USAAbout the AuthorReuben G. Neumann; Educated in MechanicalEngineering Disciplines has been employedby FLSmidth since 1973 in variouscapacities including development engineer,design engineer, pressure filtration engineeringmanager and product management.32 • October 2010 • www.filtnews.com

U.S. POSTAL SERVICE STATEMENT OF OWNERSHIPMANAGEMENT AND CIRCULATION - REQUIRED BY 39 U.S.C 3685Title of Publication: International Filtration NewsDate of Filing: 10/1/2010 - Publication Number: 1078-4136xAnnual Subsciption Price: $65.00 - Airmail $125.00 - Free for qualified poepleOwner: Eagle Publications, Inc.Mailing Address: 39555 Orchard Hill Place, Suite 600, Novi, MI 48375Known Stockholders Owning or Holding 1 percent or more of the total amount of stocks:Carol Brown, 5277 Gallagher Blvd., Whitmore Lake MI 48189Publication: International Filtration News - Issue Date of ciruclation Data Below: August 2010Extent & Nature of Circulation Average No. Copies Actual No. CopiesIssue Each issue Single IssueTotal Number of Copies 11000 111001. Mailed at other classesthrough USPS 250 2552.Paid or Requested Mailed 10500 10490TOTAL PAID AND REQUESTED: 10750 10745Free Distribution by USPS-other 0 0mail classificationsFree Distribution Outside Mail 260 255(carriers, tradeshows, or other means)TOTAL DISTRIBUTION 11000 11000Copies Not Distributed 100 100TOTAL: 11260 11100Percent paid and/or Requested 95% 97%I certify that the statements made by me above are correct and complete,Klaas De Waal, Publisherwww.filtnews.com • October 2010 • 33

Filter | TestingNew Method of Measuring Filter CutPoints and Pore Size Distributions UsingMulti-Modal Particle Size StandardsBy Dr. Graham Rideal, Whitehouse Scientific Ltd.Porometry is probably the mostwell known method of measuringpore size distribution 1 . Thisinvolves using air pressure to expel a wettingliquid from the pores of a filter. Whenthe gas pressure is applied, large poresoffer less resistance and so are cleared first.The appearance of the first bubble (the‘Bubble Point’) reflects the largest poresize but different instruments use differentmethods of detection. For example, inthe Coulter Porometer, incremental‘bands’ of pressure are applied and thefixed band within which the bubble firstappears is used for the calculations ofmaximum pore size. There, therefore,tends to be very good instrument-toinstrumentagreement.In other instruments, there is a continuousincrease in pressure and a parallelmeasure of flow. Deviations from a linearpressure/flow relationship are theoreticallymore precise, but the difficulty hereis defining the exact position of the divergence.In simple terms, how much mustthe bubble be inflated before it is deemedsignificant?The exact determination of the BubblePoint, and from it, the maximum poresize is critical as it is the benchmark fromwhich the pore size distribution is calculated.As the pressure on the wetted filteris increased, interpolation of the pressureversus flow rate can then be used to determinethe pore size distribution.A second factor, which can limit theaccuracy of the method, is the principleassumption that the pores are cylindricalin shape. The various uncertainties havelead to reproducibility issues not just betweendifferent manufactures but alsofrom instruments made by the same manufacturer,and unless stringent operatingprocedures are used, there can be significantuncertainties in the results 2,3 .In the so-called ‘Challenge Test’, poresare challenged by various powders eitherin air or as a suspension and the cut point34 • October 2010 • www.filtnews.com

or maximum pore size determined by themaximum particle just penetrating the filter1 . Spherical particles are to be preferredbecause the results are not affected by particleshape or orientation.Because the challenge particles can beunambiguously measured, especially ifthey are spherical, there is a much greatercertainty in the accuracy of the result thanin the Bubble Point method.In addition to the maximum pore sizeof a filter, it has been possible in the pastto determine pore size distributions incertain types of filters, for example wirewoven media, using the ‘near mesh’ principle.The method involves a challengetest where trapped microspheres in thepores are released and measured. The particlesize distribution of the ‘near mesh’microspheres then correspond to the porediameters 4,5 .Unfortunately, the ‘near mesh’ methodis restricted to large pore sizes, typicallyover about 50 microns, because increasingattractive forces cause the microspheresto stick to the mesh filamentsurfaces as well as lodging in the pores.Measuring pore size distributions atfines sizes, especially below 1 micron hasnot been possible so far using the challengetest method.PRECISION PARTICLE SIZE ANALYSERCentral to the success of this researchis a means of accurately measuring particlesizes in the sub-micron region. TheCPS disc centrifuge is a sedimentation instrumentemployed in particle size analysis.The unique feature of the instrumentis that a ‘line start’ technique is usedwhereby the particles are injected onto thesurface of a spinning fluid and all startsedimenting at the same time. As theytransverse into the depth of the clear liquid,largest first and smallest last, concentrationis measured optically as they passa light beam. The principle of the techniqueis shown in Figure 1.The reason that the resolution is sohigh in the Disc Centrifuge is that theparticles are separated before they aremeasured. In the case of a multimodalmixture, a series of concentric ringscan be seen sedimenting as the particlesmove to the perimeter of the disc.Figure 2 shows the effect in a 3-componentblend of 3 latex standards. Thecomplete CPS disc centrifuge isshown in Figure 3.www.filtnews.com • October 2010 • 35

MULTI-MODAL CHALLENGE TESTThe new approach to Challenge Testingdescribed herein seeks to develop a setof wide particle size distribution, sphericalstandards based on a blend of non-overlappingsingle sized latex microspheres inthe size range 0.1 – 1.5 microns. By studyingthe suppression of the individualpeaks in the ‘Multistandard’ as a result ofpassing a filter, it should be possible to determinea pore size distribution.In the past, the main limitation to thisnovel Challenge Test approach has been acombination of producing a large numberof closely sized latex standards and a highresolutionparticle sizing technique capableof differentiating the individual peaksin a multi-modal blend.The provision of suitable particle sizestandards was solved by BS-Partikel 6while the CPS disc centrifuge 7,8,9 provideda unique solution to the high-resolutionanalysis.APPARATUSA simple split filter holder mounted ona Buchner flask is all that is required forfilter testing. 20ml of a 0.02% aqueoussuspension of the standard is then drawnthrough a 47mm diameter fil ter and theparticle size after filtration is compared tothe original. The 0.02% concentrationwas used as the best balance between instrumentresolution and minimizing secondaryfiltration through cake build-upon the surface of the filter.The initial studies were carried out on4 membrane filters of nominal ratings 1.2,0.8, 0.45 and 0.2 microns.HIGH RESOLUTIONThe first phase of the program was toensure the repeatability of the testmethod. The first observation was thatthere is evidence of pores up to 1.5 micronsas this peak is not completely eliminatedfrom the Multistandard. The filtercut point is therefore likely to be approximately1.7 microns.Secondly, the peak positions after filtrationare almost identical, with the exceptionof the 0.15 and 0.1 micron peakswhere there is a variation of approximately+/-0.01 microns.The small deviations at the minimumsizes are probably due to particle diffusioneffects during sedimentation in the centrifugeas the duration of the analysis wasabout 50 minutes.In addition to the cut point, multimodalstandards can be used to estimatethe pore size distribution. While the cutpoint determines a maximum pore size,the smallest peak can be used to bench-36 • October 2010 • www.filtnews.com

mark the minimum pore size. Themethod assumes that the concentration ofthe 0.1 micron peak will be largely unaffectedas it passes the filter so can be normalizedor overlaid on the correspondingpeak from the Multistandard.The percentage suppression of eachremaining peak as the microspheresare trapped in the pores then representsthe concentration of pores at thatparticular size.The results from the cut point testsshow that the 1.2 micron filter removedalmost everything above 1.1 microns, althoughthere was still a very small residueof the 1.6 micron peak.The 0.8 micron membrane, however,performed better than its nominal ratingin that the 0.75 micron peak was totallyeliminated as well as a significant part ofthe 0.55 micron peak. The cut point isprobably about 0.65 microns.The other interesting feature of the 0.8micron filter is that the concentrations ofall the peaks below the 0.4 microns peakremain unchanged after passing, indicatingthat this membrane may have a highuniformity of pore sizes. Further work isneeded to determine whether the 0.8 micronfilter is indeed a track-etched membraneor whether a spurious result hasbeen obtained.The 0.45 micron membrane performedas expected according to its nominalrating, having the 0.4 micron peakalmost completely removed. However, thecut point of the 0.2 micron membranewas significantly higher as there was stillevidence of a small peak at 0.26 microns,giving an estimated cut point of approximately0.3 microns.To confirm that no secondary filtrationtook place, 0.2%, 0.02% and 0.002%solids concentrations of the ‘Multistandard’were passed through the 0.45 micronfilter. There was no difference in theresults. However, the 0.002% concentrationwas a little too low to give a good signal-to-noiseratio. This result confirmedthe 0.02% suspension as the optimalsolids concentration for the test.CONCLUSIONThe use of a Multi-modal standard incombination with the CPS Disc Centrifugehas shown great potential in measuringboth the filter cut point and the poresize distribution of submicron filtermedia. Although no information was suppliedwith the filters under test, the resultsclearly show that the 0.8 micron filter hada much narrower pore size distributionand so, unlike the others, was probablymade by the ‘track etched’ process.The major advantage of this novelChallenge Test method is that NIST traceablemicrospheres are used, so the resultsare totally unambiguous. It will be interestingin future work to compare the resultswith Porometry.FNwww.filtnews.com • October 2010 • 37References1. D B Purchas and K Sutherland, Handbook of Filter Media, 2nd Ed.,ElsevierAdvanced Technology, ISBN 1 85617 37552. G R Rideal and J Storey, ‘A new high precision method of calibratingfilters’, J. Filt. Soc., Vol 2(3),2002, p 18–203. R Lydon, E Mayer and G Rideal, Comparative Methods for the Pore SizeDistribution of Woven and Metal Filter Media, World Filtration Congress(9) 2004, Reprinted in www.WhitehouseScientific.com/library’, paper 224. G R Rideal, J Storey and T R Morris, ‘A New Simple, but High PrecisionApproach’, Particle and Particle Systems, 17 (2000), 1 – 7 Wiley, Reproducedin www.WhitehouseScientific.com/library, paper 125. G R Rideal, Pore Size Distribution Analysis in Critical Filter Applications –a Question of Definition, www.WhitehouseScientific.com/library’, paper 306. www.BS-Partikel.de7. B. Schied, S T. Fitzpartick, ‘The Use of Nano-sized Particle Standardsfor Particle Sizing Instrument Validation’ GIT Laboratory Journal Europe,5/2005, pp44 - 478. www.CPSinstruments.com9. Allen T. Particle Size Measurement, p120 (Chapman and Hall, London)The full scientific article can be found in FILTRATION, vol 10, number 2,April 2010, pages 115-120.

Filter | TestingProper Validation of Filter Test Stands isCritical for Product Development ProgramsBy Gerard J. Lynch, P.E., IFTS Inc. USA and Nicholas A. Faust, Sigma Design CompanyGarbage in equals garbage out.The age-old adage that hasbeen repeated in many undergraduateengineering courses forthe past decade is still an importantprinciple to remember for many oftoday’s engineering challenges – includingfilter testing.Today’s designers rely heavily ontesting and simulation data comingfrom a number of sources around theglobe to make their design decisions.If today’s designers are basing their decisionsoff of “garbage,” what can weexpect as an end product? With poortesting and simulation data, the startingpoint for future development anddesigns has already been skewed.SIMULATE DESIGN TEST VALIDATEGlobal manufacturers work hard toutilize an iterative validation processfor new product development. Unfortunately,more often than not, the simulatedresults vary significantly fromthe physical test data. The two areasthat contribute to the majority of thesediscrepancies are:Too often in new product developmentthere is a misunderstanding ormisinterpretation of the true physicswithin the device or system being developed,tested, and measured. Theproduced results show test data thatcan differ from original simulationmodels and data by as much as 100%Data acquisition inaccuracies due toelectronic noise and accuracy of the testinstruments used may occour.So What Are the Major Factors ThatInfluence Test Accuracy and Reliability?Based on Chart 1 from ISO 16889we can see the many factors that affecttesting results. Some of the most challengingbeing: viscosity, differentialpressure, solids loading, and flow rate.FILTER TESTING CONDITIONSMonitoring testing conditions andparameters is certainly an importantstep to insure accurate results. Specifically,viscosity plays a most importantrole and, as a temperature-dependentfunction, temperature must be preciselymonitored and controlled, typi-38 • October 2010 • www.filtnews.com

cally within 0.5 degrees. Uncertaintiesin temperature measurement can leadto more than 8% uncertainty in themeasurement of pressure differential.iLikewise, flow rate measurement is anotherimportant parameter shown tohave high-impact on the influence ofretention capacity.For every parameter however, it typicallyboils down to the accuracy of instrumentsand data acquisitionsoftware. This can vary as high as 10%(or more), and should be carefully calculatedand accounted for when performingand analyzing tests.iiSIMULATION DATASimilarly, simulation and CFDanalysis is becoming a more and morewidely used tool in a design engineer’stoolbox. However, the level of detail,and nuances of setting up a computersimulation, varies from software to software,including mesh size and meshcontrols, operating conditions, inputparameters and even the features of theCAD model.TEST STANDSNot all test stands are equal. Recentdiscrepancies in testing between labscaused our experts to look more closelyat the differences between filter teststands. We had heard that with somestands the injection circuit reservoir didnot mix well and test dust was oftenfound in the bottom of the reservoir aftertesting during cleanup. What we foundis that differences in tank mixing designapproaches produced different results.Chart 1Test dust, which settled on the tank bottomwas assumed to be injected andtherefore would over state the dirt holdingcapacity of the sample test filters.Near zero fluid velocities on the injectiontank inner surfaces indicate lessthan adequate mixing.TEST DUSTCorrectly selecting test dust and understandingthe differences betweenthem, is an important step in filter test-www.filtnews.com • October 2010 • 39

Near zero fluid velocities on theinjection tank inner surfaces indicateless than adequate mixing.ing and can contribute significantly tothe level of uncertainty in filter testing.All international filter-testing standardsclearly identify the test contaminant(test dust) to use. Some examples include:SAE ARP 4205 Aerospace FluidChart 2.Power - Hydraulic Filter Elements -Method for Evaluating Dynamic Efficiencywith Cyclic Flow uses ISO FineTest Dust per ISO 12103-A2.NSF/ANSI 42 Drinking water treatmentunits – aesthetic effects requiresISO Fine Test Dust per ISO 12103-A2for filter ratings from 1 to 80 micronand ISO Course Test Dust per ISO12103-A4 for filters rated up to 120 micron.ISO 16689 Hydraulic fluid power filters— Multi-pass method for evaluatingfiltration performance of a filterelement uses ISO Medium test dust perISO 12103-A3.Not only is the test dust used a contributingfactor to repeatable test results,but so is the concentration of thetest contaminant. In many specifica-40 • October 2010 • www.filtnews.com

tions this is called the Basic UpstreamGravimetric Level abbreviated BUGLand reported as mg/l or ppm. Onlineparticle counters are affected by concentrationand dilution is used to maintainconsistent results. Most standardfuel oil, diesel and hydraulics filter testinguse BUGL between 5 – 15 mg/l.Repeatability is the measure of thevariation of outcomes in an experimentcarried out using the same conditions.Repeatability and Reproducibility areimportant factors to consider, and canbe maximized by taking proper care insetting up identical testing conditions.Additionally, post-test validation, eitherwith previous data, simulation data orestimated results, should be conducted.As a final check using a control chartfor statistical analysis will show if theprocess is within the desired level of repeatability.Chart 2 shows temperature, injectionflow rate and main flow rate.Ultimately, the best way to get consistentresults between filters is to alwaystest within the same operatingconditions. This includes the sametest setup, particle counters, apparatusand dust. There will, however, alwaysbe some level of uncertainty,which will need to be accounted for.However, understanding and estimatingthis uncertainty with a reasonablelevel of accuracy will provide a betterstarting point for designers and designdecisions.Engineers must realize that evenwhen following the above recommendedguidelines, sometimes we designexperiments that are too largeand complicated to validate in a pragmaticcost effective way. With a recentsystem being developed at Sigma Design,the team had no way to validatethe simulation and experimental fieldtestingof the entire system. The solutionwas to simplify the problem. Bybreaking the system down intosmaller problems, the team could validateindividual components on a simplifiedscale, before moving up totesting the complete device.If one understands the challenges indata collection and recognizes testingand validation problems early on, engineerscan usually develop a smart anduseful solution.Gerard J. Lynch, P.E. and NicholasFaust are with Sigma Design Companyand International Filtration ServicesInc., (IFTS Inc. USA) both located inSpring field, New Jersey. Jerry Lynchserves as President and Nicholas Faustas a Mechanical Engineer.FNIFTS is an independently regulated laboratoryand res earch center for liquid filtrationand separation science. IFTS has locationsin Europe, the USA and China, providing filtrationtesting and research services tomany industries.www.filtnews.com • October 2010 • 41Sigma Design Company develops and buildsnew products, prototypes and specialtyequipment. Sigma Design provides clientswith cost-effective mechanical engineering,electronics PCB, controls and microprocessordevelopment, manufacturing engineeringand laboratory services.References1. Petillon, N., Peuchot, C. 2005, “Impact of Filter Test ParametersUpon the Uncertainty of Filtration Efficiency, RetentionCapacity and ( P vs. Q) Test Results”, AFS, Atlanta,GA.2. Petillon, N. 2007, “About Validation of Liquid Filter EfficiencyTest Stands”, Filtech, Wiesbaden, Germany.

Mini Mart Ads42 • October 2010 • www.filtnews.com

www.filtnews.com • October 2010 • 43Mini Mart Ads

Advertiser IndexPage WebsiteA2Z Filtration Specialities 24 www.a2zfiltration.comAFS Conference 27 www.afssociety.orgAir Filter, Inc. 15 www.airfilterusa.comAir Techniques International 29 www.atitest.comAmistco 10 www.amistco.comAscension Industries 12 www.asmfab.comAshby Cross 12 www.ashbycross.comChase Machine and Engineering, Inc. Cover, Back Cover www.chasemachine.comContract Pleating Services 26 www.solentech.comDexmet Corporation 15 www.dexmetfilter.comEd Gregor 20 ecg@egregor.comFiltech Exhibitions Germany 13 www.filtech.deFilterCor 34 www.filtercor.comFiltration Technology Sys. 28 www.filtrationtech.comFTG 5 www.ftginc.comGlobal Filter LLC 23 www.globalfiltercorp.comINDA 25 www.inda.orgIndustrial Netting 34 www.industrialnetting.comInterstate Specialty Products 31 www.interstatesp.comJadtis Industries 36 www.jadtis.comJCEM-USA 35 www.jcem.chKoch Filter Corporation Inside Front Cover www.kochfilter.comLawrence Industries, Inc 36 lawrenceindustries@juno.comMagnetool Inc. 38 www.magnetoolinc.comMetalex 38 www.metlx.comMetcom Inc. 40 www.metcomusa.comMid-West Inst. 4 www.midwestinstrument.comMyron L Company 14 www.myronl.comNAAMM - EMMA 40 www.emma-assoc.orgOrange Research, Inc. 32 www.orangeresearch.comOrival Inc. 19 www.orival.comPerCor Mfg. 19 www.percormfg.comPerforated Tubes 39 www.perforatedtubes.comRosedale Prod. 21 www.rosedaleproducts.comSealant Equipment 37 www.sealantequipment.comSerfilco Limited 30 www.serfilco.comSolent Technology Inc. 18 www.solentech.comSonobond Ultrasonic1, Inside Back Cover www.sonobondultrasonics.comSpati Industries, Inc. 33 www.spatiindustries.comSpinTek Filtration 11 www.spintek.comXinxiang Tiancheng Aviation 41 www.tchkjh.comDownload PDF-version of magazine at www.filtnews.com44 • October 2010 • www.filtnews.com

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