Filson: Your Premier Compressor Air Filter Manufacturer
Compressed air can be contaminated by dirt, water, oil and other impurities, these solid and liquid particles will lead to serious problem of equipment like abrasion and corrosion. Here, Filson compressor air filters can help you to get clean and dry compressed air.
To meet varying needs of different applications, Filson can offer a broad range of compressor air filter including compressed air particulate filter, compressor oil filter, air oil separator filter, coalescing compressed air filters and so on.
Filson compressed air filters perform vital functions in your commercial and industrial process. They are widely applied to regular air system, precise pneumatic components, instrumentation, semi-conductor, the production, package and transportation of food, beverage industry, etc.
Filson Compressor Air Filters
Why Choose Filson Compressor Air Filters
It is not easy for you to find a reliable compressor air filters fabricator. Here, you are in right place and Filson is your best choice. We strictly control products manufacturing process and rigorously conduct testing before shipping to you.
Compared to ordinary compressor air filters in the market, Filson compressor air filters are superior in filtration performance and durability. In detail, the filtration precision is down to 0.001 micron and nearly no oil, water, dirt particles residual.
To build a deep cooperation with our customers, Filson swears to bring unequaled products for OEM/ODM customers. We are committed to offer one-stop solution on compressor air filters fabrication. Filson professional engineers are ready to help you.
Your Optimal Compressor Air Filters Supplier in China
As a dependable air compressor filter manufacturer in China, Filson has exported the products to over 40 countries and regions worldwide. And till now, thousands of customers rely on Filson as their reliable supplier for our high quality compressed air filters.
Compressed air is a significant power resource. Unfortunately, it contains amounts of impurities such as moisture and solid particles. About 80% of the solid particles are less than 2 micron in diameter and are therefore difficult to be removed by suction filters. Large quantities of liquid water droplets are the root cause of corrosion in equipment, pipe, and valves.
Besides, the compressor system also constantly produces grinding chips, rust residue and oil carbide. These contaminants will accelerate the wear of the compressor equipment and cause the seal failure. So they must be cleaned by Filson compressor air filters.
The different quality grade and purity requirements vary across the industrial applications. For example: perfect compressed air for the textile industry, may be totally unsuitable for the food or surface-coating industry. This is why it is so important to adapt Filson compressed air filters precisely to the type of application.
As one of the best compressor air filter factories, Filson offers a broad range of compressed air filters, which ensure that you get the compressed air that you need, with the purity level suitable for your industry. And our high performance compressed air filters are always cost-effective.
Filson industrial air compressor filter are specially designed and built to remove solid and liquid particles from compressed air. They can protect valves, dedicate instrument, and other equipment from contaminants damage and reduce downtime.
Filson utilizes advanced technology and equipment to construct compressor air filters. Dirt particles like rust, dust, micron-organism, water like water vapor, condensed liquid water, water aerosol, oil like oil aerosol, hydrocarbon vapor are all eliminated by Filson compressed air filter.
Filson high quality compressor air filters have unmatched filtration performance. They can remove contaminants at a high filtration efficiency up to 99.99% for 0.01 micron droplets and particles. It can fully meet all your type compressors applications.
Compressed air containing harmful substance, such as dust, oil, and water flow into the first stage of Filson compressor air filters, the larger particles will be adsorbed on the filter element. The water aggregating by coalescing effect is discharged through automatic drainage valve.
More than 95% of the water droplets, oil and larger particles in the compressed air have been filtered in the first stage, then the compressed air filtered by the first stage enters the second stage of Filson compressor air filter.
Unfiltered droplets in the first stage will be again gasification, conversed and removed. At the same time, small to 5 micron particles are completely removed by the second stage of Filson compressor air filter.
The last stage of Filson compressor air filters is intended to remove extremely fine particles and gas oil. Particles as low as 0.01 micron are removed at this stage. Then clean and dry compressed air will be sent into the downstream process for industrial purpose.
Filson compressor air filters include different filtration grade from coarse filter to precise filter. These filter cater to the requirements of varying applications. The highest standard is particle removal down to 0.01 micron and oil content residual down to 0.001 mg/m3 at 20 ℃.
The three most important points in the use of Filson compressor air filters are: type selection, sewage discharge capacity and pressure drop. It is unreasonable that the filter is not compatible with pipeline in diameter. It will cause large pressure drop and can not guarantee the quality of compressed air.
Filtered impurities need to be discharged through the sewage system in time to ensure the normal operation of Filson compressor air filters. The best way is to set the filter with automatic discharge device, reduce the human factors caused by the discharge is not timely.
Filson compressor air filter elements is a kind of consumables. To ensure the filtration, you should replace the filter elements timely. It is unscientific that changing them such as 3 months, 6 months based on experience. You should depend on the differential pressure gauge.
Filson compressor air filters is generally installed in the post-cooler and gas storage tank near the point of use and the lowest temperature. By doing this, the oil, water vapor will be condensed as much as possible. It can prevent the air from pollution by the downstream pipe original dirt.
With features of reasonable structure, small volume, light weight, Filson compressor air filters are easy to install and remove. In one word, they can save time and space, improve work efficiency and reduce maintenance costs.
Filson compressor air filters contain a pressure differential gauge indicating when change the filter elements. And level indicators are integrated to conveniently monitor the conditions of liquids to prevent downstream pollution. They have a reliable automatic drainage mechanism.
To maintain efficient operation of Filson compressor air filters, the filter elements need to be replaced periodically. They generally contain pressure drop indicator, you should change the filter elements once above a specific value, or you can depend on instructions.
By the way, Filson is also your reliable replacement compressor air filter supplier in China, we can offer you superior replacement compressor air filters at a competitive price. Thousands of customers rely on Filson as their reliable and stable supplier.
As compressed air is a critical power resource found in manufacturing facilities which comes into contact direct or indirect with your final products or process, it is essential to strictly manage compressed air purity. Filson compressor air filters comply with ISO 8573 certification which is related to compressed air.
If you are interested in Filson compressor air filters or have any doubts about them, please feel free to contact with us. Leave your name, e-mail, specific requirements, we will instantly get in touch with you and our professional engineering will provide you excellent one.
More details to be known in following ways:
Phone: +86-157 3695 8886
Filson Compressor Air Filters Function:
- Remove dirt, water, oil and other impurities from compressed air
- Provide clean and dry compressed air to downstream process
- Decrease pressure drop loss and optimize entire process design
- Reduce the unscheduled downtime and save maintenance costs
- Prolong service life, save energy and improve process efficiency
- Protect compressors and downstream device from contaminant damage
Filson Compressor Air Filters Feature:
- Reasonable structure, small volume and light weight
- High filtration surface area by pleated filter media
- Good corrosion resistance with powder coating housing
- Low differential pressure loss and low maintenance costs
- Great reliability, sturdiness and durability to the process
- Thorough degree of filtration and less oil, water content residual
- Numerous optional material of filter element and housing
- Low air flow resistance and large dirt holding capacity
- A combination of oil, deodorization, and dust removal function
- The respiratory filter function achieved by the combined design
- Easy to assemble and remove for fast cleaning
Filson Compressor Air Filters Specification:
- Construction material: 316L stainless steel, carbon steel, high quality aluminum alloy with polyester epoxy powder coating for corrosion resistance, element: fiber glass, stainless steel,
- Filter type: stainless steel mesh, stainless steel pleated element
- Length: 15 inch – 20 inch or custom
- Filtration grade: 5 micron, 3 micron, 1 micron, 0.01 micron
- Filtration efficiency: 99.99%
- Flow capacity: 20-38400 m3/h
- Operating temperature range: from -15℃ to 80℃
- Pressure dew-point: super-low dew-point system between -70 ℃ to -40 ℃, low dew-point system: +2 ℃
- Working pressure: up to 5000psig
- Connection: threaded design and flange design
- Connection size: from 1/4 inch to 3 inch or tailor-made
- Color: blue, silver, black at your request
- Residual oil content: 1ppm, 0.01ppm, 0.003ppm, 0.001ppm
- Connection caliber: DN15-DN600
- Compressor air filters quality: ISO 8573.1: 2001
- Certification: ISO, CE
- Accessories: differential pressure gauge, automatic condensate drain, manual drain valve, level indicator, end cap
Filson Compressor Air Filters Application:
- Regular air system, air for breathing, medicine, etc
- Precise pneumatic components, instruments and equipment
- Semi-conductor industry, electronic control valves
- The production, package and transportation of food, beverage industry
- Manufacturing industry, agricultural industries, pharmaceutical industry
- Energy exploration industry, dry cleaners, home applications
- Sea exploration through scuba diving
Compressor Air Filters: The Ultimate FAQ Guide
Before you import compressor air filters from China, read this guide.
It has everything you have been looking for about compressor air filters such as working principle, quality, applications, tests, and features amongst others.
So, if you want to be an expert in compressor air filters, this is the guide you have been looking for.
Let’s get started:
A compressor air filter is a filter used for removing solid dirt/particles, water, oil vapor, oil, moisture, and types of contaminants such as rust, and carbon from the compressed air supply.
Compressor air filter
Compressor air filters are installed in condensed airlines to block the ingression of water, solid, and oil contaminants into the air compressors.
A cubic meter of compressed air contains millions of dirt particles.
Of course, this is together with a significant quantity of water and oil in the form of vapor as well as heavy metals.
If you do not remove these contaminants using compressor air filters, then they will compromise the operation of very crucial process components.
Contaminants in compressed air
Understanding the nature of contaminants present in compressed air enables you to select the best treatment and filtration systems for your application.
The contaminants can originate from the atmospheric air you are compressing.
Alternatively, it may come from within the system through compressor and system wear or process fluids.
Some of the most common types of contaminants include:
· Solid Contaminants
The size of solid particles ranges from tiny particles that are imperceptible to the human eye to particles as big as 1 mm thick.
A cubic meter of untreated atmospheric industrial air can contain between 140-150 million particles.
Approximately more than 85% of these contaminants are less than 2 microns.
Similarly, rust and metal particles generated from the distribution and pipework as a result of the ingression of water and corrosive fluids in the system are common.
Carbon contamination can also come from the wear of carbon piston rings found in oil-free compressors or the activity of compressor heat on lubricating oil.
Mechanical fixing of components and pipework is also another pathway of system generation of solid contaminants.
· Water and Vapor
The compression of atmospheric air produces a lot of heat, which warms up the air and increases the amount of water vapor it can hold.
When you compress the air, the amount of water per cubic meter increases multiple folds compared to ambient air.
When the air cools, it produces condensate water because compressed cold air cannot hold so much water.
For instance, atmospheric air can hold 28.3 g/M2 of water at 30°C and 90% relative humidity but will only 3.8 g/M2 when compressed to 7 barg.
The condensate can wash out lubricants from pneumatic components or corrode the metals.
It can also solidify when temperatures drop beyond 0°C and damage piping and other components or block the air supply due to expansion.
· Oil Contaminants
Oil contamination is common in compressed air systems because of lubricating oil used in moving parts of the compressor or atmospheric hydrocarbon oil.
The oil aerosols find their way into the system as fine vapor or mist.
When the compression process subjects the oil to high temperatures, it becomes acidic and oxidized.
This makes it an aggressive contaminant.
Atmospheric oil getting into the system as a vapor will condense into a liquid when it cools.
Consequently, risking tainting of manufactured products or blockage of pipes.
Filtration of compressed air occurs in two stages.
In the first stage, the filter removes more than 95% of the water, oil, and large particle contaminants.
The air passes through a tube-shaped mesh filter and experiences a coalescence effect.
The mesh removes larger particles and condenses the larger droplets into a honeycomb-like pad.
They then go to the separation chambers.
Condensation takes place when the velocity of air slows down.
The condensate moves to the waste collection area of the bowl where they get discharged through the manual, automatic, or electric drain.
In the second stage, the air goes through a fibrous material that produces disturbance and numerous small vortices that distribute air unevenly.
The uneven distribution increases the probability of the contaminants making contact with the surface of the medium.
Compressed air filtration
The medium captures and retains the fine particles because of their inability to go through the small pore sizes in the filter medium.
The process generates a small amount of pressure drop as a result of resistance subjected to the airflow.
Compressor air filters are mandatory in all industries that use compressed air in their process applications.
Some of the industries that require compressor air filters include:
- Manufacturing industries
- Agricultural industries
- Pharmaceutical industries
- Energy exploration industries
- Dry cleaners
- Food and beverage industries
- Home applications
- HVCA in schools
- Sea exploration through scuba diving
- Business areas, both small, medium and large businesses among others
Compressed air filter element
A good compressor air filter should possess the following features:
- Easy to install and remove
- High efficacy in contaminant removal
- Have a low-pressure drop
- Support a high flow rate
- Resistant to corrosion
- Meet the industrial quality requirements
- Long-lasting and reliable performance
- High dirt holding capacity
- Capable of withstanding high temperature and pressure
An air compressor filter comprises:
- Inlet: The inlet port is the point of air entry. It has an internal cap that forces the air downwards. Ensure that the size of the inlet port fits into your system piping.
- Filter cap: it is responsible for directing the airflow inside the filter. An arrow located on the outside of the filter will show you the direction of airflow to aid in filter installation.
- Filter element: The element is composed of fibrous material that is responsible for trapping and removing the contaminants from the compressed air stream.
- Outlet port: It discharges clean air out. The size must match the inlet port to avoid airflow restrictions.
- Housing: It is also known as the bowl. The main function of the bowl is to host the other components of the filter in place.
- Sump/quiet zone: The zone is located at the bottom of the housing and collects the removed contaminants. It has a barrier to avoid recontamination of air.
- Drain: The drains can be manual or automated. It removes the filtered contaminants out of the filter.
There are several types of compressor air filters used to remove different types of contaminants.
· Particulate Filters
Particulate compressor air filters remove solid contaminants from the air.
They remove the contaminants using different mechanisms such as direct interception, inertial impaction, and diffusion.
The filter elements trap and store the contaminants when air passes through the filter.
Also, the medium gets filled as more dirt sticks on it, the pressure drop increases, and so is the amount of contaminants that go through it.
Therefore, you have to replace the filter elements after a predetermined pressure drop level, which is indicated by a differential pressure gauge and alarm.
· Coalescence Filters
You will use this filter to remove oil, oil vapor, and moisture suspended compressed air.
They remove contaminants by amalgamating the tiny droplets into large drops that can drain through gravity into a collection chamber.
These filters can also remove tiny solid particles
· Activated Carbon Filters
Activated carbon filters remove hydrocarbons, odors, and oil vapor.
The air coming into activated carbon filters must be free of all liquid and solid contaminants.
The filters maintain extremely pure airflow and protect sensitive components such as fiber optics, instrumentation, and other susceptible equipment.
· High-efficiency Filters
These filters are better in particulate removal and reduction in pressure drop.
They can remove particles down to 0.01 microns and utilize less energy compared to regular filter
· Cold Coalescence Filter
The filters can operate 2°C making it more suitable for removal of moisture.
· Compressor Intake Filters
They are the very first filters you will use to remove contaminants down to 0.3 microns.
They are fundamental for removing chemical impurities from the air.
A cubic meter of compressed can harbor hundreds of millions of particulate, water and oil contaminants.
If these contaminants all find their way into the system, they will greatly hinder the operations of system components such as cylinders and valves.
They will make the seals bulge and wear prematurely, resulting in high energy, maintenance, and downtime costs.
Selecting the best compressor air filter will go a long way to guarantee system efficiency while avoiding undesirable component wear and tear.
You can consider the following factors when selecting a compressor air filter:
Compressed air filter system
· Type of Application
Different applications require different types of compressor air filters.
Each filter has a different set of filtration requirements and fittings.
You should refer to the requirements of your filtration or consult a reputable company before settling for a given type of filter.
· Filter Micron Rating
Similarly, the cleanliness required for the compressed air will determine the micron rating of the filter you select.
You should select a filter that will achieve the desired level of cleanliness and still maintaining good service intervals.
· Flow Rate
The size and of the filter you select will depend on the application level of airflow.
Understanding the maximum allowable pressure drop will assist you to decide on the best size of a filter to select.
The manufacturers will provide a chart showing the pressure drop versus the supply flow.
These charts indicate the performance of a filter at a given intake pressure.
Look through the chart and select the models whose port size and other features meet your system requirement.
· Efficiency and Quality
You should choose a filter that will effectively remove the contaminants at the desired level of efficiency at a minimum pressure drop.
Note that filters might have similar micron and flow rate rating but significantly differ in their effectiveness in removing contaminants.
High-performance filters might cost you more initially but will give you better results compared to ordinary filters.
To ascertain the quality of a filter, you can purchase several brands from different manufacturers and test them side by side for performance comparison.
There are different parameters considered when rating a compressor air filter.
These parameters include:
· Micron Rating and Extraction Efficiency
The micron rating of a compressor air filter indicates the size of particles the filter will be able to remove from the stream of compressed air supply.
General-purpose filters usually remove contaminants that measure between 40 and 50 micron.
On the other hand, the high-efficiency filters can remove particles down to 0.01 microns.
The efficiency of a filter depicts the percentage of contaminants at a particular micron that the filter is capable of removing from the air.
For example, a filter rated at 99.997% is a high-efficiency filter that retains almost all the particles at the specified micron.
· Flow Rate
The flow rate helps you select the correct size of a filter for a given application.
Applications with higher flow rates need bigger filters with a higher flow rate rating.
Choosing a filter that has a lower flow rate rating than that of the process application will tremendously increase the pressure drop of the filter.
ISO 8573-1:2010 contains the requirements for rating compressed air based on the class rating of three kinds of contaminants.
The classes include the number of solid particles, water, and oil content.
Air quality rating classes range from 1 through 9.
The rating indicates the maximum allowable contamination levels and particle sizes for the respective quality classes.
Also, the lower the class rating, the cleaner the air is.
The compressed air filters operate under very demanding conditions such as high temperature, pressure and humidity variations, and chemical attacks.
Other factors that degrade the air compressor filter media are:
- Acids and oils
- Varying humidity conditions for particulate filters
Additionally, high-velocity particles constantly bombard the filter media when in operation.
Eventually, the constant bombardment weakens and damages the element.
A damaged filtration media will fail to provide the desired filtration efficiency for the compressed air.
As a result, it gives the filter element finite service life.
Yes, you can clean and reuse elements which have been manufactured and labeled as cleanable.
The frequency of cleaning will depend on how often you are filtering.
The service life of a compressor air filter depends on the process flow rate and level of contamination of the process air.
The dirt-holding capacity of a filter will also influence how long it will last.
Conducting regular system checks daily for indications like oversaturation and wear will help you determine the expected life span of the filter.
You should also use an automatic differentials pressure gauge to alert you when the elements are due for replacement.
Compressor air filter element
You can construct the filter elements using a wide variety of selective fiber material to ensure that you achieve the desired level of filtration.
Among the wide selection, you can choose the following materials for making a reliable compressor air filter medium.
This material is suited for the removal of solid particles.
The cellulose fibers have wide diameters, and therefore not conducive for filtering out liquid aerosols.
You can use fiberglass to construct a high-efficiency coalescence filter element.
You can vacuum form the filter media.
So that, the downstream layer enhances coalescence filtration while the upstream layer removes particulate contaminants.
Elements made using this product can achieve extended service life, high contaminants removal efficiency, and low differential pressure.
· Activated Carbon/Molecular Sieves
You will use these materials for constructing adsorption filter media for the removal of hydrocarbons, odor, and other gas-phase impurities.
The materials can be manufactured into beds or contained in a carrier such as polyester fabrics.
Consequently, you can roll the polyester into cylindrical filter elements.
Elements made from the materials are located downstream after coalescence filters to protect the medium from any liquid aerosols or water.
· Wrapped HEPA Paper
You can use this material to construct elements that can remove both particulate and liquid aerosols at the same time.
You can use binders on the glass papers to construct the material to increase the strength of the filtration tube or enhance its filtration efficiency.
You can also use binderless media but with caution.
Prolonged exposure to liquid contaminants weakens and disintegrates or delaminate the media.
Pressure spikes are also known as pressure pulse and occur as a result of rapid drop or rise in compressed air pressure.
The spike can emerge from sudden starting or stopping of the pump.
The sudden shift of a valve from fully opened to fully closed can also cause pressure spike.
If left unchecked, strong spikes can cause system malfunction and damage sensitive components exposed to the pressure spikes.
Specifically, they can instantaneously rupture the elements enabling unfiltered air to flow into the system.
To avoid the occurrence of pressure spikes, ensure that you set slow opening and closing of the isolation valves when pressurizing systems.
You will follow the guidelines provided in ISO 12500 standards to test the effectiveness of a compressor air filter.
The test will vary depending on the type of filter you are testing.
If you want to test the performance of the coalescence compressed air filter, you will use the guidelines provided for under ISO 12500-1 as follows.
- You should start your experiment using a clean and reliable source of compressed air.
- Control the testing conditions, setting the inlet air pressure at 7 bars; inlet air temperature at 20°C and ambient temperature at 20°C.
- Record the initial (dry) pressure drop
- Using a Laskin nozzle, generate aerosols ranging from 0.1 to 0.3 microns and inject them into a clean stream of compressed air.
- Ensure that the mixture adheres to the aerosol challenge of 10 mg/m3 or 40 mg/m3 using a white light scattering photometer.
- Record the measurement once the filter reaches equilibrium, that is, the wetted condition to determine its performance.
Record the pressure drop.
Also, measure the penetration of aerosols through the elements by using a photometer scattering white light.
- Have at least three sets of reading and find the average from the three tests.
- The test will give you the penetration of oil aerosols in mg/m3, the filtration efficiency in (%) of the aerosols captured, and the pressure drop.
ISO 12500 standards provide international guidelines on production and rating of compressed air filters by manufacturers.
The standard comprises three multi-parts that deal with different types of contaminants.
ISO 12500-1 provides guidelines for testing the efficiency of coalescence filters in removing oil aerosols.
In the second part, ISO 12500-2 concerns the removal of vapor by adsorption filters.
While ISO 12500-3 gives the requirements for testing solid removal efficiency of particulate filters.
You can choose different types of drains for your compressor air filter.
- Manual drains: You remove the contaminants manually by twisting the drain plugs regularly, i.e., once per shift
- Semi-automatic and normally open drains: Immediately you shut off the compressed air, the drain will open.
- Full automatic and normally open: It will release the contaminants when the contaminants reach a certain level in the housing or the compressed air shuts off.
- Full automated closed: The drains will open when you switch on the compressed air, and the condensates reach a certain level in the bowl.
- Electric drains: An electric signal will remotely close and open these kinds of filters.
Air filter system
Dryers remove the water vapor that remains after passing the air through the micro coalescence filters.
They are classified based on pressure due point (PDP), which is the temperature at which you can cool the compressed air without the content water condensing.
When the temperature falls below PDP, condensates form and will remain and erode the materials even if you increase the temperatures.
There are different types of dryers including:
- Refrigeration dryers
- Membrane drier
- Adsorption driers
As you can see, there are many aspects you should consider when choosing a suitable compressor air filter.
The best part of this guide has outlined everything you need when choosing these types of filters.
Still, if you have any questions or inquiries, feel free to contact the Filson team.