Handbook of Nonwoven Filter Media, Second Edition PDF
Preview Handbook of Nonwoven Filter Media, Second Edition
Handbook of NONWOVEN FILTER MEDIA s Front cover image: Nanowave Filter Media by Hollingsworth and Vose Co (H&V). East Walpole, Massachusetts USA. Courtesyof Hollingsworth and Vose (H&V) Handbook of NONWOVEN FILTER MEDIA IRWIN M. HUTTEN AMSTERDAM(cid:129)BOSTON(cid:129)HEIDELBERG(cid:129)LONDON NEWYORK(cid:129)OXFORD(cid:129)PARIS(cid:129)SANDIEGO SANFRANCISCO(cid:129)SINGAPORE(cid:129)SYDNEY(cid:129)TOKYO Butterworth-HeinemannisanimprintofElsevier Butterworth-HeinemannisanimprintofElsevier TheBoulevard,LangfordLane,Kidlington,OxfordOX51GB,UK 225WymanStreet,Waltham,MA02451,USA Copyrightr2016ElsevierLtd.Allrightsreserved. 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ISBN:978-0-08-098301-1 BritishLibraryCataloguing-in-PublicationData AcataloguerecordforthisbookisavailablefromtheBritishLibrary LibraryofCongressCataloging-in-PublicationData AcatalogrecordforthisbookisavailablefromtheLibraryofCongress ForinformationonallButterworth-Heinemannpublications visitourwebsiteathttp://store.elsevier.com/ DEDICATION Soon my lovely wife, Susan, and I will start preparing for our fiftieth wedding anniversary. During all this time, Susan amazed me with her love, support, and patience. She understood the time it took to write the first edition of this book, and once again she understood as I wrote this second edition. She provided encouragement, support, and assistance for this endeavor. I am very fortunate to have a loving wife like Susan. It is with great pride that I dedicate this book to her. PREFACE When I wrote the preface of the first edition of the Handbook of Nonwoven Filter Media, I reported that the writing was a labor of love and there was an awful lot of labor to love. Four years ago I undertook the writing of the second edition and learned that upgrading and revising the first edition required as much love. The intent of this book is to provide the reader with a fundamental understanding of nonwoven filter media and to upgrade the technology from the 8 years since the first edition was published in 2007. This edition provides the following information on nonwoven filter media: how it is used, how it is made, its raw materials, how it is processed, and how it is managed and regulated. Several new features were added in this second edition. This includes a section on Computational Flow Dynamics (CFD) prepared by Prof. George C. Chase, Ph.D., University of Akron, Akron, Ohio, USA, and short sections on Global and North American marketing statistics prepared by Brad Kalil, INDA (Association of the Nonwovens Fabrics Industry), Cary, North Carolina, USA. The definition of nonwoven filter media was modified to include membrane filtra- tion technology. Membrane filtration has grown so much and so inter-wrapped with nonwoven filter media that to write about the former without including the latter is like trying to write about a large family without including the in-laws. It can be done but it is awkward. Accordingly, the second edition’s discussion of membrane filtration and separation is greatlyexpanded. Another expansion is the discussion of nanofiber technology. Nanotechnology is one of the emerging technologies of the twenty-first century. Nanofibers and nanofiber webs, as used in filter media, are an important part of that emerging tech- nology. The filtration and separation of nanoparticle sized contaminants is a major concern of modern day nanotechnology. The accelerating rate of global technology is demanding extensive legislation, reg- ulation, standardization, and control. The emphasis is on safety and environmental concerns. Sustainability has become an important issue in the marketplace and in manufacturing. The demand includes the technology of nonwoven filter media. For this reason, a whole new chapter (Chapter 10) on federal law and regulatory activity has been added to the second edition. The new legislative and regulatory activities place new burdens and hardships on the manufacturers of nonwoven filter media. However, they create abundant opportunities for nonwoven filter media to solve the problems of the environment and safety. The opportunities far outweigh the burdens. xix xx Preface The manufacturers of nonwoven filter media should be prepared to take advantage of these opportunities. Other new items that have been added to the second edition include color tech- nology and new separation processes. For example, barrier fabrics that separate oil from water as a result of oil spills are described. The second edition includes mem- brane separation processes such as ion exchange, electrodialysis, and pervaporation. Much information in the first edition had to be updated. The products of many companies had become obsolete and had to be updated. Standards and regulations have been revised. The author has attempted to present the most recent ones at the time of writing. Companies have been bought out and organizational names have been changed. Again, the author has attempted to present the company and its most recent form. A guided tour of the second edition starts off with introductory remarks in Chapter 1 followed by the marketing statistics prepared by Mr. Kalil. The Introduction includes a description of what nonwoven filter media is all about and how it is used. Definitions of filtration and separation, nonwovens, and nonwoven fil- ter media are included in Chapter 1. These definitions are necessary to set the scope of the book. In addition to the filtration of particulate matter from a fluid stream other forms of separation phenomena are included. Among these are adsorption, elec- trostatic and electrokinetic effects, coalescence, diffusion, membrane separation phe- nomena, and others. The definition of nonwoven filter media includes paper or wet lay media, felts, and membrane media. These items are not necessarily included in the ISO defi- nition of nonwoven filter media. The defining factor is that they be used as a filter medium. Chapter 1 classifies nonwoven filter media based on forming process. The major processes come under the major headings of dry formed, wet laid, and composite structures. The dry formed processes are further divided into polymer sourced and fiber sourced. Polymer sourced are those processes in which a molten or solution polymer is spun through spinnerets to form a random web. Fiber sourced are those processes such as carding or air laid in which the raw feed to the process is in a fiber form. The mechanisms and theory of nonwoven filter media are presented in Chapter 2. The theoretical presentation is classical. It includes the Monte Carlo techniques of Piekars and Clarenburg (87) to demonstrate random web structure and how pores are defined. It is in Chapter 2 that we find Dr. Chase’s introduction to Computational Flow Dynamics (CFD). Chapter 3 is an attempt to explain the broad range and variety of the properties of nonwoven filter media. The intent is to relate the properties to the use of the medium and provide guidance and its selection. The properties not only include classical Preface xxi engineering properties such as strength and rigidity, but also such as permeability and pore size that relate to filtration performance. To truly understand nonwoven filter media, one must understand how it is made. Chapter 4 discusses the raw materials of nonwoven filter media and Chapter 5 describes the processes by which they are made. The raw materials of Chapter 4 are subdivided into polymers, fibers, resins, and additives (finishes). The processes of Chapter 5 not only include the forming processes by which nonwoven filter media are classified, but also include the downstream converting and finishing operations. For example, needle punching and/or hydroentanglement of carded webs are well described. Since so much of nonwoven filter media is used in a pleated cartridge or pleated panel form, the various pleating processes are detailed. The second edition additions to Chapters 4 and 5 include the materials and processes for making filter membranes, both organic and inorganic. Test methods pertinent to nonwoven filter media are discussed in Chapter 6. The methods are presented in a way to help the reader understand the property being tested. For example, in the section on strength properties, the stress(cid:1)strain curve is presented to help the reader identify and understand the relationship of each of the strength properties to the medium. While many of the tests described are medium sheet tests, also described are filtration tests in which the medium is tested as part of a filter. Applications of nonwoven filter media are broken down into Liquid Filtration (Chapter 7), Air Filtration (Chapter 8), and Engine Filtration (Chapter 9). Engine filtration is concerned with filters for automobiles, heavy duty vehicles, off-the-road equipment, and rotating machinery. It is of sufficient market size to justify its own chapter. Gas turbine air filtration, which was part of Chapter 9 in the first edition, is reviewed in Chapter 7 of the second edition. Chapter 10 has already been mentioned above as discussing federal law and regula- tory activity that may relate to nonwoven filter media. Included is a review of major federal laws that may affect nonwoven filter media. Among the major laws included are the Clean Air Act, the Clean Water Act, OSHA, etc. Chapter 10 also provides a review of the “Globally Harmonized System of Classification and Labeling of Chemicals (GHS).” This is a system administered by the United Nations and adopted by the USA. Chapter 10 also includes an attempt to explain the concept of “sustain- ability.” I found this difficult to do. This attempt in Chapter 10 to introduce the reader to federal and regulatory law that may affect his or her job and his or her busi- ness is only a beginning. As this book was being written, there was so much regula- tory activity in progress, that probably, by the time this book is published, many changes in the business of filtration media will already be in place. It is important to identify those organizations that are involved in developing, coordinating, promulgating, revising, amending, reissuing, interpreting, certifying, xxii Preface regulating, or otherwise maintaining standards that are related to filtration and filter media. This was done in Chapter 11. The list is by no means complete, but does pres- ent a representative spectrum of those organizations involved. In Chapter 11, many of the worldwide standards applicable to nonwoven filter media are tabulated. Included is the table of contents for the most recent (2012) INDA (cid:1) EDANA Harmonized Test Methods (347). In the world of nonwovens, words are everything. A number of words are bandied about that have different meanings to different people. Sometimes they are used in the wrong context. For example, many people use the word porosity when they mean permeability. These twowords are related to each other; however, they are two differ- ent properties of nonwoven filter media. Another example is the variety of words used to describe the distribution of particles in a fluid. Included are words such as sol, aerosol, emulsion, latex, dispersion, suspension, and solution. In many cases they are used interchangeably and incorrectly. This book includes a glossary of filtration terms and terms related to filtration. The primary purpose of the glossary is to provide the reader with meanings of words related to filtration and separation media that he may not be familiar with, and to provide specific definitions to confusing words or terms. There is a bibliography with approximately 350 references. They are numbered in the order in which they appear in the book. In the text they are identified by a num- ber in parentheses. When I wrote the first edition, much of my references came from the archives of support organizations such as INDA, TAPPI, and the American Filtration Society. In writing this second edition, I was able to take great advantage of Google. I could Google just about every topic that I was researching and find all kinds of information concerning that topic. Some of the best information came from the websites of companies involved in the filtration industry. Some very good information came from Wikipedia, although, I always had to check it out to make sure it was not erroneous or misleading. I found the following books very helpful: Advances in Aerosol Filtration Editor: Spurny, LewisPublishers,1998 Air Filtration Brown, Pergamon Press,1993 Air Filtration Davies,AcademicPress,1973 FiltersandFiltration Handbook5th Edition, Dickensen,Elsevier, 2008 Filtration (cid:1)Equipment Selection Modeling and Process SimulationWakeman and Tarleton, Elsevier, 1999 Filtration Technology Handbook Butler,INDA,2000 Handbookfor Pulp and Paper Technologists 2nd Edition, Smook, Angus WildePublications, 1997 Handbookof Filter Media Purchasand Sutherland, Elsevier, 2002 Introduction toNonwovens Technology Batra and Pourdeyhimi, DEStechPublications, Inc.,2012 MembraneTechnology Cui and Muralidhara, Elsevier,2010 NAFAGuide toAir Filtration 4th Edition, National Air Filtration Association, 2007 Nonwovens: Theory,Process,Performance,and Testing Editor: Turbak, TAPPI Press,1993 Preface xxiii Perry’s Chemical Engineers’Handbook7th Edition, Perryand Green,McGraw Hill, 1997 Transport Phenomena Bird, Stewart, and Lightfoot, JohnWileyand Sons, 1960 A “Handbook” like this cannot be written without the assistance of organizations and people in the filtration industry. The following organizations and their people were particularly supportive of this work and should be acknowledged as such: INDA (Association of the Nonwovens Fabrics Industry) was particularly supportive. Brad Kalil has already been acknowledged above for writing the sections on Marketing Statistics. In addition, President David Rousse and his predecessor Rory Holmes provided additional support by allowing me to visit their facilities, consult with their personnel, review their research material, and provide me with contacts and items of information that were of great value in writing the book. Personnel who were extremely helpful included Jessica Franken, Steve Ogle, Phil Pitt (no longer with INDA), Joan Izzo, Ian Butler (now retired), and Cindy Garcia. AFS (American Filtration and Separations Society) was very important to me in pro- viding reference material, and the names of contacts. Whenever I needed help, Executive Manager Lyn Shol and her predecessor Suzanne Sower went out of their way to provide it. H&V (Hollingsworth and Vose Company), my former employer, was one of the big- gest providers of information used in this book. Much of this required copyright per- mission. Cathy Aikman and Angelika Mayman were very thorough in coordinating my permission requests and making sure that I got the proper response. Other person- nel who made themselves available were Bob Murphey, Andrew Shepard, Per Lindblom, Eric Westgate, and Dr. John Fitzgerald. Ahlstrom was another big contributor of information for this book. Many times I consulted with Rod Komlenic who either provided the information I needed or referred me to the person who could. I also received help from Kent Williamson, Stephanie Mulligan, and Tomi Tekala. Donaldson Company provided a large amount of information in this book. Laura Russell was my prime contact and did an outstanding job in coordinating the large number of permission requests that I had submitted. Joe Israel and Kristine Graham were other personnel who I had consulted with. Donaldson Tetratex was another part of the Donaldson organization that helped me. Sara Meyer did a lot of work in help- ing to prepare the Tetratexs product tables. Ed Ricketts was also involved. Cerex Advanced Fabrics provided powerful support to me in thewriting of the book. President Jim Walker and his management team of John Hancock, Jim Bostick, Erin Carter, Albert Ortega, and Warren Whitfield invited me to their facilities and provided mewithawealthofinformationaboutnylon:itsfiber,itsfabric,anditsspunbondnon- wovens.JohnHancockwasexcellentinhelpingmecoordinatewiththeorganization.
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