CN115400508A - Oil content filter element and manufacturing method thereof, oil-gas separator and air compression system - Google Patents
Oil content filter element and manufacturing method thereof, oil-gas separator and air compression system Download PDFInfo
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- CN115400508A CN115400508A CN202211366034.3A CN202211366034A CN115400508A CN 115400508 A CN115400508 A CN 115400508A CN 202211366034 A CN202211366034 A CN 202211366034A CN 115400508 A CN115400508 A CN 115400508A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
- B01D46/0001—Making filtering elements
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
- B01D46/24—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
- B01D46/2403—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies characterised by the physical shape or structure of the filtering element
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H23/00—Registering, tensioning, smoothing or guiding webs
- B65H23/04—Registering, tensioning, smoothing or guiding webs longitudinally
- B65H23/26—Registering, tensioning, smoothing or guiding webs longitudinally by transverse stationary or adjustable bars or rollers
Abstract
The invention belongs to the technical field of oil-gas separation, and discloses an oil content filter element and a manufacturing method thereof, an oil-gas separator and an air compression system, wherein the method comprises the following steps: diluting the phenolic resin liquid by using a diluent to obtain phenolic resin diluent; soaking the alkali-free glass fiber cloth by using phenolic resin diluent, and drying the alkali-free glass fiber cloth after the soaking treatment in the shade; winding the alkali-free glass fiber cloth after drying in the shade on a core rod to form a filter element; and drying the filter element by adopting a gradient heating mode. The invention not only can ensure the original oil-gas separation effect, but also has the technical effects of high strength, high air permeability, lower resistance, longer service life, energy conservation, environmental protection, economy and high manufacturing efficiency.
Description
Technical Field
The invention belongs to the technical field of oil-gas separators, and particularly relates to an oil-gas separator, an oil-gas separator and an air compression system.
Background
At present, the basic performance of an oil separation filter element in the world is as follows: the service life is 4000-8000 hours, the oil-gas separation effect, namely the oil content is less than 3ppm, and the initial pressure difference is 0.2bar. Typical oil and gas separation filter elements are represented by MANN + HUMMEL (Man Hu Moer) from Germany, and the famous product is a standard filter element used by Atlas Copco (Atlas); another representative of the filter element is SULLAIR (longevity), which is a chicapee filter element from KELTEC (kelteck).
The traditional oil separation filter element comprises German and American products, and has a problem that the oil content is increased along with the reduction of resistance, and even the phenomenon of oil leakage occurs; if the resistance is increased, the energy-saving effect is exponentially reduced; the oil content of the existing oil filter element on the market can not reach 3ppm basically, and the real data is between 5ppm and 8ppm, even higher. Therefore, there is a need for an oil filter cartridge and a method for manufacturing the same that has high strength, high air permeability, lower resistance, oil content within 3ppm, longer life, energy saving, environmental protection, and economy.
Disclosure of Invention
The invention aims to provide an oil content filter element, a manufacturing method thereof, an oil-gas separator and an air compression system, so as to solve the problems in the background technology.
In order to achieve the above object, one aspect of the present invention provides the following technical solutions:
a method for manufacturing an oil separation filter element includes:
diluting the phenolic resin liquid by using a diluent to obtain phenolic resin diluent;
soaking the alkali-free glass fiber cloth by using phenolic resin diluent, and drying the alkali-free glass fiber cloth after the soaking treatment in the shade;
winding the alkali-free glass fiber cloth after drying in the shade on a core rod to form a filter element;
drying the filter element by adopting a gradient heating mode, wherein the gradient heating mode comprises the following three continuous stages:
the first stage is as follows: drying for 20-40 minutes at 40-60 ℃;
and a second stage: drying at 70-90 deg.c for 40-60 min;
and a third stage: drying for 10-20 minutes at 120-140 ℃.
Further, the gradient heating mode comprises the following three successive stages:
the first stage is as follows: drying at 50 deg.C for 30 min;
and a second stage: drying at 80 ℃ for 50 minutes;
and a third stage: oven-drying at 130 deg.C for 15 min.
Furthermore, the diluent is ethanol, and the weight ratio of the ethanol to the phenolic resin liquid is 5:1-10.
Further, winding the alkali-free glass fiber cloth after drying in the shade on a core rod through winding equipment; the winding equipment comprises a feeding roller, a tension roller, a driving roller, a driven roller and two compression rollers; the core rod is positioned above the middle of the driving roller and the driven roller and is abutted against the driving roller and the driven roller; the two compaction rollers are detachably arranged above the core rod, and the two compaction rollers are tightly abutted against the core rod through self weight; when the winding equipment works, the feeding roller is used for conveying the dried alkali-free glass fiber cloth, the tensioning roller is used for applying pretightening force to the dried alkali-free glass fiber cloth, the driving roller drives the driven roller to synchronously rotate, the driving roller and the driven roller drive the core rod to rotate, the rotating directions of the driving roller and the driven roller are opposite to the rotating direction of the core rod, and the dried alkali-free glass fiber cloth is wound on the driving roller and further wound on the core rod through the rotation of the driving roller and the driven roller.
Furthermore, the winding tightness of the core rod is changed by changing the weight of the two compression rollers, and the density of the filter element is further controlled.
Further, the weight of the pinch roller is 5 +/-0.5 kg.
Further, the winding thickness of the core rod is 12-13 mm.
In another aspect of the present invention, there is provided an oil filter cartridge manufactured by the method for manufacturing an oil filter cartridge described above.
In another aspect of the present invention, there is provided an oil and gas separator including the oil separating cartridge described above.
In another aspect of the invention, there is provided an air compression system comprising an air-oil separator as described above.
Compared with the prior art, the invention has the beneficial technical effects that:
the data of the oil separation filter core in the installation test of the rich electricity group show that the pressure difference is only about 50% of that of a German MANN + HUMMEL (Man Hu Moer) product while the oil content is ensured to be less than or equal to 3ppm, and the oil leakage phenomenon does not occur.
Compared with the existing product, the oil separation filter core manufactured by the manufacturing method of the invention not only can ensure the original oil-gas separation effect, but also has the technical effects of high strength, high air permeability, lower resistance, oil content below 3ppm, longer service life, energy conservation, environmental protection, economy and high production efficiency.
Drawings
Fig. 1 is a schematic flow chart illustrating a method for manufacturing an oil filter according to an embodiment of the present invention;
fig. 2 is a schematic structural diagram of a winding device used in a manufacturing method of an oil separation filter element according to an embodiment of the present invention;
FIG. 3 is a comparison of the raw material used in the conventional product (filter C, also the oil content filter on the market) and the raw material of the oil content filter B of the present invention at a magnification of 500 times;
FIG. 4 is a comparison of the raw material used in the conventional product (filter C, also the oil content filter on the market) and the raw material of the oil content filter B of the present invention at 300 times magnification;
fig. 5 is a schematic diagram showing a change rule of a differential pressure (bar) of the oil separation filter element B according to the operation time (h).
100-winding equipment;
101-a feed roll;
102-a tension roll;
103-drive roll;
104-driven rollers;
105-a mandrel;
106-pressure rollers;
107-alkali-free glass fiber cloth.
Detailed Description
In order to make the objects, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are some, but not all, embodiments of the present invention. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
The terminology used in the embodiments of the invention is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used in the description of the invention and the appended claims, the singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise.
It should be understood that although the terms first, second, third, etc. may be used to describe the acquisition modules in the embodiments of the present invention, these acquisition modules should not be limited to these terms. These terms are only used to distinguish the acquisition modules from each other.
The word "if," as used herein, may be interpreted as "at … …" or "at … …" or "in response to a determination" or "in response to a detection," depending on context. Similarly, the phrases "if determined" or "if detected (a stated condition or event)" may be interpreted as "when determined" or "in response to a determination" or "when detected (a stated condition or event)" or "in response to a detection (a stated condition or event)", depending on the context.
It should be noted that the terms "upper," "lower," "left," "right," and the like used in the description of the embodiments of the present invention are illustrated in the drawings, and should not be construed as limiting the embodiments of the present invention. In addition, in this context, it will also be understood that when an element is referred to as being "on" or "under" another element, it can be directly formed on "or" under "the other element or be indirectly formed on" or "under" the other element through intervening elements.
The invention is further described with reference to the following figures and specific examples.
Referring to fig. 1, an embodiment of the present invention provides a method of manufacturing an oil separation filter, including the steps of:
and step S101, diluting the phenolic resin liquid with a diluent to obtain a phenolic resin diluent.
Through a large number of experimental tests, the alkali-free glass fiber cloth soaked by the phenolic resin can influence the strength and the channel area of the finished oil separation filter element, and the concentration of the phenolic resin in proportion is in direct proportion to the strength of the finished filter element and in inverse proportion to the channel area of the finished filter element. That is, since a high concentration increases the strength and also loses the channel area, resulting in an increase in the resistance, a lower concentration is preferable if the strength is satisfied. Therefore, in this embodiment, in order to ensure the strength of the oil filter element finished product, a phenolic resin solution is selected as the soaking solution of the winding material. When the oil content filter element is manufactured, the larger the size of a finished product is, the higher the strength is needed, and the proportion of the phenolic resin solution needs to be more concentrated; if the size of the finished filter element is smaller and the strength requirement is not so high, the lower the proportioning concentration of the phenolic resin is.
Specifically, when the phenol resin solution is formed, the phenol resin solution is diluted with a diluent to obtain a phenol resin diluted solution. The diluent may be, but is not limited to, ethanol or other alcohols. Preferably, the weight ratio of the ethanol to the phenolic resin liquid is 5:1-10, the concentration ratio range can be suitable for filter element finished products of various sizes in the market, and the strength of the finished products is ensured, and the acceptable resistance of the finished products is also ensured.
And step S102, carrying out soaking treatment on the alkali-free glass fiber cloth by using the phenolic resin diluent, and drying the alkali-free glass fiber cloth after the soaking treatment in the shade.
A large number of tests show that the diameter of the alkali-free glass wool is smaller, the fibers cannot be made to be very fine by the high-alkali glass wool, and the finer fibers can enable the filtering precision of the product to be higher so as to obtain better oil removal performance. Therefore, the present embodiment uses the alkali-free glass fiber cloth as the winding material of the filter element. Specifically, the alkali-free glass fiber cloth is placed in a phenolic resin diluent to be soaked for a period of time, and after the alkali-free glass fiber cloth is completely soaked, the alkali-free glass fiber cloth is placed in a shade to be dried until no liquid drips. It should be noted that the drying in the shade can remove the alcohol solvent on the surface of the finished product, and if the alcohol solvent is directly dried, the instant vaporization and expansion of the solvent can occur, which is easy to cause danger.
And step S103, winding the alkali-free glass fiber cloth dried in the shade on a core rod to form the filter element.
Specifically, the alkali-free glass fiber cloth after being dried in the shade can be wound on a core rod to form the filter element through manual work or winding equipment, and the winding thickness of the core rod is 12-13 mm. The reason for selecting the winding thickness is that a great number of experiments show that the finished filter element product can hardly meet the requirement of 3ppm oil-gas separation when the thickness is less than 12-13 mm, although the thickness can make the finished product thicker than the traditional product, the resistance of the finished product is only half of that of the traditional product, and the performance is still greatly improved.
In order to wind the alkali-free glass fiber cloth on the core rod more regularly and densely, control the density of the finished filter element, and achieve standardization and industrialization of the manufacturing process, the present embodiment further provides a winding apparatus 100 for manufacturing an oil separation filter element, and the specific structure is shown in fig. 2.
The structure and operation of the winding apparatus 100 will be described with reference to fig. 2.
In this embodiment, the alkali-free glass fiber cloth 107 after drying in the shade is wound on a core rod by the winding apparatus 100.
The winding apparatus 100 includes a feed roller 101, a tension roller 102, a drive roller 103, a driven roller 104, and two pinch rollers 106. The number of the tension rollers 102 may be one or more, and may be determined according to a specific production environment. The core rod 105 is positioned above the middle between the drive roller 103 and the driven roller 104, and abuts against the drive roller 103 and the driven roller 104. Preferably, the driving roller 103 and the driven roller 104 are connected by a timing belt or a transmission belt. The two pinch rollers 106 are detachably disposed above the mandrel bar 105, and the two pinch rollers 106 are tightly abutted against the mandrel bar by their own weight. The pressure roller 106 can perform the fixing and density control functions during winding. The resistance increases due to the excessive weight of the pressure rollers 106 which results in excessive filter element product density; if the compressing roller is too light, the alkali-free glass fiber cloth can not be tightly wound, the density of the finished filter element product is too low, the filtering effect is reduced, and the content of residual oil is increased. Therefore, in the embodiment, the weight range of the pressure roller is preferably 5 ± 0.5kg, the optimal density values of filter cores of various sizes can be achieved, and the density of the filter core finished product can be controlled by manually or automatically replacing the pressure rollers 106 with different weights.
The operation of the winding apparatus 100 will be described below:
when the winding equipment 100 works, the feeding roller 101 is used for conveying the dried alkali-free glass fiber cloth 107, the tensioning roller 102 is used for applying a pretightening force to the dried alkali-free glass fiber cloth 107, the driving roller 103 drives the driven roller 104 to synchronously and unidirectionally rotate, the driving roller 103 and the driven roller 104 drive the core rod 105 to rotate, the rotating directions of the driving roller 102 and the driven roller 103 are opposite to the rotating direction of the core rod 105, the dried alkali-free glass fiber cloth 107 is firstly wound on the driving roller 103, then the driving roller 103 sends the alkali-free glass fiber cloth 107 to the lower part of the core rod 105, the driven roller 104 winds the alkali-free glass fiber cloth 107 on the core rod 105 through self rotation, and then the alkali-free glass fiber cloth 107 can be continuously wound on the core rod 105 through the rotation of the driving roller 103 and the driven roller 104. During the winding process, the pressure roller 106 tightly presses the alkali-free glass fiber cloth 107 against the surface of the core rod 105 by its own weight, thereby controlling the winding density.
Step S104, drying the filter element by adopting a gradient heating mode, wherein the gradient heating mode comprises the following three continuous stages: the first stage is as follows: drying for 20-40 minutes at 40-60 ℃; and a second stage: drying at 70-90 deg.c for 40-60 min; and a third stage: drying for 10-20 minutes at 120-140 ℃.
In particular, since the phenolic resin used in the present invention is alcohol-soluble, the alcohol component therein is extremely unstable at high temperature, and if it is directly heated and dried at high temperature, it is very likely to cause explosion. In order to ensure the safety during production, the invention adopts an original staged heating forming method. Namely: preheating for 20-40 minutes at 40-60 ℃ in the first stage; preferably, the preheating is carried out at 50 ℃ for 30 minutes. In the second stage, drying is carried out for 40-60 minutes at the temperature of 70-90 ℃; preferably, the drying is carried out at 80 ℃ for 50 minutes, so as to fully volatilize the alcohol. In the third stage, because the flammable and explosive alcohols are volatilized completely, the phenolic resin and the alkali-free glass fiber cloth can be fully dried for 10 to 20 minutes at a higher temperature of between 120 and 140 ℃ so as to realize the solidification of the phenolic resin and the alkali-free glass fiber cloth; preferably, the curing effect is best when the mixture is dried for 15 minutes at 130 ℃.
According to the manufacturing method of the oil separation filter element, the obtained filter element can not only ensure the original oil-gas separation effect, but also has the technical effects of high strength, high air permeability, lower resistance, oil content below 3ppm, longer service life, energy conservation, environmental protection, economy, high production efficiency and the like.
In another embodiment of the invention, the oil separation filter element manufactured by the manufacturing method provided by the embodiment of the method, the oil separator comprising the oil separation filter element and an air compression system comprising the oil separator are further disclosed.
Comparative experiment:
according to the manufacturing method of the oil filter element and the traditional manufacturing method, the three-part oil filter element is manufactured. The oil content filter element A is made of common plant fiber cloth wound by the existing equipment, the oil content filter element B is made of alkali-free glass fiber cloth wound by the winding equipment, and the oil content filter element C is made of 848/2 glass fiber paper wound by the existing equipment and manufactured by American HV.
1. The instrumentation (meter), see table 1, shows:
TABLE 1 detecting instrument (Instrument)
| Detecting items | Instrument name |
| Resistance of oil filter element | Precision pressure gauge |
| Oil filter separation performance (oil content test) | Gas suspension impurity density detector |
| Flow test-barometric pressure | Empty box barometer |
| Flow test-ambient temperature | Thermo-hygrometer |
| Flow test-ambient humidity | Thermo-hygrometer |
| Flow test-inlet air temperature | Glass mercury thermometer |
| Flow test-nozzle temperature | Glass mercury thermometer |
| Flow test-nozzle differential pressure | U-shaped water level differential pressure gauge |
| Specific power-power | Double watt meter |
The following tests were carried out using the instrument in table 1 above.
2. Detecting items:
(1) Performing appearance detection on the filter element to determine that the sample is not damaged in appearance;
(2) Testing the front and rear resistance of the filter element and the oil and gas separation function of the filter element under the working conditions of 0.7MPa and 0.8 MPa;
(3) An initial pressure differential;
(4) And (5) service life.
3. The detection method comprises the following steps:
(1) A0421 oil injection screw air compressor of a tin-free tin pressure compressor company Limited is selected for testing, pressure measuring points are respectively connected to the front and the rear of an oil content filter element, a switching valve is used for switching, and a precision pressure gauge is connected to record the front and rear pressure difference and the initial pressure difference of the oil content filter element (the time interval between every two adjacent recorded serial numbers is 1 min), and the specific data are shown in a table 2;
(2) After the resistance detection of the oil separation filter element is completed, removing a pressure measuring point behind an oil separation barrel, installing an oil content detection tool, and recording the maximum value, the minimum value and the average value of the oil content in the compressed air behind the oil separation filter element; the specific data are shown in tables 3 to 5 (the time interval between every two adjacent recording sequence numbers is 1 min);
(3) Operating on the computer, and recording the operating condition of the computer, wherein the specific data are shown in tables 6-8.
4. And (3) detecting data:
TABLE 2 oil filter front and back pressure difference (oil filter resistance performance data)
| Oil content filter element A | Oil content filter core B | Oil content filter core C | |
| Initial resistance of oil filter element (MPa) | 0.010 | 0.012 | 0.015 |
| Oil filter element running resistance (MPa) | 0.020 | 0.018 | 0.020 |
TABLE 3 oil content (mg/m) of oil separation cartridge A 3 ) Test data
| Boot state | Exhaust pressure 0.7MPa | Exhaust temperature 77 deg.C | Exhaust pressure 0.8MPa | Exhaust temperature 77 deg.C | |||
| Serial number | MAX | MIN | AVG | | MIN | AVG | |
| 1 | 26.8 | 14.7 | 19.1 | 26.8 | 12.8 | 17.8 | |
| 2 | 28.2 | 12.9 | 19.1 | 25.1 | 13.2 | 17.6 | |
| 3 | 25.6 | 12.3 | 18.0 | 28.2 | 15.5 | 19.7 | |
| 4 | 26.3 | 10.2 | 17.7 | 28.6 | 14.9 | 20.6 | |
| 5 | 25.1 | 9.6 | 17.6 | 27.4 | 15.3 | 19.4 | |
| 6 | 30.2 | 12.5 | 21.4 | 29.2 | 12.8 | 19.6 | |
| 7 | 27.2 | 13.8 | 19.8 | 28.4 | 15.8 | 20.0 | |
| 8 | 28.6 | 14.2 | 19.5 | 27.6 | 14.2 | 19.6 | |
| 9 | 27.9 | 13.7 | 19.2 | 28.2 | 12.9 | 19.2 | |
| 10 | 28.1 | 14.3 | 19.3 | 26.9 | 15.4 | 19.0 | |
| 11 | 29.2 | 11.5 | 19.2 | 27.2 | 13.5 | 19.1 | |
| 12 | 25.4 | 10.2 | 18.4 | 26.9 | 14.2 | 19.4 |
TABLE 4 oil content (mg/m) of oil separation cartridge B 3 ) Test data
| Boot-up state | Exhaust pressure 0.7MPa | Exhaust temperature of 77 DEG C | Exhaust pressure 0.8MPa | Exhaust temperature of 77 DEG C | |||
| Serial number | MAX | MIN | AVG | | MIN | AVG | |
| 1 | 1.76 | 0.612 | 0.808 | 2.59 | 1.02 | 1.65 | |
| 2 | 1.82 | 0.628 | 0.861 | 2.88 | 1.15 | 1.61 | |
| 3 | 1.68 | 0.725 | 0.826 | 2.69 | 0.90 | 1.36 | |
| 4 | 1.65 | 0.684 | 0.812 | 2.83 | 1.21 | 1.51 | |
| 5 | 1.82 | 0.692 | 0.926 | 2.72 | 0.952 | 1.30 | |
| 6 | 1.67 | 0.695 | 0.840 | 2.68 | 0.948 | 1.17 | |
| 7 | 1.72 | 0.663 | 0.847 | 2.82 | 0.886 | 1.22 | |
| 8 | 1.58 | 0.589 | 0.796 | 2.14 | 0.842 | 1.01 | |
| 9 | 1.64 | 0.697 | 0.772 | 1.98 | 0.752 | 0.945 | |
| 10 | 1.69 | 0.569 | 0.796 | 1.82 | 0.615 | 0.828 | |
| 11 | 1.36 | 0.684 | 0.788 | 1.86 | 0.598 | 0.800 | |
| 12 | 1.13 | 0.592 | 0.727 | 1.53 | 0.623 | 0.787 |
TABLE 5 oil content (mg/m) of oil content in oil filter C 3 ) Test data
| Boot-up state | Exhaust pressure 0.7MPa | Exhaust temperature 77 deg.C | Exhaust pressure 0.8MPa | Exhaust temperature of 77 DEG C | |||
| Serial number | MAX | MIN | AVG | | MIN | AVG | |
| 1 | 4.36 | 2.25 | 3.13 | 5.38 | 3.25 | 4.11 | |
| 2 | 4.23 | 2.29 | 3.13 | 4.62 | 3.45 | 3.68 | |
| 3 | 4.38 | 2.34 | 3.12 | 4.58 | 3.48 | 3.79 | |
| 4 | 4.26 | 2.16 | 2.97 | 4.56 | 3.26 | 3.74 | |
| 5 | 4.68 | 2.52 | 3.24 | 4.67 | 3.98 | 3.74 | |
| 6 | 4.72 | 2.48 | 3.25 | 4.82 | 2.86 | 3.35 | |
| 7 | 4.25 | 2.06 | 3.01 | 4.52 | 2.56 | 3.21 | |
| 8 | 4.12 | 2.34 | 3.06 | 4.75 | 2.19 | 3.20 | |
| 9 | 4.23 | 2.19 | 3.10 | 4.81 | 2.57 | 3.28 | |
| 10 | 4.52 | 2.11 | 3.09 | 4.66 | 2.82 | 3.20 | |
| 11 | 4.34 | 1.98 | 3.02 | 4.26 | 2.63 | 3.16 | |
| 12 | 4.38 | 2.26 | 3.06 | 4.12 | 2.29 | 3.14 |
Table 6 product usage data sheet for oil content filter element B structure
| Compressor brand and model | Oil filter core code | Run time | Differential pressure of oil content (bar) | Oil | Operating temperature | ||
| 1 | Atlas GA160-8.5 | 1614905600 | 4120h | 0.4 | / | 78 | |
| 2 | Atlas GA250VSD | 1614905600 | 1266h | 0.2 | / | 88 | |
| 3 | Atlas GA132AP-10 | 1614952100 | 1839h | 0.3 | / | 91 | |
| 4 | Atlas GA250-10P | 1614952100 | / | / | / | / |
The operation time in table 6 is the operation time accumulated in the period 2021.08.16 to 2021.10.27, and the data when the oil pressure difference, the oil temperature, and the operation temperature are all the operation time peak, for example, the data collected when the oil pressure difference, the oil temperature, and the operation temperature of the oil filter element B of number 1 in the table are all the operation time 4120 h;
table 7 product usage data sheet for oil content filter element B structure
| Compressor brand and model | Oil filter core code | Run time | Differential pressure of oil content (bar) | Oil | Operating temperature | ||
| 1 | Atlas GA160-8.5 | 1614905600 | 5822h | 0.52 | 72 | 87 | |
| 2 | Atlas GA250VSD | 1614905600 | 1520h | 0.2 | 63 | 91 | |
| 3 | Atlas GA132AP-10 | 1614952100 | 2779h | 0.3 | / | 95 | |
| 4 | Atlas GA250-10P | 1614952100 | 1838h | 0.3 | 60 | 88 |
The operation time in table 7 is the operation time data in the period of 2021.10.27 to 2022.03.02 added on the basis of table 6, and the oil pressure difference, the oil temperature and the operation temperature are all data at the highest operation time, such as the data collected when the oil pressure difference, the oil temperature and the operation temperature of the oil filter element B with number 1 in the table are all the operation time 5822 h;
table 8 product usage data sheet for oil content filter element B structure
| Compressor brand and model | Oil filter core code | Run time | Differential pressure of oil content (bar) | Oil | Operating temperature | ||
| 1 | Atlas GA160-8.5 | 1614905600 | 6552h | 0.61 | 81 | 95 | |
| 2 | Atlas GA250VSD | 1614905600 | 4520h | 0.4 | 73 | 83 | |
| 3 | Atlas GA132AP-10 | 1614952100 | 3748h | 0.4 | 82 | 96 | |
| 4 | Atlas GA250-10P | 1614952100 | 3838h | 0.4 | 77 | 99 |
The operation time in table 8 is the operation time data in the period of 2022.03.02 to 2022.07.08 added on the basis of table 7, and the oil pressure difference, the oil temperature and the operation temperature are all data at the highest operation time, such as the data collected when the oil pressure difference, the oil temperature and the operation temperature of oil filter element B with number 1 in the table are all the operation time 6552 h;
TABLE 9 technical parameters-1 for each model
| Model (atlas) | Installed power | Operating pressure max | Working pressure min | Flow rate FAD | Flow rate FAD |
| GA160-8.5 | 160 | 8.5 bar | / | 482 L/S | 28.9 m 3 /min |
| GA250VSD | 250/VSD-10 | 10 |
4 bar | 182-697 L/S | 10.9-41.8 m 3 /min |
| GA132AP-10 | 132 | 10 bar | / | 367 L/S | 22.0 m 3 /min |
| GA250-10P | 250 | 10 bar | / | 708 L/S | 42.5 m 3 /min |
* FAD maximum flow was measured at 7bar (e);
TABLE 10 technical parameters of each model-2
| Model (atlas) | Size of exhaust port | Air-cooled-weight (kg) | Water cooled-weight (kg) | Size (mm) |
| GA160-8.5 | DN100 | 3275 | 2899 | 2800L*1600W*2000H |
| GA250VSD | DN100 | 3972 | 3698 | 2800L*1600W*2000H |
| GA132AP-10 | DN100 | 3215 | 2839 | 2800L*1600W*2000H |
| GA250-10P | DN100 | 4954 | 4729 | 3400L*2174W*2300H |
The above tables 9 and 10 are technical parameters of each model under test.
5. And (4) conclusion:
as can be seen from the table 2, the pressure difference, namely the resistance, between the front and the back of the oil content filter element A is 0.020MPa under the working conditions of 0.7MPa and 0.8MPa, and the requirement that the resistance is less than or equal to 0.020MPa is met, and as can be seen from the table 3, the average value of the oil content test of the filter element is far higher than 3ppm and is not met with the requirement;
it can be known from table 2 that the oil content filter element B has a resistance of 0.018MPa under the working conditions of 0.7MPa and 0.8MPa, and meets the requirement that the resistance is not more than 0.020MPa, and it can be known from table 4 that when the resistance is 0.018MPa, the oil content is only 1.65ppm at most, and is much less than 3ppm, and the average value of the oil content test meets the requirement and the data is relatively stable along with the extension of the service time; and has no deformation after high temperature and high pressure test.
The left photograph of fig. 3 is a 500-fold magnified electron microscope photograph of the raw material used in the filter cartridge C and also the raw material used in the oil separation filter cartridge on the market, the right photograph of fig. 3 is a 500-fold magnified electron microscope photograph of the raw material of the oil separation filter cartridge B according to the present invention, the left photograph of fig. 4 is a 300-fold magnified electron microscope photograph of the raw material used in the filter cartridge C and also the raw material used in the oil separation filter cartridge on the market, and the right photograph of fig. 4 is a 300-fold magnified electron microscope photograph of the raw material of the oil separation filter cartridge B according to the present invention;
in the structure of the material used for the filter element C, which is also a material product used for an oil-separating filter element on the market, the fibers are relatively fine, the number of fibers per unit thickness is n1, the lamination thickness H1 of the fibers is about 7 to 10mm, and the total amount of the fibers is w1= H1 × n1. The glass fiber paper of the glass fiber filter material of the traditional product is flexible, when the air compressor normally works, fibers of the oil content filter element are extruded under the action of high temperature and high pressure, so that the thickness of the filter element is changed, and pores among the fibers are reduced, so that the resistance is increased, the filtering efficiency is also changed, and even the filter element is invalid; in addition, although the filtering effect of the conventional oil product can be enhanced by increasing the lamination thickness, the resistance value is increased along with the increase of the lamination thickness, so that the filtering effect of the conventional oil product cannot be improved by increasing the lamination thickness;
in the structure of the oil content filter element B, the fibers are rigid, the number of the fibers per unit thickness is n2, the electron microscope photograph can clearly show that n2 is less than n1, the lamination thickness H2 of the fibers is about 13-16 mm, and the total amount of the fibers is w2= H2 x n2, because the fibers are rigid, the oil content filter element can be ensured not to deform in the using process, so that the resistance value caused by the deformation is prevented from increasing, when the number of the fibers of w2 and w1 is large, the oil mist can be contacted with the fibers of the same number for condensation, so that the oil content can be ensured to be less than 3ppm, on the basis, along with the increase of the lamination thickness, the filtering effect is enhanced, the oil content is gradually reduced, even can be reduced to below 1ppm, and meanwhile, the resistance value cannot be increased; therefore, the present invention can improve the filtering effect by increasing the thickness of the laminate.
As can be seen from Table 2, the oil content filter element C has a resistance of 0.020MPa under the working conditions of 0.7MPa and 0.8MPa, and meets the requirement that the resistance is less than or equal to 0.020MPa, and as can be seen from Table 5, the average value of the oil content test is higher than 3ppm, but the oil content test tends to become small slowly along with the lapse of time, but the numerical value is still higher than 3ppm, so that the oil content filter element C does not meet the requirement;
the low oil content can effectively recover the lubricating oil of the compressor so as to save the use cost of the air compressor and provide cleaner compressed air, and a gas pipeline is not easy to be polluted by oil mist;
the initial pressure difference of the existing oil filter element is between 0.018 and 0.025 MPa; as can be seen from Table 2, the initial pressure difference of the oil separation filter element B is 0.012MPa, the oil content is ensured to be below 3ppm, the low resistance can reduce the running cost of the air compressor, and the purpose of energy conservation is achieved; for example: an increase of 1% in energy consumption per 138mbar (0.0138 MPa) will occur.
Fig. 5 of the specification describes: the change rule of the pressure difference (bar) of the oil separation filter element B along with the operation time (h), wherein the horizontal axis represents the operation time (h), and the vertical axis represents the pressure difference (bar) of the oil separation filter element B;
"- □ -" curve, representing the most excellent oil product in the international market at present, the pressure difference (bar) of the German MANN + HUMMEL (Man Hu Moer) oil filter element changes along with the change rule of the operation time (h), the initial pressure difference is 0.2bar, the failure pressure difference is 1bar, and the service life is 8000 hours at most;
"-" curve, representing the curve of the change rule of the pressure difference (bar) of the oil content filter element along with the operation time (h) obtained from the experimental data (tables 6 to 8) collected by the oil content filter element B of the present invention, the energy saving effect which can be brought by the curve will be significant;
the curve of- "delta-" represents a regular curve estimated according to the current data, and the estimated service life of the oil separation filter element B can exceed 10000 hours, so that the maintenance interval of the air compressor is prolonged, and the maintenance cost of the air compressor is reduced.
The service life of the conventional oil separation filter element can only reach 8000 hours to the maximum; the on-machine use data of the oil separation filter element B disclosed by the invention is that when the operation time is 5822 hours, the pressure difference is 0.050MPa, and when the operation time is 6552 hours, the pressure difference is 0.061MPa. The operating rule curve of the oil separation filter element shown in fig. 5 can be estimated according to the operating time and the differential pressure data in tables 6-8 when the filter element fails at a differential pressure of 0.1MPa, and the curve shows that the oil separation filter element also has longer service life; the filter element is not failed at present, experiments are also in progress, the accumulated time for obtaining the final data can be as long as ten thousands of hours, and an inventor can supplement the data as required.
In addition, the traditional oil filter element including Germany and American products has a problem that the oil content is increased along with the reduction of resistance, and even the oil leakage phenomenon occurs. However, if the resistance is increased, the energy saving effect is exponentially reduced. The oil content of the products on the market is not 3ppm at all, and the real data even reaches 5ppm-8ppm. The data of the oil content filter element of the invention in the installation test of the rich electricity group show that the pressure difference is only 50% of that of German MANN + HUMMEL (Man Hu Moer) products while the oil content is ensured to be less than or equal to 3ppm, and the oil leakage phenomenon does not occur.
Compared with the existing product, the oil content filter core B manufactured by the method can not only ensure the original oil-gas separation effect, but also has the technical effects of high strength, high air permeability, lower resistance, longer service life, energy conservation, environmental protection and economy, and the models tested by the oil content filter core B are all large flow 20-40 m 3 Min (see tables 9, 10), even greater than 40 m 3 The service life of the model of/min is longer if the model of the tester is a low-flow model, and the existing products are basically designed for the low-flow 10m 3 The/min model, which can achieve a useful life also for installation on low-flow models, therefore, the invention is comparable to the prior artThe oil separation filter element has better universality.
The above description is only for the purpose of illustrating the preferred embodiments of the present invention and is not to be construed as limiting the invention, and any modifications, equivalents, improvements and the like that are within the spirit and principle of the present invention are intended to be included in the scope of the present invention.
Claims (10)
1. A method for manufacturing an oil separation filter element, comprising:
diluting the phenolic resin liquid by using a diluent to obtain phenolic resin diluent;
soaking the alkali-free glass fiber cloth by using the phenolic resin diluent, and drying the alkali-free glass fiber cloth after the soaking treatment in the shade;
winding the alkali-free glass fiber cloth after drying in the shade on a core rod to form a filter element;
drying the filter element by adopting a gradient heating mode, wherein the gradient heating mode comprises the following three continuous stages:
the first stage is as follows: drying for 20-40 minutes at 40-60 ℃;
and a second stage: drying at 70-90 deg.c for 40-60 min;
and a third stage: drying for 10-20 minutes at 120-140 ℃.
2. The method for manufacturing an oil separation filter according to claim 1, characterized in that:
the first stage is as follows: drying at 50 deg.C for 30 min;
and a second stage: drying at 80 ℃ for 50 minutes;
and a third stage: oven-drying at 130 deg.C for 15 min.
3. The method for manufacturing an oil separation filter according to claim 1, wherein the diluent is ethanol, and a weight ratio of the ethanol to the phenolic resin liquid is 5:1 to 10.
4. A method of manufacturing an oil separation cartridge according to any one of claims 1-3, characterized in that:
winding the alkali-free glass fiber cloth dried in the shade on a core rod by winding equipment;
the winding equipment comprises a feeding roller, a tensioning roller, a driving roller, a driven roller and two pressing rollers; the core rod is positioned above the middle of the driving roller and the driven roller and is abutted against the driving roller and the driven roller; the two compaction rollers are detachably arranged above the core rod, and the two compaction rollers are tightly abutted against the core rod through self weight;
work as coiling equipment during operation, the feed roll is used for carrying the alkali-free glass fiber cloth after the shade is dried, the tensioning roller is used for right the pretightning force is applyed to the alkali-free glass fiber cloth after the shade, the drive roll drives the driven voller rotates in step, and drive roll and driven voller drive the plug rotates, the direction of rotation of drive roll and driven voller with the direction of rotation of plug is opposite, the alkali-free glass fiber cloth after the shade is dried twine in on the drive roll, and pass through the rotation of drive roll and driven voller is further twined on the plug.
5. The method of claim 4, wherein the weight of the two pressure rollers is changed to change the tightness of the mandrel wrap, thereby controlling the density of the filter element.
6. The method of claim 4, wherein the compression roller weighs 5 ± 0.5kg.
7. The method for manufacturing an oil separation filter according to claim 1, wherein the winding thickness of the mandrel is 12 to 13mm.
8. An oil separating filter cartridge produced by the method for producing an oil separating filter cartridge according to any one of claims 1 to 7.
9. An oil-gas separator, characterized in that the oil-gas separator comprises the oil separation cartridge of claim 8.
10. An air compression system characterized in that it comprises an oil separator according to claim 9.
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| GB1208008A (en) * | 1966-11-15 | 1970-10-07 | Sayama Seisakusho Kk | Method of manufacturing a screen cloth |
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