Coalescing Fiberbed Mist Collectors (AIRCLEAR™)

Coalescing Fiberbed Mist Collector Systems capture, collect, and remove the liquid mists, aerosols, and sub-micron particles, that cause opacity, smoke, and blue haze. Coalescing Fiberbed technology eliminates aerosol mists and submicron particles from virtually any gas stream.

Impaction: 

Air Clear’s Coalescing Fiberbed Mist Collector Systems use the field-proven processes of Impaction, Interception, and Brownian Diffusion: Impaction occurs when particles in the <4 micron range is carried via inertia until they strike a filter fiber and are collected. Interception occurs when microns (1-3 range) possess less momentum and typically follow the air stream until they deviate and graze the side of a filter fiber, removing them from the air stream. Brownian Diffusion is sub-micron particles (<1 micron) that contain very little mass and follow the air stream. As the air cools, random movement of particles slow down as they collide and coalesce until increasing in size enough to be filtered via impaction/interception. Air Clear Fiberbed Mist Collectors work to eliminate opacity and other industrial air pollution problems.


(3) 25,000 ACFM Coalescing Fiberbed Filter Mist Collector Systems on Textile Printing Process

(3) 20,000 ACFM COALESCING FIBERBED MIST COLLECTOR SYSTEMS ON TEXTILE PRINTING PROCESS. THESE UNITS HAVE BEEN IN OPERATION AT TIETEX TEXTILE PLANT SINCE 1992

Air Clear Coalescing Fiberbed Mist Collectors are custom designed for many Industrial Processes

  • Asphalt processing
  • Saturation
  • Coaters
  • Tank Vents
  • Loading Stations
  • Textile Processing
  • Tenter frames
  • Curing ovens
  • Coaters
  • Vinyl Manufacturing – Plasticizer emissions- Calendar lines
  • Vinyl coaters-Battery cases etc.
  • Pre-filter for other APC systems such as RTO’s
  • Acid mist control
  • Chemical process
  • Fertilizer Manufacturing
  • Emergency Air Filters
  • Compressed air filters- Lube oil vents & reservoirs
  • Electronics
  • Etching
  • Food processing
  • Deep Frying
  • Coffee Roaster
  • Cocoa Processing
  • Heat treating/annealing
  • Metalworking (oil mist)
  • Incinerator emissions
  • Internal combustion engine crankcase vents
  • Nuclear Waste filtration
  • Precious metal recovery
  • Printing-Web Offset
  • Vacuum pumps
  • Wood products -Plywood composite board Manufacturers

Air Clear’s Coalescing Fiberbed Mist Collectors is proven Technology that offers a cost effective solution for the control of opacity and odors … Here’s why…

Low capital cost when compared to other technologies.

Air Clear’s Coalescing Fiberbed Mist Collector Systems save customers money with its low operating costs

  • Low initial pressure drop saves energy
  • Fan motor runs on VFD to minimize power usage
  • Long filter life means low replacement cost
  • Collected liquids are often recycled saving material costs
  • Low maintenance cost

Superior Filter Performance

  • Air Clear Coalescing Fiberbed Mist Collectors are guaranteed to reduce stack opacity to 5% or less, excluding steam and uncondensed materials (see cooling for a discussion of this subject generally they achieve near zero opacity.

     

  • Air Clear Coalescing Fiberbed Mist Collectors also offer very high particulate removal efficiency, in excess of 99%. They exceed the proposed OSHA requirement of 0.5 mg/m3 for indoor coolant/oil mist, and so are ideal for bringing Indoor Air Quality such as in, metalwork facilities into compliance.
  • Air Clear Coalescing Fiberbed Mist Collectors are subjected to rigorous testing to ensure design level field performance. This testing is the most stringent in the industry. Test conditions are more demanding than most field conditions. Our customers are welcome to witness this testing in our shop.
  • When tars, stone dust, talc, etc are present an Air Clear indexing prefilter is recommended to extend the life of the main filters.

Superior Filter Performance<

AIR CLEAR’S COALESCING FIBERBED FILTERS ARE TESTED TO ASSURE MAXIMUM PERFORMANCE

Quality WorkmanshipSoil Vapor Remediation, thermal oxidizer Regenerative Thermal Oxidizers, RTO's eliminates organic fumes, VOC Destruction. RTO's are Cost Effective & Energy Efficient Air Pollution Control devices, heat exchanger, Catalytic Thermal Oxidizer, CATOX, Coalescing Fiberbed Filters Mist Collectors (AIRCLEAR™), impaction

Shop assembly

  • Typically, the equipment is totally assembled for verification of fit of components. Shop assembly and testing allow Air Clear Engineers to verify performance prior to shipment. Any non-conformity is corrected before installation at the customer’s site.
  • The fiberbed filters themselves are subject to a performance test procedure which checks the opacity control and pressure drop levels are within Air Clear’s design parameters.
    • Benefits to the customer are:

      Inspection of Air Clear Coalescing Fiberbed Filter Mist Collector

      INSPECTION OF AIR CLEAR COALESCING FIBERBED MIST COLLECTOR SYSTEM

    • Faster, trouble free installation reduces installation costs
    • Less downtime, increased revenue from production
    • Higher on-line reliability from day one
  • Our customers are encouraged to witness the shop testing. This is often an excellent opportunity for our customers to receive training on the equipment. This allows for the customer’s personnel to become comfortable and knowledgeable with the equipment before it’s shipped! Air Clear Systems are designed, manufactured, assembled, and tested prior to shipment to ensure trouble-free installation and start-up.

Complete Turnkey Service
Remote Monitoring Services
Field Support
Engineering Services

Field Support for (2) 15,000 ACFM Coalescing Fiberbed Filter Mist Collectors w/pocket pre-filters on GAF Asphalt Roofing Manufacturing Process

FIELD SUPPORT FOR (2) 15,000 ACFM COALESCING FIBERBED FILTER MIST COLLECTORS W/POCKET PRE-FILTERS ON GAF ASPHALT ROOFING MANUFACTURING PROCESS

500 ACFM Coalescing Fiberbed Filter Mist Collection Pilot Test Unit

25,000 ACFM COALESCING FIBERBED FILTER MIST COLLECTOR SYSTEM WITH INDEXING PRE-FILTER ON CARPET MANUFACTURING PROCESS LA GRANGE, GA

Pilot Testing

Application (Sales) Support

  • Our technical sales team is committed to understanding the unique requirements of our customers on every project.
  • Our technical sales team is passionate about investigating all relevant technologies before recommending a suggested solution.
  • Air Clear’s Engineers constantly strive to improve existing designs.
  • Our technical sales staff has a combination of 90+ years’ of technical expertise and unequaled dedication to customer service that sets Air Clear apart from the other.

The Importance of Cooling The Process Air Temperature

  • Filters will not collect vapor phase molecules and particulate.
  • Vapors must be cooled to between 120°F -150°F to condense most materials before entering filter for maximum efficiency. The cooler the exhaust, the more efficient the filter is.
  • Cooling Methods

    • CYCLONIC SCRUBBER

      Shop Photo of Air Clear's Cyclonic Scrubber for Coalescing Fiberbed Filter Mist Collection System

      SHOP PHOTO OF AIR CLEAR’S CYCLONIC SCRUBBER FOR COALESCING FIBERBED MIST COLLECTOR SYSTEM

      For many applications such as asphalt coaters, saturators, textile tenter frames where the exhaust temperature is as high as 400°F adiabatic (water evaporation) cooling is used to lower the exhaust temperature. The bottom of the filter tank becomes the holding tank of the recycled water. The water is distributed over the Cyclonic tray which in addition to mixing the hot air and water it helps remove(scrub) solids from the exhaust.

    • AIR DILUTION COOLING
      Dilution with ambient air controlled by a damper, or a temperature controller and actuated damper.
    • AIR-TO-AIR HEAT EXCHANGERS
      Clean ambient air on one side of the air-to-air heat exchanger used to cool the hot process exhaust passing along other side of air-to-air heat exchanger.
    • COOLING COILS
      Finned or smooth water cooling coils allow heat exhaust to pass outside the finned tube while cool water flows through it. The exhaust is cooled by transferring heat to the cooling water indirectly-without direct contact.

Coalescing Fiberbed Filter Mist Collector preceding Regenerative (RTO) Thermal Oxidizer.

COALESCING FIBERBED MIST COLLECTOR SYSTEM PRECEDING REGENERATIVE (RTO) THERMAL OXIDIZER.  THE MIST COLLECTOR PROTECTS THE RTO’S CERAMIC MEDIA FROM FOWLING. THE SYSTEM IS OPERATING ON A ASPHALT ROOFING & SHINGLE PROCESS

25,000 ACFM Coalescing Fiberbed Filter Mist Collector w/Cyclonic Scrubbing and Pocket Pre-filter System on Interface Flor, Georgia, USA Carpet Manufacturing Process.  Mist Collector operates with 0% Opacity

25,000 ACFM COALESCING FIBERBED MIST COLLECTOR W/CYCLONIC SCRUBBING AND POCKET PRE-FILTER SYSTEM ON INTERFACE FLOR, GEORGIA, USA CARPET MANUFACTURING PROCESS.  MIST COLLECTOR OPERATES WITH 0% OPACITY

3,600 ACFM Fiberbed Filter Mist Collector System on Ammunition manufacturing process.

3,600 ACFM FIBERBED FILTER MIST COLLECTOR SYSTEM ON AMMUNITION MANUFACTURING PROCESS. FIBERBED SYSTEM HAS BEEN IN OPERATION FOR OVER 30 YEARS

Shop Photo of a 3,150 ACFM Coalescing Fiberbed Filter Mist Collector for Chocolate Manufacturing Process

SHOP PHOTO OF A 3,150 ACFM COALESCING FIBERBED MIST COLLECTOR FOR COCOA MANUFACTURING PROCESS. AIR CLEAR HAS SEVERAL MIST COLLECTORS ON COCOA MANUFACTURING PROCESSES THROUGHOUT THE UNITED STATES

27,000 ACFM Stainless Steel Coalescing Fiberbed Filter w/prefilter on Fabric Coating Process.

27,000 ACFM STAINLESS STEEL COALESCING FIBERBED MIST COLLECTOR W/PREFILTER ON FABRIC COATING PROCESS

(3) 25,000 ACFM Coalescing Fiberbed Filter Mist Collector for Carpet Manufacturing process

(3) 25,000 ACFM COALESCING FIBERBED MIST COLLECTOR FOR CARPET MANUFACTURING PROCESS

15,000 ACFM Coalescing Fiberbed Filter Mist Collector on Owens Corning Roofing Plant Process in Korea

15,000 ACFM COALESCING FIBERBED MIST COLLECTOR ON OWENS CORNING ROOFING PLANT PROCESS IN KOREA