Innovation In
Air Filtration
Clean Air
ZeroMist™
&
ZeroSmoke™
High-Performance Coalescing Fiber Bed
Mist & Smoke Collection Systems
7 Superior Drive, Rome, GA 30161 | (706) 291-1700
|
(866) 665-1829
www.clean-air.com | sales@clean-air.com
Competitive Comparison
The Clean Air ZeroMist™ and Clean Air ZeroSmoke™ coalescing fiber bed
technology was designed to overcome inherent design flaws with competitive technologies. Current conventional technologies of mist and smoke collection systems
are not designed to handle modern CNC machining process demands with highpressure coolant delivery, sub-micronic particulate generation, and realistic maintenance demands. The Clean Air ZeroMist™ and Clean Air ZeroSmoke™
are application-specific solutions that will overcome these deficiencies.
Current Conventional Mist and Smoke Collection System Overview
Mechanical Filtration Systems
Mechanical filtration systems typically consist of a mesh pre-filter, metal impingement filter, and
typical ASHRAE or MERV bag/envelope of cylindrical or square cartridge filters. These systems
are only 70 to 80% efficient on sub-micronic particulate and require a DOP or HEPA filter for the
particulate that passes through their primary filter elements. It is important to note that airflow
diminishes rapidly with loading of the primary filter, therefore, requiring frequent filter changes and
excessive maintenance with disposal.
Electrostatic Precipitators
Electrostatic precipitators operate with low voltage power supplies that apply an electrostatic field
to their collection components. These systems are 95% efficient on sub-micronic particulate,
however, require an additional or tandem pass to handle additional process loads from highspeed machining or high-pressure coolant delivery. The electrostatic precipitators require frequent
maintenance and downtime for cleaning. This technology is not well suited for modern facilities
with cutbacks to maintenance staff and maintenance contracts.
Centrifugal or Stacked Disc Mist Collectors
Centrifugal mist collector or stacked disc separation collectors operate with rotational force with
direct drive motors and an impeller or a stack of polymer disc stacks. They are limited to particulate over 1.0 micron and require an external HEPA or DOP filter for re-circulation. The centrifugal
mist collectors also require special pre-filtration for solid particulate to protect the impeller or
stacked disc. These systems are limited to machine tool sized applications and are limited in size
and airflow for larger multiple installations. The external HEPA or DOP filters require frequent
changes and disposal on continuous duty manufacturing environments.
Clean Air ZeroMist™ and Clean Air ZeroSmoke™ Development
The Clean Air ZeroMist™ and Clean Air ZeroSmoke™ coalescing fiber bed
technology was developed to overcome the inherent flaws with current mist and
smoke collection equipment.
The advanced coalescing fiber bed filtration technology with self-draining design is
engineered to collect mist and smoke aerosols with maximum collection efficiency,
minimal maintenance, and maximum reclaim of coolant or oils. The coalescing
fiber beds create a wicking layer through a unique process that allows the fiber
beds to keep the collected aerosol in a liquid state, preventing evaporation and
or bypass. This technology allows for draining whether the collector is online or
offline.
Packaged units include multiple coalescing fiber bed filters in series to allow for
99.97% collection efficiency, on sub-micron particulate, prior to the final HEPA
filter stage. The HEPA filter is a standard H13 HEPA filter with 99.997% collection
efficiency on 0.3 micron particulate. Due to the wicking and free draining effect
of the fiber bed filters, airflow is maintained throughout operation. The Clean Air
ZeroMist™ and Clean Air ZeroSmoke™ units are designed for airflow delivery
at maximum saturation, ensuring maximum efficiency.
The vertical and modular design allows for machine tool mounted units, central
units for multiple machines, and larger central systems that can operate for an
entire machining line. Packaged units include direct-drive, dynamically balanced
backward incline blower wheels with AMCA rated performance and energy efficient motors that are VFD duty rated.
Clean Air
ZeroMist™
& Clean Air ZeroSmoke™
The Most Advanced Oil Mist and
Oil Smoke Collector On The Market
What are the risks of oil mist and oil smoke?
• Oil mist can contain small metallic particles, bacteria and spores that can
give rise to respiratory problems.
• Oil mist can cause skin problems, including oil acne and eczema.
• Oil mist eventually settles on the floor, increasing the risk of slipping.
• Oil mist accumulating on surfaces inside HVAC systems will impair its
function, efficiency, filter life, and cause premature failures, which will cause
foul indoor air.
• Generally unclean environment due to the oil attracting other impurities,
causing them to stick to machines and other equipment.
UL 508A:2005 CAN
• Oil mist harms the electronics in modern metalworking machines.
CSA C22.2 No. 14:2005
MADE IN THE USA
SELF-DRAINING FILTER
TECHNOLOGY
KEY COMPONENTS OF THE
Clean Air ZeroMist™ & Clean Air ZeroSmoke™
1. Centrifugal Fan: Packaged units include direct-drive centrifugal backward
inclined blowers with AMCA rated performance. The direct drive blowers include energy efficient VFD duty rated motors. The direct drive fan arrangement
simplifies operation and maintenance. The blowers and motors are housed in
a sound-attenuated plenum to reduce sound pressure levels.
2. Stage 1 & 2 Coalescing Fiber Bed Filters: Application-specific coalescing fiber bed filters are the heart of these systems and are provided with specific
permeability for the customer’s application. These filters are self-draining and
allow for maximum collection efficiency, minimal maintenance, and maximum
draining with a filter life of 1-5 years dependent upon application. The combined fiber beds are 99.97% efficiency prior to the final HEPA safety filter.
3. Final Safety Filter: The final stage is the HEPA safety filter which is a H13
HEPA filter rated for 99.997% efficiency at 0.3 micron. This filter is positioned
after the primary coalescing fiber bed filters and receives minimal loading and
ensures discharge air quality at a level of 0.002 mg/m3 well below current and
future oil mist regulations.
4. Inlet Plenum: A sloped inlet plenum with 1” NPT allows for a change in
direction of inlet air and a reduction in velocity to separate out large particulate
and for the drainage of the collected fluid. The inlet plenum includes a standard
leg set to allow for draining.
5. Pump: An automatic pump package with small tank, automatic float
controls, and a low voltage pump with 28’ of head pressure allows you to discharge the collected fluids back into the machining center or a larger coolant
filtration system.
(Not Shown)
6. Optional PreFilter to collect larger
particles.
7. Optional Spray
System for drier
applications.
1
3
2
5
4
All Clean Air ZeroMist™ &
ZeroSmoke™ collectors utilize a
unique technology that is designed to
increase the filter life span and
decrease maintenance costs.
By using a special media type, these
filters collect the oil and coalesce it
into larger oil droplets until they are
heavy enough to fall off the filter’s
media fibers. This allows you to reuse
the captured coolant and see a longer
filter life vs filters that become saturated with collected oil.
An optional pre-filter can be added
(as seen below) to the unit for
applications where larger particulate
is present. This pre-filter captures
these particles before it can reach
and potentially ruin the deep
fiber bed filters.
Clean Air
ZeroMist™ and Clean Air ZeroSmoke™
System Platforms
The Clean Air ZeroMist™ mist collection system is designed for light to
moderate inlet concentrations from
2-20 mg/m3. Packaged units are
available from 400 to 3,600CFM
with direct drive centrifugal fan packages. Larger centralized systems are
available.
The Clean Air ZeroSmoke™ mist
collection system is designed for
light to moderate inlet concentrations from 20-150 mg/m3. Packaged units are available from 600 to
1,800CFM with direct drive centrifugal fan packages. Larger centralized
systems are available that will require
external centrifugal fans.
Both Systems are designed so that each filter stage includes differential
pressure gauges to monitor filter conditions. Filters are mounted in
each filter stage with positive mounting filter clamps to compress filter
gaskets securely to eliminate any potential bypass to the final safety
HEPA filter. Integral pre-filter housings allow for the addition of a prefilter stage for protection of fiber bed filters from grinding swarf, solids,
and sticky residue that would blind the first stage fiber bed filter.
Clean Air ZeroMist™ Applications:
•
•
•
•
•
Grinding (water-based & synthetic coolants)
Turning (water-based & synthetic coolants)
Milling (water-based & synthetic coolants)
EDM
Machining (water-based & synthetic coolants)
with moderate to high spindle speeds
Clean Air ZeroSmoke™
Applications:
•
•
•
•
•
•
Heat-treating processes
Cold-heading and bolt making
Gear cutting
High-speed grinding with oil
Forging
Rotary transfer machining
Clean Air Machining Solutions
are trusted by:
Clean Air HighSmoke™ 2400 for Heavy Smoke Applications
The Clean Air HighSmoke™ 2400, designed for “high smoke” applications, features a larger coalescing fiber
bed filter system with a lower permeability rating and deep fiber bed media suitable for filtration of higher
concentrations of sub-micron particulate.
HighSmoke™ 2400 applications
include:
•
Heat treating
•
Cold heading
•
Die casting
•
High-speed grinding with oil
•
Rotary transfer precision machining
•
Forging
•
Roll mills
Clean Air HighSmoke™ features include a robust, industrial-welded cabinet complete with a positive locking cam to compress filter gaskets to eliminate bypass, oversized specially designed coalescing fiber bed filters designed to filter up to 150 mg/
m3 of sub-micron particulate, final safety HEPA filter, and differential pressure gauges
for each filter stage, test ports for each filter stage, hinged access doors, inlet plenum
with 1”FPT drain fitting, as well as drain options that include p-trap or automatic pump
back system c/w tank, float controls, and pump w/28’ of head pressure.
The Clean Air HighSmoke™ 2400 can be mounted on a stand or floor mounted
for use with automatic pump back system. It is rated for 2,400CFM at maximum saturated conditions. A 10HP energy efficient motor with a narrow width backward inclined
high-pressure blower wheel provides 2,400CFM (at maximum saturation) with approximately 2.5”IN WG of external static pressure. A sound-attenuated fan plenum reduces
sound pressure levels. Inlet connections can be supplied for either side of the unit or
the rear of the unit to meet installation requirements. An optional VFD package with
HMI PLC can be supplied for basic energy savings or advanced system management
with feedback for fan HP, amperage, voltage, filter conditions, and operational parameters that can be linked to process machine for tailoring performance to machine tool
or process.
The Clean Air HighSmoke™ 2400 model is also a modular design and can be
supplied with common inlet and outlet plenums for a larger centralized system with
remote external centrifugal fan packages. The basic unit is rated for 2,400CFM at
maximum saturation and can be expanded to limitless CFM requirements to suit larger
installation requirements or total plant or cell ventilation.
Die Casting
Forging
Hydromat
Machining
Clean Air ZeroMist™ & Clean Air ZeroSmoke™
•
•
•
•
•
•
FEATURES:
BENEFITS:
Self-draining filters
Optional VFD packages for energy savings
Heavy duty cabinet construction, Made in the USA
High filtration efficiency
Maximum reclaim of coolant for reuse
Customization with modular construction
• Maximum Filter Life, 2-5 years
• VFD allows for decreased operation costs by
providing energy consumption
• Designed for continuous duty with maintained airflow
throughout operation
• Flexible modular construction for installation versatility
N
005
Clean Air
ZeroMist™
& Clean Air ZeroSmoke™
The Most Advanced Oil Mist and
Oil Smoke Collector On The Market
COMPLETE TURNKEY SOLUTION for OIL MIST and OIL SMOKE
Many manufacturing processes such as machining, heat-treating, CNC turning,
cold-drawing, and more can create a oil/emulsion based mist or smoke that can
be extremely hazardous to your employee’s health along with decreasing the life
time of your equipment causing unexpected and costly repairs, and create a slippery working environment. Clean Air America designed the Clean Air ZeroMist
and ZeroSmoke to effectively filter out this oil mist and smoke to create a clean
and safe working environment. Utilizing an advanced and unique technology,
the Clean Air ZeroMist and ZeroSmoke allow for optimum filtration while providing low maintenance and ownership costs.
ABOUT CLEAN AIR AMERICA, INC,
With over 20 years of proven designs and installations, Clean Air America, Inc.
is the clear choice for industrial ventilation solutions for manufacturing and vocational/educational facilities. Clean Air America provides application-specific
solutions for welding smoke/fume, dust collection, and coolant mist, oil smoke,
and oil mist processes. Clean Air America, Inc. has designed these systems with
exceptional quality, high-efficiency, and durability in mind to provide units that not
only hold up to a 24/7 manufacturing environment but outperform competitor’s
technology and conventional systems on the market.
Clean Air America, Inc. provides:
• Factory-direct pricing
• Turnkey Installation and Proven Engineering
• Efficient designs with minimal impact to plant layout, maximum energy
conservation, compliance with regulations, minimal maintenance, and
maximum collection efficiency.
All Clean Air America, Inc. products are proudly Made in America.
All electrical panels are UL and CSA approved.
MADE IN THE USA
UL 508A:2005 CAN
CSA C22.2 No. 14:2005
MADE IN THE USA
Clean Air America, Inc. LEAF Initiative:
The Clean Air LEAF (Low Energy Air Filtration) Initiative is a dedication by Clean Air America to design units and
promote the use of “green” features for air filtration. By using recirculated air, sending dirty air outside is eliminated, helping to protect the environment from the same particles you are trying to protect your employees from.
From a system standpoint, Clean Air systems are engineered with low energy and increased filter life in mind. With
various features such as VFD (Variable Frequency Drive), Economizer, and self-cleaning pulse technology, each unit
is designed to decrease unit energy consumption, decrease facility AC and heating costs, and decrease waste by
providing the longest filter life in the market.
Other Clean Air America Systems
Welding Application Based Units
Clean Air Smart Collector™
Clean Air WeldCell™
Clean Air WeldStation™
Ranging from 2 cartridge to 48 cartridge,
& FlexiBooth
Designed specifically for a variety of
the Clean Air Smart Collector™ is
The self-contained welding booth solurobotic welding situations, the Clean Air
the most versatile collector on the market. WeldCell™ is a 100% turnkey solution for tion is an easy-to-install welding solution
Utilizing patented Down Flow© technology
that requires no duct work and is easy
your welding robot cell. From the
and high efficiency filters, the Clean Air collector, duct, hood through installation, to move. Featuring backdraft filtration
Smart Collector™ can be used in plasma
and a 4 cartridge collector on top of the
Clean Air provides a complete solution
cutting, welding, laser cutting, and more.
booth, this solution is perfect for parts
for your specific welding robot cell.
welding up to 12’.
Ambient Air Filtration Systems
Clean Air Streamer™
The Clean Air Streamer™ is an ambient air filtration unit that is completely
self-contained unit and requires ZERO
duct work, making install and maintenance quick and easy. This system
continuously moves clean, filtered
air around the facility, preventing the
formation of a welding smoke layer.
Clean Air DFX
Clean Air Push Pull System
The Clean Air DFX Unit is a compact,
Powered by the Clean Air Smart
continuous-duty and self-contained
Collector™, this system cuts out the
ambient air cleaning system. The
need to ventilate air to the outside by
polluted air enters the system at the recycling the dirty air after it is filtered
filter side and is filtered through a
through a cartridge filter system. The
multi-stage process to achieve the
cross-flow of air movement return s
desired cleaning.
clean air to the plant, eliminating a
significant heat loss that is
common when air is exhausted
outside.
7 Superior Drive, Rome, GA 30161 | (706) 291-1700
|
(866) 665-1829
www.clean-air.com | sales@clean-air.com