Search Results (22)

Electret filter media are electrostatically charged during the manufacturing process to activate effective electrical separation mechanisms. In order to investigate the influence of humidity on these mechanisms, the electric field, and filtration efficiency, a Direct Numerical Simulation (DNS) study of the aerosol deposition within wetted fibrous nonwoven filter media used in masks was carried out. Initial experimental investigations determined key properties of the filter material, including porosity, fiber diameter, and surface charge density. Using Micro-Computed Tomography (µCT), preferred locations for droplet deposition within the filter were identified. Additional experiments quantified the amount of water absorbed by the filter medium and assessed its impact on the existing electric field. Numerical simulations examined various models with differing porosity and fiber diameter, incorporating different levels of water content to analyze the changes in the electric field, flow velocity, and resulting filtration efficiency. The results provide valuable insights into the significant effects of fiber change on filtration performance, demonstrating the electret filter’s ability to partially compensate for the negative impacts of water. Full article

Pore sizes on the micrometre scale are a critical factor influencing the fluid transport properties of textiles. Consequently, the pore size distribution function is a desirable parameter in the design of textiles for technical applications. However, the experimental determination of pore size and its distribution can be challenging, costly, or impractical. Knitted fabrics offer a wide range of porosity and pore size distribution properties. While statistical models have shown reasonable accuracy in predicting pore size distributions in nonwovens and filter media, no equivalent model exists for twist-texturized yarns and single-jersey knitted fabrics. This study presents a hierarchical pore model for single-jersey fabrics. The model uses a log-normal distribution for the intra-yarn pores in the yarn and cylindrical pores for inter-yarn pores between the yarns in the fabric. With these two pore sizes, the model quantitatively characterises the porous structure of the fabric. Initial validation of the model for intra-yarn pores on four yarns of different fibre finenesses shows that the model can cover the influence of different fibre counts. For the validation on the fabric scale, two tomography datasets of single-jersey knitted fabrics show that the presented model can capture the effect of different fabric structures. A parameter study visualises the effects of both yarn and knitting parameters on the pore size distribution function of single-jersey knitted fabrics. The mean pore sizes of the fabrics are given. The results deepen the understanding of the porous properties of knitted fabrics and provide a valuable direction for structural fabric development on knitting machines. Full article

Rotating biological contactors (RBCs) are widely utilized in aerobic wastewater treatment due to their high stability, efficiency, and ease of maintenance. The choice of disc carrier material for biofilm formation is a critical factor influencing treatment performance. In the context of rural domestic wastewater treatment, the biofilm carriers must balance cost-effectiveness and high efficiency. This study focuses on the aerobic unit of a combined anoxic denitrification–deodorization filter–aerobic RBC system, specifically, the waterwheel-driven aerobic RBC, and evaluates three types of biofilm carrier media: felt, carbon felt, and nonwoven fabric. The study compares their pollutant removal performance and biofilm enrichment characteristics to identify the optimal material. The results indicate that RBCs using nonwoven fabric as the biofilm carrier exhibit superior nitrification efficiency and biocompatibility compared to the other materials, achieving average removal rates of 84.3% for COD_Cr and 80.5% for ammonia nitrogen. While the addition of nonwoven fabric slightly reduced the driving efficiency of the waterwheel-driven aerobic RBC, it significantly enhanced oxygen transfer efficiency, which explained the enhanced organic degradation and ammonia nitrification. During the biofilm stable phase, the two-stage waterwheel-driven RBC with a nonwoven fabric carrier achieved average COD_Cr and ammonia nitrogen removal rates of 86.76 ± 0.85% and 92.15 ± 1.49%, respectively. Nonwoven fabric demonstrates significant potential as a biofilm carrier for aerobic rotating biological contactors. Full article

Most FFP (Filtering Face Piece) masks are made from nonwoven filter media that are electrostatically charged, resulting in the additional electrostatic capture mechanism of particles. The protective effect of these masks is therefore mainly dependent on the electric field surrounding the charged fibers. Upon prolonged wear, the mask becomes saturated with exhaled air, resulting in humidification on the wearer’s side. However, speaking, coughing, or sneezing also generate droplets, which can deposit on the mask from the person wearing it, as well as from other people. In order to investigate this influence on the filtration efficiency and the existing electric field, an experimental study was carried out. To imitate human breathing, a test setup was constructed using a Sheffield Head with different types of masks. This was followed by the cyclical humidification and drying of the masks through simulated breathing. By observing these phases in detail using sample sections, it was possible to continuously record the water content in the samples, the relative humidity, and the pressure drop (breathing resistance). The results demonstrate that moisture has an impact on the filtration efficiency of the electret FFP masks when worn under real-life conditions and that the initial condition can be restored with sufficient drying time. Full article

The study aims to eliminate the effect of coalescing filter blocking due to on–off operation by changing the wetting properties of the non-woven fiberglass filter media through their chemical modification with the use of a polydimethylsiloxane (PDMS) solution in hexane and a few commercial products that give the surface oleophobic properties. The best results—high separation efficiency, no redispersion of droplets at the outlet, and low flow resistance—were obtained for materials coated by immersion in a 0.2% PDMS solution, for which a reduction in oleophilicity was found, but the material was not oleophobic and still moderately wetted with the test liquid. The corresponding static contact angle with the VG-46 rotary compressor oil measured on the flat borosilicate glass wafer made of the same material as the fiberglass media was equal to 54° for the PDMS dip-coated surface. Moreover, the good stability of the applied polymer on the material surface was confirmed by the SEM imaging, the FTIR analysis, and maintaining a high performance in multiple tests run for a single coalescing element. Full article

Nonwoven filter media are used in many industrial applications due to their high filtration efficiency and great variety of compositions and structures which can be produced by different processes. During filter operation in the separation process, the fluid flow exerts forces on the filter medium which leads to its deformation, and in extreme cases damage. In order to design or select a reliable filter medium for a given application, it is essential to have a comprehensive understanding of the mechanical properties of the nonwoven material. In general, the properties of the filter material are influenced by temperature and can be changed during loading due to irreversible deformation, fatigue, and aging processes. In order to gain a deeper comprehension, the presented study examines the influence of temperature and repeated tensile stress on the filter medium properties. The focus is on fuel and oil filters employed in automotive applications. The characteristic properties of the samples, including thickness, porosity, and permeability as well as Young’s modulus and Poisson’s number, are measured. Young’s modulus is determined for both new and aged samples. In addition, the viscoelastic behavior is investigated via a dynamic mechanical thermal analysis. The results demonstrate a significant dependence of mechanical properties on the material composition and the aging effects. Full article

Various modifications of standard glass fiber filtration media using electrospun PA66 nanofibers are described. PA66 were selected because they were readily available from commercial sources. Other polymers, such as PP, PET and PBT, could also be used. The first set of samples was prepared by mixing the nanofibers at two, three and five weight percent with glass fibers, and the second by laying the same proportion of the nanofibers directly onto the downstream side of the substrate. The aim of these modifications was to improve the three most basic functionalities of filter media, the separation efficiency, the differential pressure (ΔP) and the dirt holding capacity (DHC). The modified media samples were evaluated with the standard textile characterization techniques and filtration performance evaluation procedures. The results showed differences in the several tens of percentage points achieved with the two modification methods. Moreover, additional differences in performance were observed depending on the percentage of nanofibers admixed to the substrate. These differences were most apparent in the filtration efficiency and the DHC, both by several percentage points, with no apparent effect on the ∆P. The results strongly suggest that the preparation of new filter media by incorporating nanofibers directly into the matrix can result in significant improvements in filtration performance characteristics. Full article

This study reports on the two-step manufacturing process of a filtration media obtained by first electrospinning a layer of polycaprolactone (PCL) non-woven fibers onto a paper filter backing and subsequently coating it by electrospraying with a second layer made of pure acidolysis lignin. The manufacturing of pure lignin coatings by solution electrospraying represents a novel development that requires fine control of the underlying electrodynamic processing. The effect of increasing deposition time on the lignin coating was investigated for electrospray time from 2.5 min to 120 min. Microstructural and physical characterization included SEM, surface roughness analysis, porosity tests, permeability tests by a Gurley densometer, ATR-FTIR analysis, and contact angle measurements vs. both water and oil. The results indicate that, from a functional viewpoint, such a natural coating endowed the membrane with an amphiphilic behavior that enabled modulating the nature of the bare PCL non-woven substrate. Accordingly, the intrinsic hydrophobic behavior of bare PCL electrospun fibers could be reduced, with a marked decrease already for a thin coating of less than 50 nm. Instead, the wettability of PCL vs. apolar liquids was altered in a less predictable manner, i.e., producing an initial increase of the oil contact angles (OCA) for thin lignin coating, followed by a steady decrease in OCA for higher densities of deposited lignin. To highlight the effect of the lignin type on the results, two grades of oak (AL-OA) of the Quercus cerris L. species and eucalyptus (AL-EU) of the Eucalyptus camaldulensis Dehnh species were compared throughout the investigation. All grades of lignin yielded coatings with measurable antibacterial properties, which were investigated against Staphylococcus aureus and Escherichia coli, yielding superior results for AL-EU. Remarkably, the lignin coatings did not change overall porosity but smoothed the surface roughness and allowed modulating air permeability, which is relevant for filtration applications. The findings are relevant for applications of this abundant biopolymer not only for filtration but also in biotechnology, health, packaging, and circular economy applications in general, where the reuse of such natural byproducts also brings a fundamental demanufacturing advantage. Full article

Air pollution is becoming a serious issue because it negatively impacts the quality of life. One of the first most useful self-defense approaches against air pollution are face masks. Typically made of non-renewable petroleum-based polymers, these masks are harmful to the environment, and they are mostly disposable. Poly(butylene succinate) (PBS) is regarded as one of the most promising materials because of its exceptional processability and regulated biodegradability in a range of applications. In this regard, nanofiber-based face masks are becoming more and more popular because of their small pores, light weight, and excellent filtration capabilities. Centrifugal spinning (CS) provides an alternative method for producing nanofibers from various materials at high speeds and low costs. This current study aimed to investigate the effect of processing parameters on the resultant PBS fiber morphology. Following that, the usability of PBS nonwoven as a filter media was investigated. The effects of solution concentration, rotating speed, and needle size have been examined using a three-factorial Box–Behnken experimental design. The results revealed that PBS concentration had a substantial influence on fiber diameter, with a minimum fiber diameter of 172 nm attained under optimum production conditions compared to the anticipated values of 166 nm. It has been demonstrated that the desired function and the Box–Behnken design are useful instruments for predicting the process parameters involved in the production of PBS nanofibers. PBS filters can achieve an excellent efficiency of more than 98% with a pressure drop of 238 Pa at a flow rate of 85 L/min. The disposable PBS filter media was able to return to nature after use via hydrolysis processes. The speed and cost-effectiveness of the CS process, as well as the environmentally benign characteristics of the PBS polymer, may all contribute considerably to the development of new-age filters. Full article

Fibrous nonwoven coalescence filters are commonly utilized in gas-cleaning processes to separate liquid droplets from a gas stream, e.g., oil mists. These filters are mainly composed of micro glass fibers and in some cases, small amounts of synthetic fibers. The shape of the deposited oil on filter fibers of the filter media depends on several factors, including the oil saturation, wettability, roughness, diameter of the fibers and fiber arrangement. The oil deposits can take the form of, e.g., axially symmetric barrel-shaped droplets or larger structures, such as oil sails between adjacent fibers. Understanding the initial state of the coalescence filtration process and the impact of the deposited oil structures on the separation efficiency requires characterizing these structures. X-ray microtomography (µ-CT) and artificial intelligence tools for segmentation can be utilized to visualize, identify and analyze deposited oil structures in the micrometer region. To quantify and compare oil structures formed at three distinct filtration velocities (10, 25 and 40 cm s${}^{-1}$) commonly utilized in industrial applications and one defined oil saturation of oleophilic coalescence filter media, applying X-ray microtomography is the main emphasis of this work. The results indicate that there is no significant influence of the filtration velocity on the local saturation (determined via µ-CT), the number- and volume-based fractions of the identified deposited oil structures on or between adjacent fibers as well as the droplet concentrations and distributions of deposited oil droplets. It is assumed that the structure of the deposited oil formed by coalescence in the filter medium is dominated by the wetting properties of the fibers (surface tension and surface energy) and the saturation, independent of the filtration velocity. Full article

Particulate matter air pollution and volatile organic compounds released into the air from the incomplete combustion of fossil fuels and wildfires creates significant damage to human health and the environment. Advances in air filtration and purification technology are needed to mitigate aerosol hazards. This article details an effort to explore the potential benefits of new materials and methods for the production of nonwoven air filtration media through electrospinning and stabilizing polyacrylonitrile fibers. The investigated production methods include electrospinning fibrous matting onto a stainless steel wire mesh and stabilizing the nonwoven media in a chamber furnace. The media is then tested for air filtration penetration and airflow resistance, and the fiber size distribution is measured using scanning electron microscopy. The experimental results show that the electrospun media approaches the performance criteria for airflow resistance and particle capture efficiency of high-efficiency particulate air (HEPA) filter media. Furthermore, performance estimations for electrospun media of increased thickness and for a decreased filtration velocity show potential to exceed the HEPA media resistance and efficiency criteria. Thus, it is suggested that electrospun and stabilized nonwoven fibrous media are candidates as alternatives to traditionally manufactured HEPA media and may potentially benefit modern air filtration technology and reduce hazards associated with particulate matter. Additionally, the authors recommend future exploration into the carbonization and activation of electrospun filter media for the adsorption and mitigation of volatile organic compounds as a secondary benefit, while maintaining high efficiency and low airflow resistance in the removal of particulate matter from aerosol streams. Full article

Currently, the storage of ore processing residues is a major challenge in the mining industry. These tailings are increasingly filtered in advance of disposal using filter presses to make storage safer and to recover water effectively. However, the falling of the detached filter cakes between the individual filtration cycles results in the abrasive wear of the filter cloths at specific points of the chamber geometry and is a main reason for the necessity of a regular replacement. Improved filter media selection through abrasion testing replicating this specific load case increases plant economics by reducing the risk of unplanned downtimes. Therefore, this article explains a test procedure adapted to the direction-specific wear. A brush apparatus is presented, which abrasively loads filter fabrics stretched over an exchangeable edge geometry uniaxially in one direction. The effects of important apparatus setting parameters (sample clamping torque, brush overlap, and brush speed) are shown. Furthermore, the resistances of three different filter media typical for tailings filtration were compared and different edge geometries investigated. Thereby, significant differences were found with regard to filter media type, filter media material, and edge geometry. Depending on the edge geometry used, the polypropylene fabric withstands a load amount by a factor of 3.3 to 8.9 higher than the nonwoven polypropylene, the nylon fabric withstands a load amount by a factor of 3.6 to 5.3 higher than the polypropylene fabric and the nylon cloth withstands a load amount by a factor of 16.1 to 31.8 higher than the nonwoven polypropylene. Full article

Computational modeling of air filtration is possible by replicating nonwoven nanofibrous meltblown or electrospun filter media with digital representative geometry. This article presents a methodology to create and modify randomly generated fiber geometry intended as a digital twin replica of fibrous filtration media. Digital twin replicas of meltblown and electrospun filter media are created using Python scripting and Ansys SpaceClaim. The effect of fiber stiffness, represented by a fiber relaxation slope, is analyzed in relation to resulting filter solid volume fraction and thickness. Contemporary air filtration media may also be effectively modeled analytically and tested experimentally in order to yield valuable information on critical characteristics, such as overall resistance to airflow and particle capture efficiency. An application of the Single Fiber Efficiency model is incorporated in this work to illustrate the estimation of performance for the generated media with an analytical model. The resulting digital twin fibrous geometry compares well with SEM imagery of fibrous filter materials. This article concludes by suggesting adaptation of the methodology to replicate digital twins of other nonwoven fiber mesh applications for computational modeling, such as fiber reinforced additive manufacturing and composite materials. Full article

The purification of indoor pathogenic microorganisms has become a topic of concern. The use of nonwoven media air filters causes high resistance, and the problem of noise limited their application under high air volume. Thus, we propose a micro-electrostatic filter, which has improved performance compared to an electrostatic filter, with a new type of cylindrical structure to tackle indoor pathogenic microbial aerosol pollution. Through simulation, it is found that the filtration performance of a cylindrical structure is better than that of a plate structure under all simulation conditions. For particles larger than 1 μm, the shortest theoretical length of the dust collecting plate required for the cylindrical structure is 34% shorter than that for the plate structure. For 0.1 μm particles, the filtration efficiency of the cylindrical structure is nearly 20~30% (the maximum value is 29.76%) higher than that of the plate structure, while the air velocity is 1.5 m/s~2.5 m/s. The resistance of the cylindrical micro-electrostatic filter is only half of that of the combined plate type micro-electrostatic filter, indicating that the cartridge structure has enormous energy-saving potential. The introduction of the quality factor further proves that the integrated filtration performance of the cartridge micro-electrostatic filter is better. The application of cylindrical micro-electrostatic filters in HVAC systems can help improve indoor air quality and reduce health risks. Full article

The presented research aims to characterize hydrolytic resistance of highly crystalline and oriented polylactide (PLA) as a prerequisite for exploiting this bio-based material in durable applications. Industrially melt-spun PLA monofilaments and nonwovens have been subjected to environmental aging in a temperature range of 50–70 °C at a wide range of relative humidity (RH) in order to identify the onset of the material degradation under application conditions. Along with the measurements of mechanical and thermal behavior of the aged samples, the suitability of FTIR spectroscopy to probe the initial changes in the crystalline structure and in chemical composition of the fibers, caused by hydrolytic degradation, has been evaluated. The diagrams of stability and hydrolytic degradation under employed environmental aging for 7–14 days are presented for both types of PLA materials. Assessment of filtration performance of the artificially aged fibrous PLA media indicated a good agreement with the established stability diagram and confirmed the application potential of PLA nonwoven media, spun from currently available PLA grades, in air filtration under moderate climatic conditions up to max 50 °C and 50% RH. The presented results advance the knowledge on hydrolytic resistance of bio-based industry-relevant fibers and therefore open new application areas for sustainable materials with biodegradable components. Full article