1 BSK Global Alaaddinbey Mh. 628. Sk. Kaan Plaza No: 2/K 16120 Nilüfer, BURSA T: +90 224 441 99 62 F: +90224 443 63 28 [email protected]
Jul 18, 2015
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BSK Global
Alaaddinbey Mh. 628. Sk. Kaan Plaza No: 2/K 16120 Nilüfer, BURSA
T: +90 224 441 99 62 F: +90224 443 63 28
Providing environmental solutions to industry since 1928, in Einbeck - Germany
� Needlefelt production
� Treatments
� ePTFE Membrane lamination
� Filter bag stitching
� Filter cage production
� Project Management, Selectionof Filter Media
� Maintenance, Exchange ofFilter Bags
� Laboratory Tests,Investigations
� Filterbag Testing2
KAY-TEX® is an expanded microporous PTFE-membrane that is bonded to the surface of conventional filtermedia, including felts and woven fabrics.
This membrane provides high filtration efficiencies (99.99+ %), superior dustcake release and improved airflow at lower energy consumption levels.
KAY-TEX® ePTFE-Membrane provides:
� Higher airflow
� Near Zero emissions
� Superior clean-down
� Longer bag life
� Lower differential pressure
KAY-TEX® – MEMBRANE PRODUCTS
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▪ Mikroporous Membrane is made out of expanded Polytetrafluorethylene (ePTFE)
▪ stable to chemical attacks
▪ water-repellent
▪ fibre distance is that big to allow air passage, but not that big for particles
▪ extremely fine pored and smooth filtration surface
▪ helps to have a better dedusting during the filtration process
▪ Free of PFOA (Perfluorooctanoic acid)
▪ Pore size ≤ 1µm
Mikroporous ePTFE-Membrane & characteristics
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1.PTFE powder blended with extrusion aid (lubricant)
2.Powder and lubricant pre-formed into cylinder shape
3.Preform extruded through a die into tape
4.Tape calendared to desired thickness
5.Lubricant removed through drying
6.Tape stretched to desired width to create
membrane
Production of ePTFE-Membrane
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Dedicated for these substrates:
▪ Needlefelts
▪Woven fiberglass
ePTFE Membrane thermal laminated at
▪ Polypropylen (PP)
▪ Polyester (PES)
▪ Meta Aramid (MAR)
▪ Polyacrynitril (PAN)
▪ Polyphenylensulfid (PPS)
▪ Polyimid P84 (PI)
▪ Polytetrafluorethylene (PTFE)
▪ Fiberglass (GL)
KAY-TEX® – INNOVATIVE MEMBRANE LAMINATES
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Dr. Roy J. Plunkett & team at his laboratory at DuPont, where he discovered Teflon in
1938
� Polytetraflurethylene (PTFE) is a fluoroplastic
� PTFE is used nowadays at different products, due to its unique characteristics:• Medical technology (e.g. Stents / Bypass / Implants)• Sealing material for the aerospace as well as for the chemical and pharmaceutical industry• Textile industry (breathable – water and draftproof clothes / shoes etc.)• expanded PTFE-film (ePTFE) – used at filtration
� PTFE discovered by DuPont in 1938
� Development of ePTFE Membrane by Gore in 1969
� Expanded PTFE (ePTFE) is a special processed type ofPolytetrafluoroethylene by the guidance of the molecule fibres
� The ePTFE membrane consists of very thin expanded layers. Thismembrane has such fine pores that are still big enough to let water steampenetrate, but not water in liquid form
� Tetratec starts production of ePTFE Membrane in 1981. Donaldson aquiredTetratec in 1994
� BHA Technologies starts producing its own ePTFE Membrane in 1994
� KAYSER aquired the technology of BHA in 2010
PTFE characteristic& diversity
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2,54 cm: 25.400 µm
Human hair: 40-120 µm
Ballpoint pen tip:500-1.200 µm
KAY-TEX® – ePTFE Membrane Size comparison
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Magnification: 2000x
KAY-TEX® – qualitydetermining criterias
Established & proven ePTFE Membrane Types
Firstclass Substrates� Needlefelts� Woven Fiberglass
controlled Laminationprocess� Cleanliness� Temperature� Pressure� Speed 9
Conventional filtermedia vs. membrane laminates
Conventional filtration:Dust particles penetrating thru the filtermedia
Staubpartikel…
Membrane filtration:Dust particles are collected on the membrane surface
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� KAYSER offers with its own production line the full portfolio ofmembrane products.
� The Kayser ePTFE-Membrane can be laminated to followingsubstrates:
• Polypropylen (PP)• Polyester (PES)• Meta Aramid (MAR)• Polyacrynitril (PAN)• Polyphenylensulfid (PPS)• Polyimid P84 (PI)• Polytretrafluorethylen (PTFE)• Fiberglass (GL)
� KAYSER offers ePTFE-Laminates, which are well-establishedand proven technology at high quality standards (BHA).
KAY-TEX® Product series
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Traditional Industries
Cement
Asphalt
Steel
Foundry
Minerals
Mining
Aluminium
Incineration
Energy
Gypsum
Glass
Waste combustion
Lime
Carbon black
ferro-silicon
Indust. Boiler
Battery/Lead
Sec. Smelting
Process Industries
Chemistry
Plastics
Food
Pharmacy
Tire / Rubber
TiO2
Fiberglass
Paint
Wood / Paper
Grain
KAY-TEX® - area ofapplications
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KAY-TEX® - ReferenceWoven fiberglass with ePTFE
Membrane
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KAY-TEX® - ReferencePTFE Needlefelt with ePTFE Membrane
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KAY-TEX® OFFERS:
� Increased airflow at lower energy consumptionKAY-TEX® prevents penetration of fine particulate without restricting airflow
� Lower pressure dropThe non-stick properties of KAY-TEX® make filters easier to clean, allowing a lower pressure drop to be consistently maintained
� Lower outlet emissionswith KAY-TEX® emissions are reduced to nearly ZERO
� Longer filter bag lifeKAY-TEX® filters can extend the life of your filters dramatically.
KAY-TEX® - Advantages
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� Homogeneous and consistent fabricstructure
� PTFE-Finish takes place in a specialmethod under high temperature and untilthe deep of the fabric after an efficientdesizing of the woven fibre glass (ovenprocess used to clean the fabric prior to thefinishing step).
� PTFE-Impregnation is predominant on thesurface
• only little limitation for the laminating process
� Removal of textile size / facing from theproduction of the glass yarns does not oronly insufficient take place
• Impregnation more or less on the surface• PTFE-Finish realized under lower
temperatures
Asian Substrate KAY-TEX® Substrate
KAY-TEX® Substrate vs. Asian Substrate
High Magnification
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KAY-TEX® Substrate vs. Asian Substrate
Asian Substrate KAY-TEX® Substrate
High Magnification
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KAY-TEX® Substrate vs. Asian Substrate
Asian Substrate KAY-TEX® Substrate
� KAYSER woven fibre glass produced withtexturised weft yarns / homogeneous
� Caramelization process and PTFE-Finish ensure:
• Maximum mechanical durability• Very good lamination results
KAY-TEX® Substrate vs. Asian SubstrateMIT Flex-Test results
MIT Flex Test – ResultsFor
Fiberglass - Substrate (750 g/m²)
Specification KAY-TEX Asian
Weight g/m² 770 g/m² 780 g/m²Thickness mm 1,0 mm 1,0 mm
LOI % > 10% >10%
MIT Flex Test results(Cycles to failure) Warp 100.000 70.000(Cycles to failure) Weft 20.000 15.000
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Membrane damages at bonding points
Membrane damages and delamination
SEM-images of an asian PTFE-Membrane Fiberglass material
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Membrane damages Membrane damages, broken fibers
High Air Perm Test Results
• Fiber diameter is 10 microns ���� Fiber grade is G-Glass (lower cost, less flex resistance)
• Industry standard is the high quality DE-filament ( 6 microns, higher flex resistance)
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SEM-images of an asian PTFE-Membrane Fiberglass material
Example of a less homogeneous PTFE-finish with possible future consequences
PTFE Finish non-homogeneous PTFE Membrane will be damaged thru Glass fibres after wear (Flextest)
Influencing factors at theWoven Glass-Laminate
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Example of an homogeneous and perfectPTFE-Finish of a woven fiberglass
PTFE Finish homogeneousPTFE Membrane with a good bonding and an homogeneous structure
Standard23
Influencing factors at theWoven Glass-Laminate
Pore structure (Asian) Pore structure (KAY-TEX®)
KAY-TEX laminateAsian laminate
SEM-comparison ofMembrane structures
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Asian PTFE Needlefeltwith Membrane
The physical characteristics of the laminate comply with the specification, but the membrane structure and the lamination
indicate „Overbonding“
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KAY-TEX® PTFE Needlefeltwith an ePTFE Membrane
Excellent controlled and homogeneous bonding of the membrane, Well-preserved Membrane structure for high filterperformance
Standard 26
The correct manufacturing of Membrane filter bags
Consider some characteristics during construction and man ufacturingof membrane filter bags:� Tight bag-to-cage fit
Pinch at needlefelt: 6-10mmPinch at woven glass: 0-5mm
� Adjustment of cutting preferablywith a sample filter cage
� Longitudinal wire distance max. 30mm at needlefelt and 25mm at woven glass
� Increased care at seams needed� Welded longitudinal seam preferred (if possible)
if applicable additional seam sealing� GMP-special designs are possible,
to prohibit product contact with fibresrespectively to minimize bonds
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Turned filter bag Reinforcement with bottom seam
protection
Seam sealing with PTFE-tape at top
area
Seam sealing with PTFE-tape and Siliconinlay at
bottom area
GMP-seam at Needlefelt28
The correct construction of Membrane filter bags
Installation of membrane filter bags without installation sleeves causes membrane damages
Improper installation of the snapring � leakage consequences
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The correct installation of Membrane filter bags
KAYSER belongs to the 5 leading producers of textil e filtermedia in Europe
KAYSER has appropriate experiences and is the only producer worldwide, who � produces needlefelts� Laminates with an ePTFE-Membrane � stitches filter bags � manufactures filter cages � provides engineering services
YOUR FILTRATION PARTNER, SINCE 1928