Air-Clear Coalescing Fiberbed Mist Collectors capture, collect, and remove the liquid mists, aerosols, and submicron particles, that cause opacityOpacity
The amount of light which is blocked by a medium, like smoke or a tinted window. Opacity is a measurement and is usually stated as a percentage. An opacity of 0% means that all light passes through, and an opacity of 100% means that no light can pass through. Opacity is important because it gives an indication of the concentration of pollutants leaving a smokestack. The more particles which are passed through a stack, the more light that will be blocked, and, as a result, a higher opacity percentage is achieved. , smoke, and blue haze. Fiberbed coalescing filter technology eliminates aerosol mists and submicron particles from virtually any gas stream. Using the field-proven processes of Impaction

Impaction
Particles in the <4 micron range are carried via inertia until they strike a filter fiber (impaction) and are collected

Air-Clear Coalescing Fiberbed Mist Collectors are custom designed for many Industrial Processes. Industrial Processes
These are some of the many industrial processes that routinely apply Coalescing Fiberbed Mist Collectors for control of visible and odorous emissions.

Air-Clear's Coalescing Fiberbed Filters Mist Collectors is proven Technology Technology
Fiberbed technology was originally developed in the early 50’s by General Electric Company for the filtration of Radioactive Aerosols at the Hanford Works under a government contract # W-31-109-eng-52. The technology was applied to numerous industries by various companies. Often referred to as mist eliminators for their use for acid mist control, packed fiberbeds are also known as ‘candles’ (due to the filter shape) that offers a cost effective solution for the control of opacity and odors ... Here's why...

Low capital cost when compared to other technologies.Other technologies
that compete with fiberbed filters include Thermal and Catalytic oxidizers, Scrubbers, and Electro Static Precipitators (ESP) all have initial capital cost that range up to three times more than the fiberbeds

Air-Clear's Coalescing Fiberbed Filters save customers money with its low operating costs.

• Low initial pressure drop Pressure Drop
  Air-Clear Coalescing Fiberbed Mist Collectors have a start-up pressure drop of about 2" W.C.(inches of water column). Our competitors starting pressure drop is typically as high as 10"W.C. The result is that much more horse power is required to move the air through the filters. saves energy.
• Fan motor runs on VFD VFD
  
  • Since all of the pressure is not needed when the filters are clean, a damper or VFD (variable frequency drive) is used to adjust fan motor speed
  • Fan motor runs on VFD to save costs when running with reduced flows or when filters have a low pressure drop
  • As pressure drop increases, damper is open or the VFD speeds the fan up to overcome the additional pressure drop
  • When damper is fully open or VFD is running at maximum speed, the fan has reached its limit and the coalescing fiberbed filters needs to be replaced. 
  to minimize power usage.
• Long filter life Filter Life
  
  • Average Air-Clear Filter Life is in excess of two years
  • Exhaust fan is typically sized for pressure well in excess of the initial pressure drop so filter life averages 2+ years.
  • Typical Air-Clear fan is sized for 15-20” W.C.
  means low replacement cost.
• Collected liquidsLiquids
  Collected liquid materials are stored in the bottom of the unit and gravity drained or pumped. These process liquids are often reused or sold to recyclers are often recycled saving material costs.
• Low maintenance Maintenance
  
  • In its simplest form maintenance on fiberbed filters includes draining the self contained sump on a weekly basis and routine fan maintenance. The filters are stationary and require no ongoing service until, after an average of two to three years, they are replaced.
  • Large service doors provide access to the top tube sheet and the filter section
  • Although a messy job to be sure, the filters weigh less than 100 pounds, so two workers can handle them without mechanical equipment.
  • When cooling is involved the complexity increases a little, adding a pump and flow sensor to the maintenance list.
  cost.

Superior Filter Performance 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.

Quality WorkmanshipWorkmanship
Air-Clear systems are manufactured in house by Air-Clear certified welders under Air-Clear’s Quality Assurance Program

Shop assembly  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:
• Faster, trouble free installation reduces installation costs
• Less downtime, increased revenue from production
• Higher on-line reliability from day number 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 is even shipped!

Complete Turnkey Turnkey
Air-Clear can provide a range of installation services to suit Air-Clear customer’s requirements. These can include assembly crews or supervision of customer crews, startup assistance and complete "turnkey" responsibility. Air-Clear strives to offer those services that will minimize the installed cost of our systems. Service

Remote Monitoring Remote Monitoring
Air-Clear offers remote monitoring, enabling us to monitor the status of your systems, diagnose problems, and change operating settings from our offices in Elkton, MD. This allows Air-Clear to quickly determine the status of your systems, without the delay of waiting for a technician to arrive at your site. Services can include daily monitoring and data logging of operating parameters, remote diagnostics and troubleshooting, and adjustment of operating parameters. These services can be provided not only for Air-Clear Systems, but also for a variety of other equipment. Please contact Air-Clear to discuss your particular monitoring needs. Services

Field Support Field Support
Field support is provided throughout the world on all of Air-Clear Systems. Air-Clear has full-time field technicians and engineers ready to support all of Air-Clear equipment. Additionally, Air-Clear often provides in-depth training to local mechanical / electrical contractors who can support Air-Clear's field technicians. Field support can be extended indefinitely by means of maintenance / service contractors. Remote support for our customer's personnel is only a phone call away. Air-Clear Engineers can dial up equipment through modems integrated in our controls to provide real time monitoring and diagnostic services.

Engineering Services Engineering Services
Air-Clear offers various engineering services to our customers. These include permit assistance, remote equipment monitoring and process integration. Many Air-Clear Customers look to us for help not only in integrating their emission control systems into their process, but also to upgrade their entire process control and monitoring systems. Air-Clear’s expertise from experience in other industries can often bring a fresh perspective to the table.

Pilot Testing Pilot Testing
Air-Clear has a variety of Pilot Systems available for use. These are used to demonstrate the benefits of our technology, and to optimize system design prior to full-scale system fabrication. Most pilot systems are small, skid-mounted units with a complete integrated control system. These pilot units include most of the features of our full-scale systems, and allow the evaluation of optional components

Application (Sales) Support 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 others

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 -150F to condense most materials before entering filter for maximum efficiency. The cooler the exhaust, the more efficient the filter is.
• Cooling Methods
• CYCLONIC SCRUBBER
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 exchanger used to cool the hot process exhaust passing along other side of 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.