PLANT MANAGEMENT


design of Donaldson’s UltraPleat fi ltration technology optimises compressed air treatment, utilising coated high-tech fi bres to create a pleated fi lter medium. This structure supports exceptional separation eff iciency for liquid and solid particles, boasting a surface area over 400% larger than traditional media. The fi lter attains an oil aerosol separation eff iciency of ≥99.9% according to ISO standards, while concurrently cutting the diff erential pressure by 50%. An illustrative calculation


exemplifi es the signifi cant economic benefi ts of this technology: a 300- mbar reduction in diff erential pressure over 8,000 operating hours translates to approximately £5,650 in savings per UltraPleat fi lter annually (considering 7 bar system pressure, 110kW installed compressor power, and a cost of 0.21p/kWh). The eff iciency of UltraPleat


technology can be maximised by fl ow- optimised fi lter housings, combined with continuous monitoring through an economizer. This monitoring system not only indicates the most economical replacement time for the fi lter but also provides data for higher-level control of compressed air systems. For applications with larger


compressed air volume fl ows, UltraPleat fi lters are fully optimised while remaining scalable. This ensures a prolonged service life with consistently low diff erential pressure, a vital factor for achieving energy savings. Ultrapac Smart adsorption dryer


technology incorporates UltraPleat fi lters too, along with capacity control and compressor couplings that contribute to substantial savings in regeneration air. Additionally, energy-eff icient alternatives in dryer technology comprise prefi lters equipped with electronic, level- controlled drains, intermittent operation standards, zero purge technology, and energy-saving control systems such as Ultraconomy.


STOP THE LEAKS But even the very best fi lter technology can’t generate miracles. Pipe connections, conditioning units, shut-off valves, quick couplers and terminal equipment are all common sources of small air leaks that add


A diagram showing how Donaldson’s UltraPleat technology delivers results


up to a fl ood, with 25% losses before air reaches the application being common. For a company operating a 150kW compressor for 6,000 hours a year, that can mean almost £50,000 is needlessly wasted. Unlike natural gas, a small air leak


can easily go relatively unnoticed. The fi rst response is often to increase the system pressure which has the potential to result in a signifi cant annual fi nancial loss. Unplanned changes in ΔP also


indicate changes in the fi lters, with pressure drop increasing as contaminants build up, and a sudden dip in that level being a potential sign of a leak or rupture. Regular servicing and preventive maintenance are therefore essential for cost-eff ective operation – and Donaldson can apply the same technology and techniques it uses successfully at its own facilities to help detect leaks and minimise energy costs (as well as conduct air quality audits) at the sites of its customers too. Even leaks as small as 0.1lpm


can be identifi ed, while the plant is operating normally, as the company’s experienced customer service engineers check the entire piping system and terminal equipment. Sometimes only small adjustments are needed, such as tightening a tube connection, sealing a leaky pipe, or


repairing a conditioning unit. A detailed report is produced,


containing all necessary information for the elimination of the leaks, the size of the leakages and the fi nancial and CO2


savings potential per leak.


An optimisation concept can then be tailored to your specifi c needs. “Better energy management is one


of our priority sustainability goals as we target an absolute reduction of greenhouse gas emissions by 42% by the end of FY30 from a FY21 baseline,” says Bart Robbeets, general manager Industrial Gas Filtration at Donaldson. “Filtration technology plays an important role in this, but preventing pressure losses is a continuous task and an eff ective energy-reducing tool – not just for Donaldson, but for all our customers worldwide. Our local engineers are eager to get out on the road and help UK customers optimise and update their compressed air systems and boost their bottom line. This will result in a more eff icient system, bringing substantial savings in energy and overall fi nancial costs. Ultimately, our commitment lies in serving our customers and contributing to the reduction of the total cost of ownership. Last but not least, advancing fi ltration for a cleaner world is what we do at Donaldson.” ●


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