the proper filter cartridge retention for a given application reduces operating costs and ensures process specifications are achieved.
Filter cartridge retention is expressed in microns (μm); 1 micron =
1/1000 (0.001) millimeters. Filter cartridges provide depth
filteration, which means particles are blocked from passing thorugh
progressively finer openings for a true three-dimensional level of
filter media utilization. Since filter cartridges are used for
relatively small particle retention there is usually a coarser level of
filtration upstream of the filter cartridge system, such as a bag filter
or pipeline strainer with cleanable or inexpensive elements. In
this way the filter cartriges are only tasked with retaining fine
particles an not prematurely blinded with large particles.
Filter cartridges provide depth filteration, which means particles are blocked from passing thorugh progressively finer openings for a true three-dimensional level of filter media utilization. Since filter cartridges are used for relatively small particle retention there is usually a coarser level of filtration upstream of the filter cartridge system, such as a bag filter or pipeline strainer with cleanable or inexpensive elements. In this way the filter cartriges are only tasked with retaining fine particles an not prematurely blinded with large particles.
Once you determine how fine of a particle to remove, next you need
to consider the efficiency of the filter cartridge. T
Once you determine how fine of a particle to remove, next you need to consider the efficiency of the filter cartridge. The efficiency is often overlooked or perhaps "assumed", thus contributing to insufficient or over-filtration.
Nominal Efficiency is a manufacturer defined efficiency and for our nominal rated filter cartridges they are 70% efficient unless otherwise specified. Therefore, with a new (clean) filter cartridge, =>70% of the particles of the stated retention will be retained by the filter cartridge. As particles become trapped within the filter cartridge media, the open area available decreases and thereby increases the efficiency of the filter cartridge.
As mentioned above, there is no "universal" retention efficiency required to be referred to as "nominal" - it is manufacturer defined, often not overtly stated; you will need to ask if your application is one of those sensitive to the initial retention efficiency.
Therefore it is incorrect to assume that
two different brands of "50 micron nominally rated filter cartridges"
have the same efficiency; you will need to try each to determine which
is the best value for your application. Generally speaking the
more efficient the media is, the more costly it is because the
manufacturers of the filter media can get top dollar for the more
efficient portion of the media run. Efficiency is also
related to the design, filtration layers that are better defined improve
Efficiency is also related to the design, filtration layers that are better defined improve efficiency.
In comparison to absolute rated filter media, nominal rated filter cartridges are relatively inexpensive and used for non-critical applications. They are also used as "pre-filters" to reduce the loading on the more expensive "absolute" efficiency filter cartridges.
Absolute Efficiency is much more intuitive and straightforward to understand. It refers to a laboratory defined retention efficiency, often expressed with a Beta value or a Beta Ratio. Most of our absolute rated filter cartridges have a Beta Ratio Chart expressing their efficiency based upon a stated particle size.
Example: our LOFPLEAT-HP 1.0 micron filter cartridges have a Beta 5000 or 99.98% retention efficiency for particles => 1.0 micron. They can also be described as Beta 100 (99%) efficient for retention of particles => 0.60 microns or Beta 50 (98%) efficient for retention of particles => 0.30 microns.
The Beta Ratio is established via laboratory testing and is the number of particles up-steam of the cartridge divided by the number of particles downstream of that same cartridge for the targeted particle size.
Therefore a Beta ratio of 5000 means that for every particle of a given size that bypasses the filter cartridge, there were 4999 that did not. The math follows:
Beta 5000 = 4999 particles retained from a total of 5000 and therefore 4999/5000 = 99.98% efficiency.
The testing methods used to determine efficiency can be complex and they are not to a universal standard; each manufacturer determines how they will test their efficiencies.
The testing method used for Eaton's Beta Ratios are based upon a "single-pass test method" using ambient water at a flow rate of 2.5 GPM for a 10" length cartridge. The type of particles used during testing are latex beads and special "coarse and fine test dust" (imagine that, "test dust"!). The removal efficiencies are determined using multiple laser particle counters which is the most sophisticated and effective method of counting "dust" particles.
The actual efficiency for your application will differ due to operating conditions such as pressure fluctuations, differences in temperature and viscosity. This is another reason why trying different filter cartridge brands, media and designs can be beneficial to you, your process results will not likely correlate directly to "retention sizes or efficiencies" due to process variations anyway.
It is important not to confuse filtration efficiency with particle retention capacity; they are unrelated. The total volume of particles that can be retained within a cartridge and how the rate of increase in efficiency due to reduction of the open area available are not reflected in the Beta Ratio and testing. Underscoring once again that the physical design of the filter cartridge may offer capacity advantages even if the media used is the same across multiple brands/designs.
Our differential performance advantage compared to other brands are often based upon the manufacturing technology and design of the filter cartridge to provide higher volume of particle retention at relatively low differential pressures without sacrificing retention efficiency. The picture above illustrates a pleated design, although other advanced features can include a fixed pore structure that prevents particle unloading even under high differential pressures or a heavy molded "cage" to increase the overall integrity/strength of the filter cartridge.
Do you require nominal or absolute rated filter cartridges?
If you have sensitive applications requiring absolute rated media, you probably already know it and have an application that involves the food, beverage, pharmaceutical, cosmetics or petrochemical industries. It is important to note that the lesser expensive nominal rated cartridges can be used to extend the life of the much more expensive absolute rated cartridges, so the answer might be "both"!
We can provide you with free filter cartridges for testing and evaluation combined with free water test analysis/report which will characterize the particle sizes and population within a given sample that you provide. The analysis eliminates "trial and error" for proper filter cartridge material and design. Why not take advantage of these free services today?