Oil mist separation and filter systems HIGHLY EFFICIENT AIR FILTRATION (STATUS 07/2014) THREADING TURNING MILLING BROACHING RUBBING HONING SPINNING LAPPING HOBBING DRILLING We set air in motion
2 We set air in motion TEKA 3nine emulsion- and oil mist separators TEKA 3nine products are special products for filtration, protection and re-utilization of oil and emulsion mists. TEKA 3nine products not only help thousands of companies world wide to lower unnecessary costs of operation but also contribute to a greener metal processing industry in general. 1 Recycling x64 2 3 Reduction Saving of heat costs Recycling The worldwide investments into 3nine oil mist separators surpass 7000 units. These units segregate more than 2.9 million litres of oil annually. This equals 64 truckloads of recycled oil for the metal processing industries. / CO 2 Reduction Conventional technologies collect oil mist inside the filter medium (f.e. mechanical and rotating filters) and require frequent filter changes. The TEKA 3nine solutions liberate the world of thousands of used filters that otherwise would have needed to be disposed of as toxic waste. Reduced consumption rate of filters also leads to reduced transporting costs. In combination with the reduced disposing costs this means one thing: We help companies reduce CO 2 emissions. Heat cost savings The air that is separated by our oil mist separator is slightly warmed-up in the machining center before it is returned into the production hall. That way the energy consumption decreases in many companies. In combination with the cleaned air the operating costs of your company are reduced even more.
3 Functional principle of TEKA 3nine oil mist separators 1 1. The core piece of the technology consists of a rotor with 2 lamellas (plates). The motor driven rotation causes a suction of the oil mist from the machining center into the oil mist separator. 2. Inside the plate package the centrifugal power causes the liquid particles to be flinged against the conic plates. The particles merge and become bigger and heavier. The bigger they become the faster they move while being pressed to the inner walls of the unit housing. 3 3. The seperated coolant/oil is being captured in a 4 collecting tray or redirected to the tank of the machining center. 4. Particles smaller than 1μm are separated into the additional HEPA Filter H13. Schematic depiction Deposition of droplets and particles in the lamella stack. The droplets coalesce and flow outward. Clean air helps to transport the separated coolant to the outlet. Larger droplets leave the lamella stack and are pressed against the wall. Pure air is directed upwards.
4 We set air in motion Technology The technology to separate liquid from the gas has been developed over 100 years ago. In the last ten years TEKA 3nine signed about 100 patents for this technology and is the global patents leader with a share of more than 40%. Safe working environment Emulsion and oil mist can cause serious health damage. Due to the high purity of our systems, the clean air is redirected back into the production environment. A healthy working environment is maintained. Due to clean air, the risk of oil film formation in the production hall is minimized and optimum clean working environment will help to ensure the health of your personnel. Your employees will be most thankful! Flexible solutions without pipelines TEKA 3nine systems are generally built directly onto the machines. A complex and very expensive laying of ducting is no longer needed, since the clean air is redirected back into the production environment. Your company gains additional production space and a relocation of the machine can be done very easily and flexibly. You save the costs of installation and cleaning of ducting. Collecting instead of disposing While other technologies capture particles in a filter medium (e.g. electrostatic, mechanical or rotating filter) the TEKA 3nine technology is based on plate separation. This allows the reutilization of the coolant and reduces maintenance costs to a bare minimum. The HEPA filter (H13) To grasp the finer particles of less than 1 μm, TEKA 3nine uses HEPA filters (H13). These are highly efficient filters that capture 99.97% of particles. Since most particles are already separated by the plate separation, the average lifespan of a filter will be 12-18 months per filter if used for an average of one work shift a day. Deposition by plate separation 1% collected in HEPA-Filter Intelligent and revolutionary technology The unique patented technology separates the emulsion and oil mist by centrifugal force with particle sizes from 1 μm up to 99.9% from. This technology requires only minimal maintenance. The rotor inside of the 3nine systems consists of separation plates and separates the process air mist much more effectively than conventional rotary filters or cyclones. Since the press/suction power is generated by the rotor, no further blower, fan or propeller is required. Low operating costs Due to the high efficiency the largest share of oil and emulsion mist is continuously separated directly. The coolant can be re-utilized in the existing system circuit. The low loss of the coolant reduces costs. Filter change and production breaks are reduced to a minimum. All systems are designed for continuous operation to ensure maximum productivity.
5 Automatic cleaning system CIP With our automatic Cleaning in place -system (CIP) the air flow remains constant and does not break off. The CIP system uses clean coolant of the machining center to periodically flush the rotor and the plate package. Image: Fully automatic cleaning of the example of the oil mist separator CLARA (cross-sectional view) Image: The CIP-flushing system with auxiliary pump (detail view) Low maintenance system The CIP unit has an electronic box with a power pack and a timer. The operation of the CIP unit works by means of a rotary switch on the box. In comparison with other coercially available technologies TEKA 3nine products require very low maintenance. There is no manual cleaning required. Image: Functional principle of the CIP Cleaning Filter change Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec TEKA 3nine no manual cleaning required Mechanical fllter Electrostatic Filter Rotating Filter
6 We set air in motion Oil mist separator LINA Appropriate for Purifying mist of cooling lubricants in the workshop area, especially for small, enclosed machines with limited required suction. LINA is mounted directly onto the machine. This saves floor space and avoids unnecessary laying of ducting. In addition, the machines can be relocated easily in case of changing production needs. The operators of small machines are now offered the same flexible and maintenance-free solutions that come with the other products of TEKA 3nine, but at a lower cost. LINA offers high efficiency over its entire life cycle. LINA is a typical centrifugal separator and requires only a minimum of maintenance as the other products of TEKA 3nine. Due to the rotating blades inside, oil mist is separated much more efficiently than in conventional technologies, such as cyclones and rotating filters. For volumes up to 2 m³ Image: Oil mist separator LINA Technical data Suction/pressure power up to 900 Pa Operating temperature 5-50 C Voltage 3-phase 400V, 16A Effect consumption 0,55 kw Current 1,4 A Weight 54 kg Dimensions (L x W x H) 618 x 618 x 927 Inlet diameter 125 Noise < 65 db (A) Hue blue* Art. # 68 00 105 00 *Different hues available on request
7 Accessories Floor stand Dimensions: 610 x 610 x 1 850-2 750 Article No.: 68 250 003 Wall mounting Article No.: 68 100 000 8 Adjustable console Dimensions: 610 x 610 x 187-303 Article No.: 68 100 020 2 Filter monitor Messbereich: 0-1 000 Pa Article No.: 68 005 0 HEPA filter H13 Dimensions: 610 x 610 x 292 Article No.: 68 013 1 HEPA filter fixture Dimensions: 610 x 610 Article No.: 68 010 000 14 Prefilter package Contains prefilter F9, HEPA filter bracket, high and prefilter frame Article No.: 68 20 000 1 Prefilter F9 Dimensions: 610 x 610 x 150 Article No.: 68 013 0 Prefilter frame Article No.: 68 15 000 3 HEPA filter bracket, high Article No.: 68 0378 Application photos Images may show optional equipment
8 We set air in motion Oil mist separator CLARA Appropriate for Purifying mist of cooling lubricants in the workshop area, particularly versatile and can be used with almost any working machine. CLARA is our best selling oil mist separator. It is suitable for most working machines. Clara is installed across Europe on virtually any type of working machine for a large number of customers. CLARA is a typical centrifugal separator and thus requires only a minimum of maintenance. Clara also prevails under extreme conditions with large amounts of solid particles, as they occur in the machining of cast iron and grinding. There is no risk of constipation like in a generic filter. Like the other products of TEKA 3nine CLARA offers a very high degree of purification. Due to the patented system of rotating disks the the oil mist is much more effectively separated than with conventional technologies, such as cyclones and rotating filters. Due to its low maintenance and compact design CLARA provides a high economic efficiency. Compared to conventional filter aggregates annual savings of operating costs of up to 50% are possible. CLARA is light, compact and can be mounted directly onto the hood of the machines. This saves floor space and avoids unnecessary laying of ducting. In addition, the machines can be easily relocated in case of changing production needs. For volumes up to 6 m³ Image: Oil mist separator CLARA Technical data Suction/pressure power up to 1000 Pa Operating temperature 5-50 C Voltage 3-phase 400V, 16A Effect consumption 1,5 kw Current 3,2 A Weight 89 kg Dimensions (L x W x H) 618 x 618 x 1098 Inlet diameter 160 Noise < 65 db (A) Hue blue* Art. # 68 00 110 00 *Different hues available on request
9 Accessories Floor stand Dimensions: 610 x 610 x 1 850-2 750 Article No.: 68 250 003 Wall mounting Article No.: 68 100 000 8 Adjustable console Dimensions: 610 x 610 x 187-303 Article No.: 68 100 020 2 Filter monitor Messbereich: 0-1 000 Pa Article No.: 68 005 0 HEPA filter H13 Dimensions: 610 x 610 x 292 Article No.: 68 013 1 HEPA filter fixture Dimensions: 610 x 610 Article No.: 68 010 000 14 Prefilter package Contains prefilter F9, HEPA filter bracket, high and prefilter frame Article No.: 68 20 000 1 Prefilter F9 Dimensions: 610 x 610 x 150 Article No.: 68 013 0 Prefilter frame Article No.: 68 15 000 3 HEPA filter bracket, high Article No.: 68 0378 Application photos Images may show optional equipment
10 We set air in motion Oil mist separator EMMA Appropriate for Purifying mist of cooling lubricants in the workshop area, especially where high flow rates are required. Can be connected in series to further increase the performance. EMMA is the largest member of 3nine BLUE LINE series. The device is specifically designed for applications where high flow rates are required, for example for very large or open working machines. In addition, several units can be linked together by TEKA 3nines module system to cope with volume flows over 2500 m³/h. Like the other TEKA 3nine products EMMA is a typical centrifugal separator and requires only a minimum of maintenance. Compared to conventional filtration units you halve your annual operating costs. EMMA is extremely compact in relation to its capacity - with its dimensions the unit is only one third the size of a corresponding filter unit. Therefore, EMMA can be mounted directly on machines, allowing you to gain ground surface and avoid unnecessary laying of ducting. For volumes up to 15 m³ Image: Oil mist separator EMMA Technical data Suction/pressure power up to 1500 Pa Operating temperature 5-50 C Voltage 3-phase 400V, 16A Effect consumption 5,5 kw Current 11,3 A Weight 131 kg Dimensions (L x W x H) 700 x 700 x 1144 Inlet diameter 315 Noise < 70 db (A) Hue blue* Art. # 68 00 125 00 *Different hues available on request
11 Accessories Floor stand Dimensions: 610 x 610 x 1 850-2 750 Article No.: 68 250 003 Wall mounting Article No.: 68 100 021 1 Adjustable console Dimensions: 610 x 610 x 187-303 Article No.: 68 250 004 Filter monitor Messbereich: 0-1 000 Pa Article No.: 68 005 0 HEPA filter H13 Dimensions: 610 x 610 x 292 Article No.: 68 013 1 HEPA filter fixture Dimensions: 610 x 610 Article No.: 68 025 0000 4 Prefilter package Contains prefilter F9, HEPA filter bracket, high and prefilter frame Article No.: 68 20 000 1 Prefilter F9 Dimensions: 610 x 610 x 150 Article No.: 68 013 0 Prefilter frame Article No.: 68 15 000 3 HEPA Bügel Article No.: 68 0378 Application photos Images may show optional equipment
12 We set air in motion Oil mist separator PETRA Appropriate for Purifying mist of cooling lubricants in the workshop area, particularly for applications with large amounts of solid particles (grinding, die casting and machining of cast iron). PETRA is based on an enhanced development of the technology that is used in other devices of the TEKA 3nine family. The machine is specially designed for applications where large quantities of solid particles occur. Some examples of such applications include grinding, curing, casting and machining of cast iron. PETRA can ideally be mounted directly on any machine. You save floor space and avoid unnecessary laying of ducting and maintenance of the ductings, which would otherwise be required for this type of processing due to the release of large amounts of particles and debris. In addition, the machines can be put easily in case of changing production needs. PETRA is a typical centrifugal separator and requires, like the other products of 3nine, only a minimum of maintenance. Due to the rotating blades inside, oil mist is separated much more efficiently than in conventional technologies, such as cyclones and rotating filters. For volumes up to 6 m³ Image: Oil mist separator PETRA Technical data Suction/pressure power bis 1500 Pa Operating temperature 5-50 C Voltage 3-Phasen 400V, 16A Effect consumption 1,5 kw Current 3,2 A Weight 96 kg Dimensions (L x W x H) 610 x 610 x 1159 Inlet diameter 160 Noise < 70 db (A) Hue blue* Art. # 68 00 210 00 *Different hues available on request
13 Accessories Floor stand Dimensions: 610 x 610 x 1 850-2 750 Article No.: 68 250 003 Wall mounting Dimensions: 610 x 610 x 50 Article No.: 68 100 000 8 Adjustable console Dimensions: 610 x 610 x 187-303 Article No.: 68 100 020 2 HEPA filter H13 Dimensions: 610 x 610 x 292 Article No.: 68 013 1 Filter monitor Messbereich: 0-1 000 Pa Article No.: 68 005 0 Prefilter package Contains prefilter F9, HEPA filter bracket, high and prefilter frame Article No.: 68 20 000 1 Prefilter F9 Dimensions: 610 x 610 x 150 Article No.: 68 013 0 Prefilter frame Article No.: 68 15 000 3 HEPA filter bracket, high Article No.: 68 0378 Application photos Images may show optional equipment
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TEKA Absaug- und Entsorgungstechnologie GmbH Industriestraße 13 46342 Velen Germany Tel. + 49 28 63 92 82-0 Fax + 49 28 63 92 82-72 info@teka.eu www.teka.eu We set air in motion