The life of the FFU filter element in the new energy workshop is shortened. How to check the inlet pollution load?

Shortened filter life is not necessarily a quality problem

New energy workshops include production scenarios such as lithium batteries, photovoltaics and energy storage. In these workshops, the high-efficiency filters of FFU may reach the replacement condition early due to the high inlet pollution load. Some projects find that the filter replacement cycle is shorter than expected. The first reaction is that there is a problem with the quality of the filter element. But the actual cause may come from inlet contamination, initial maintenance, system air leakage or process changes.

The purpose of a high-efficiency filter is to intercept particles. If the particle concentration in the inlet air is high, the filter will accumulate dust faster, the resistance will rise faster, and the replacement cycle will be shortened. This is not a quality problem of the filter element itself, but a problem of the inlet load.

Therefore, when checking for shortened filter element life, the inlet pollution load, pressure difference trend and actual air volume should be combined, rather than just checking the filter element. Aili Industrial has complete production capabilities in FFU complete machines and filters, and can cooperate with projects to analyze inlet contamination and filter element life. For the basic structure of the FFU machine, please refer toAili Industrial FFU fan filter unit。

How to check for dust at the entrance

Inlet dust is the main factor affecting the life of the filter element. The inspection contents include: where the FFU air inlet comes from; whether there are dust sources in the air inlet area; whether there is equipment exhaust, material handling or construction activities near the air inlet; whether there is a primary filter at the air inlet and what its status is.

If there are cutting, grinding, welding or material handling processes in the shop, these processes may generate particles. If the air inlet is close to these areas, inlet dust may be higher.

A particle counter can be used to measure the particle concentration near the air inlet and compare it to the clean area or return air area. If the particle concentration at the air inlet is obviously high, it means the inlet pollution load is large.

How to check the status of primary filter

If the FFU is equipped with a primary filter, the state of the primary filter directly affects the load of the high-efficiency filter element. Check whether the primary filter is installed in place, whether there is serious dust accumulation, and whether it is maintained according to regulations.

If the primary filter is not maintained for a long time, the resistance will rise after dust accumulation, and some particles may penetrate or bypass, increasing the load of the high-efficiency filter element. If the primary filter is damaged or missing, the high-efficiency filter element directly bears all inlet contamination.

Maintenance records can help determine whether the primary filter is maintained according to the prescribed period.

How to observe the pressure difference trend

The pressure difference trend is an important basis for judging the status of the filter element. The resistance of the new filter element is low, and as the dust accumulation increases, the resistance gradually increases. If the resistance rises quickly, it means the inlet pollution load is high or the filter element has insufficient dust holding capacity.

If the project has differential pressure monitoring, the changes in differential pressure with operation time can be recorded. If the rising curve of the pressure difference is steep, you can compare the dust content at the inlet and the initial effect state to find the reason.

If the FFU adopts constant air volume control, the fan power may increase after the resistance rises, which can also be used as a basis for judgment. If constant speed control is used, the air volume may decrease after the resistance increases.

How to troubleshoot system air leaks

System air leakage may also affect filter element life. If there is air leakage in the FFU box, installation frame or air duct, unfiltered air may enter the system and increase the load on the filter element. Air leakage may also affect air volume and cleanliness.

To check for air leakage, you can check the box seams, sealing strips, installation frames and air duct connections. If air leakage points are found, they should be treated and observed to see if the life of the filter element is improved.

How process changes are related

The process of the new energy workshop may change with product adjustments. If process changes result in an increase in dust generation, or if new processes that generate particles are added, the inlet pollution load may increase. Reduced filter life may occur simultaneously with process changes.

During the investigation, you can compare the filter element replacement records and pressure difference data before and after the process change to determine whether there is a correlation.

How to improve filter life

If the inlet pollution load is confirmed to be high, improvements can be made in several directions. Strengthen the maintenance of the primary filter or upgrade the primary filter efficiency. Increase local exhaust or collection near dust sources. Adjust the FFU air inlet position to avoid being close to the pollution source. Check and repair air leaks in the system. Select a filter with a more suitable dust holding capacity based on the inlet conditions.

For projects that require high-efficiency filters, you can refer toFFU is equipped with ULPA ultra-high efficiency filter. Understand the interface requirements between the filter and FFU. Aili Industrial has complete production capabilities in FFU complete machines and filters, and can provide filter configuration suggestions based on project entrance conditions.

Issues that should be confirmed in advance during project communication

During the FFU filter element life investigation stage in the new energy workshop, it is recommended to confirm the following with the FFU manufacturer: air inlet source and inlet dust; primary filter configuration and maintenance records; pressure difference monitoring data; FFU operating status and control methods; system air leakage inspection results; process changes and dust generation; filter element replacement records; improvement measures and verification methods.

If you are dealing with the issue of FFU filter element life in the new energy workshop, you can visitAili Industrial FFU fan filter unit to learn about the complete machine configuration, you can also contact Aili Industrial to obtain filtration solution support.

in conclusion

The shortened life of the FFU filter element in the new energy workshop may be related to dust at the entrance, initial maintenance, system air leakage or process changes. The investigation should be combined with inlet inspection, pressure difference trend and actual air volume, and cannot be simply attributed to the quality of the high-efficiency filter. Improvement measures include strengthening initial maintenance, increasing local exhaust, repairing air leaks and selecting appropriate filters.

Aili Industrial has complete production capabilities in FFU complete machines and filters, and can cooperate with projects to analyze inlet contamination and filter element life. If you need to know more about the FFU configuration of the new energy workshop, you can visitAili Industrial FFU fan filter unit , you are also welcome to contact Aili Industrial for project support.