Oil Mist Separators promote safe, healthy working environment.
The New GREEN LINE Series from 3nine - Oil Mist Separation has Never Been this Easy
3nine USA Inc.
25244 Via Lido
Laguna Niguel, CA, 92677, USA
For many years now, companies within all Industries have looked at ways at becoming "greener" in their day to day operations. The socio-economic benefits to do so are numerous. Within the Metalworking Industry there's been an increasing awareness given to solutions that offer the shop staff a safe and healthier working environment. One of the on-going challenges in the shop environment is the oil mist created by machine tools and a cost effective way dealing with it.
For the shop staff, the lungs and skin (including nose and eyes) are the organs of first contact for most environmental exposures. Oil mist exposure on the skin can lead to various health conditions such as eczema or oil acne, drying, irritation, and in some cases even skin cancer. The inhalation of oil mist may cause asthma, airways irritation, coughing, stinging sensations in the nose and throat and in some cases even lung cancer. Oily floors, due to settled oil mist, are problematic and can contribute to slip and fall injuries.
Various technical solutions for air purification have been available for many years. These solutions have employed different filter based technologies to collect the oil mist during multiple stages of cleaning the air and they require regular maintenance time and money if the highest stated efficiency level is to be maintained. For twelve years now, 3nine has offered an alternative solution that delivers a constant 99.9% purification level down to 1Ám without the use of filters and requires minimal maintenance. Now with the further development of the technology, our new GREEN LINE oil mist separators ensure an even higher level of efficiency.
Technology based on centrifugal separation
The centrifugal separation technique was invented more than 100 years ago. 3nine developed and introduced the technology for oil mist purification with its first generation of "separators" launched in 2002. "Disc stack" separation uses conical discs that are attached to a rotor which are spun at a high rpm. This rotating disc stack sucks the oil mist from the machine tool cabin and into the separator where the particles coalesce with one another. The radial centrifugal force exerted on the particles move them to the periphery of the disc stack, where they are forced onto the inner wall of the separator. The separated particles (oil/coolant) flow down to the bottom of the separator and are channeled back to the machine tool for reuse. This separation purifies the air to 99.9% down to 1Ám. For particles smaller than 1Ám a HEPA-filter is used as a final stage cleaning, ultimately providing 99.995 % purified air that can be vented into the workshop. To guarantee that the disc stack is kept clean, 3nine has a patented self-cleaning system called CIP (Clean in Place). The CIP uses the machine tool’s cutting fluid to automatically spray and clean the disc stack throughout any shift, which results in a minimal amount of required maintenance throughout the year.
Counter flow technology expands the application area
In order to handle applications with the larger particle volumes and heavier particle types associated with grinding and die casting as an example, 3nine introduced an enhanced separator in 2006. It utilizes Counter Flow Technology. A fan draws the oil mist through the side of the separator where the larger particles are immediately separated without ever touching the disc stack, the smaller particles are separated in the disc stack and all the fluid is returned to the machine tool for reuse. This technology also provides an ultimate purification level of 99.995%.
The new GREEN LINE series introduces "multi-rotor" technology
The products described above use different rotor and disc sizes depending on the air flow needed, which is based on the cabin size and application being performed by the machine tool. With the new GREEN LINE series, a single rotor and disc size is used for all the separators regardless of the application being performed and works with emulsions or straight oils. For the different air volumes needed to accommodate cabins as they increase in size, additional rotors are added to the separator.
The GREEN LINE series has taken centrifugal separation to a new level of efficiency by separating even smaller particles than ever before in the disc stack. The GREEN LINE series separates 100% of the fluid particulate down to 1Ám, 91% at 0.9Ám and 82% at 0.75Ám. With the HEPA filter for the final stage cleaning, the GREEN LINE series ultimately delivers 99.997% clean air.
NOVA - The first unit in the GREEN LINE series
The Nova is the first separator to be introduced in the GREEN LINE series. In March 2012, it won the prestigious Innovation Award at the "Salon Industrie Paris" within the category of "security". This was awarded by a jury of industrial journalists and rewards the creation or use of new technology to improve the protection of operators in the workshop. It is designed to work on small machine tools with cabins up to 70CF, handles all types of process applications and works with 99% of all cutting fluids.
Simplicity and Safety
A safe and secure working environment helps to optimize production time. 3nine oil mist separators provide high efficiency with consistent performance coupled with minimal maintenance. These benefits result in the lowest cost of ownership for any oil mist solution on the market today. On all of 3nine separators the CIP ensures that the units are automatically cleaned on a regular basis. With the Nova the CIP has an enhanced cleaning cycle program where each time it is shut down it is cleaned, preventing any build-up of particulates. About the only maintenance that needs to be performed is watching for the separator to tell the machine tool operator that it needs to replace the HEPA filter. With the high rate of particle separation in the disc stack, the HEPA filter will only be loaded with the particles smaller than 1Ám thereby providing a long life cycle. The Nova is equipped with a front and rear easy to see LED stripe, so that one can always be informed of its operational status. As an example, when the Nova is running the LED stripe will shine green and when it is shut off it shines red. When the HEPA filter has around ten days of life left, the LED stripe will intermittently flash blue for 3 seconds and when the filter is only working with half its capacity, it will intermittently flash blue for 10 seconds. With the Nova replacing the filter is quick and easy. It can be done while the Nova is running by simply opening a side door, taking out the old and inserting the new.
Flexible solutions without piping
As with all the 3nine separators, the Nova can be mounted directly on top of or on the side of the machine tool. There's also a free standing pedestal for mounting close to the machine tool. The Nova's light weight and compact design facilitates simple installation and saves valuable floor space thereby creating a flexible production environment for when machine tools need to be moved. The mounting options also eliminate the need for expensive piping, on-going maintenance of the piping, reduces the fire risk and the risk of airborne bacteria due to oil deposits in the piping.
3nine has helped hundreds of companies all over the world in providing a cleaner and safer shop environment with over 8,000 separators in place. These companies are both large and small. 3nine separators have a distinct eco-friendly focus, as the technology delivers the following operational benefits.
- Recycle and reuse of virtually all the cutting fluids separated
- Major savings on the disposal of used filters
- Reduction of oily surfaces and the associated housekeeping
- Major reduction of bio-hazardous waste (used filters, water for clean-up, rags, etc...)
- Reduced energy consumption because when the clean air is dispensed into the shop it doesn’t “foul” the heating and cooling units. In cooler climates, the warm vented air even allows for the reduction of heat needed in the shop, thereby saving energy dollars.
3nine is a Swedish technical development company with a unique core expertise in process air purification solutions and holds 105+ patents in the area of centrifugal separation of gases. The company was founded in 2001 and is headquartered in Nacka Strand, Sweden. It has subsidiaries in the US, Germany and China and is represented by its own direct sales teams in Sweden, Germany, France, Finland, Norway, Switzerland and Austria. Distributors and Independent Agents represent 3nine in the rest of Europe, Japan and North America.