CAMFIL – Clean Air Solutions

CityPollution

NO. 2 2014

CLEANING UP INDOOR AIR IN STOCKHOLM, PARIS AND LONDON

TAKING THE STING OUT OF DUST EXPLOSIONS

QUICK TURBINE RETROFIT IN INDIA

2 AirMail No. 2 2014

EDITORIAL – MAGNUS YNGEN

Cleaner air for urban dwellers The world is urbanising and people are migrating to city centres for many reasons.

We see this trend in statistics: more than 50 percent of the world’s population lives

in cities today and the World Health Organisation (WHO) expects this proportion to

increase in coming years.

This urbanisation trend is impacting the eco-nomic, social and political setup of countries and regions. Urban crowding is also affecting life at street level – the air we breathe. In many metropolises, concentrations of particulate mat-ter and harmful gases are already higher than WHO’s recommended limits. Vehicle emissions – especially the content of diesel exhaust – are very much the villain in this drama and we need to be more aware about the dangers of breath-ing everything from very fine particles (PM2.5) to harmful gases like nitrogen dioxide.

While governments enact legislation and set stricter air quality standards, Camfil is also do-ing its share for cleaner air by developing new and innovative filtration solutions to improve indoor air quality (IAQ). As urban dwellers and officials also get more “street savvy” about air quality, we are helping to alleviate problems with better filtration solutions that are more “street-smart” in dealing with city centre pollution.

You can read more about this in the articles about Hornsgatan (Stockholm) and Oxford Street (London), where the air pollution situa-tion calls for more effective filtration of outdoor air before it is introduced through ventilation systems.

A wake-up callThese trends are a wake-up call for us all. We need to stop these pollutants “at the door” with good air filtration.

Camfil has always led product development in this field and our IAQ experts already have the solutions. We can offer innovative filters like the City series and our new range of City room air purifiers. Combining particle and molecu-lar filtration, these products are benefitting the health, wellness and productivity of occupants in commercial, public and residential build-ings. Our customers are using them with great success today.

Inside, you can also read about several customer-specific filtration solutions for turbines and in-dustrial air pollution control. One article intro-duces an APC solution from the newest member of the Camfil Group – Camfil Handte. And while you are browsing, read the portrait feature about one of our seasoned filter professionals, Anders Freyschuss, EVP for Camfil’s home base – the Nordic region.

Enjoy this issue! And don’t hesitate to get in touch with us if you would like more informa-tion about our products and services – the most comprehensive range of clean air solutions on the market.

Magnus YngenPresident and CEO

CAMFIL AIRMAIL is a world-wide publication for Camfil customers. Available in nine languages.

Published by: Camfil AB, Sveavägen 56E SE-111 34 STOCKHOLM, Sweden Tel +46 8 545 12 500. Fax +46 8 24 96 50 E-mail: info@camfil.se www.camfil.com

Publisher: Alain Bérard, Executive Vice President Marketing & Products

Editor: Liza Braaw/Magnus Jerräng Tel +46 8 545 12 513. Fax +46 8 24 96 50

Text/Artwork: Camfil and Thorn PR Sweden AB/Kaigan AB

Head Office: Camfil AB, Sveavägen 56E, SE-111 34 STOCKHOLM, Sweden. Tel +46 8 545 12 500. Fax +46 8 24 96 50

Want to know more: www.camfil.com

December

2-4 P-MEC India, Bombay Convention and Exhibition Centre, Mumbai, India

9-11 PowerGen International, Orange County Convention Center/West Halls, Orlando, Florida, USA

12-14 Hospital Infrastructure India 2014, Bombay Exhibition Centre, Mumbai, India

January

22-28 IMTEX 2015, Indian Metal-Cutting Machine Tools Exhibition, Bangalore International Exhibition Center, Bengaluru, India

29-31 Filter Tech Asia 2015 Exhibition, Bangkok, Thailand

March

2 ACAT Exhibition (Air-Conditioning Engineering Association of Thailand) Bangkok, Thailand

10-12 CFIA, Parc expo, Rennes Airport, Rennes, France

10-14 ISH, Frankfurt, Germany

11 Sisäilmastoseminaari 2015 “Indoor Air Quality 2015”, Helsinki, Finland

31/3-2/4 Contaminexpo, Contaminexpert, Porte de Versailles, Paris, France

April

21 VGB Conference Power Plants, Dresden, Germany

May

7-9 PowerGen India & Central Asia 2015, New Delhi, India

12-14 FCE PHARMA, Transamerica Expo Center, São Paulo, Brazil

June

2-5 Sairaalatekniikan päivät 2015 (Hospital Technics 2015) together with IFHE-EU 2015, European Congress for Hospital Engineering, Turku, Finland

23-26 FISPAL TECNOLOGIA, Anhembi Show Pavilion, São Paulo, Brazil

10-13 Entech Pollutec Asia 2015 Exhibition, Bangkok, Thailand

The exhibitions above are a selection of the various events that Camfil is participating in around the world from December 2014 to June 2015. For the complete list, please visit www.camfil.com/About-Camfil/Events/

EXHIBITIONS DECEMBER 2014 – JUNE 2015

Camfil Power Systems had six months to

engineer and install a new barrier-type filter

system and diverter damper at a key power

plant serving India’s most populous city.

Time is of essence when a power producer needs a retrofit solution for a gas turbine at an important plant – especially when it provides half the elec-tricity needs for Mumbai, the most populous city in India. This was the situation at the Trombay thermal power plant operated by Tata Power Ltd., India’s largest integrated power company with a total installed generation capacity of approximately 8,500 MW on the Indian subcontinent.

The retrofit project was for the air intake system and diverter damper at Unit 7, a 180 MW gas-fired combined-cycle turbine from Siemens. The con-

tract, awarded through Siemens, specified a delivery period of six months, from order to commissioning, and a maximum shutdown of 37 days for dismantling the old systems and installing the new ones.

Tough operating environmentTrombay produces 1,580 MW of power to supply 50% of Mumbai’s power needs.

Unit 7 was furnished in 1993 with a competitor’s filter housing with hanging pulse cartridges. Due to the plant’s location near the Indian Ocean, the original air intake system and diverter damper were exposed to high humidity and salt-laden winds, causing heavy corrosion damage in the filter hous-ing and a high pressure drop across the system.

The coast is just behind the power plant and the average relative humidity can be as high as 85%. The hot and humid climate gradually caused the entire system to degrade. Dust particles, mixed with water droplets and salt, penetrated the surface layer of the filters and were not being released when the filter media was pulsed.

A site survey conducted by Camfil Power Systems and Siemens indicated improper weather protec-tion and insufficient dust removal in the pulsing unit. Several pre-filter and pulse-filter elements were damaged or missing, allowing unfiltered air through both filtration stages. The hydraulically driven diverter damper also suffered from corro-sion, hot spots and heat leakages around its expan-sion joints. There were also several areas of damage to the internal insulation of the hydraulic system.

Three-stage solutionA new air intake system was needed for higher safety, reliability and performance. Camfil Power Systems proposed a three-stage static/barrier filter system for a complete retrofit and was awarded the contract.

The first stage of the new inlet filtration system consists of coalescer pads to prevent water drop-lets from entering the following stages. Trombay is located in an industrial zone and local air pollution problems required a pre-filter with high dust-hold-ing capacity. The solution was a Cam-Flo XMGT M6 bag filter. A CamGT 4V-300 F9 was also installed to provide maximum protection against submicron particles and salt penetration.

The modification of the diverter damper involved a range of repair work that included replacing the entire drive system and retrofitting the damper sys-tem with new components, such as insulation and expansion joints, and a new hydraulic power unit and actuator.

These changes have increased reliability, reduced thermal energy losses and boosted turbine efficiency.

All systems were installed and commissioned in 37 days according to plan. Camfil Power Systems’s manufacturing facility in Trichy did a major portion of the fabrication work.

Quick retrofit for Tata Power in India

TURBINE FILTERS FOR TOUGH CLIMATES

Cam-Flo XMGT M6 bag filter with non-discharging synthetic media and high dust-holding capacity

CamGT 4V-300 F9 barrier-type filter with high filtration efficiency and low pressure drop

4 AirMail No. 2 2014

SERVICE

How a pollution solution was found for Sweden’s nastiest street

AirMail No. 2 2014 5

CITY POLLUTION

It is now measured, tested, documented and verified: the dynamic duo of City-Flo™ XL and a Camfil air purifier is literally knocking the air – the bad air – out of apartments on Hornsgatan, the most polluted street in Stockholm and all of Sweden. A comprehensive long-term study proved that this filtration solution improved indoor air quality (IAQ) significantly, removing up to 80% of harmful outdoor particles and gases.

Hornsgatan is located in the Söder-malm district, one of the most popu-lar neighbourhoods in Stockholm. Air on this busy arterial street has con-sistently been the victim of high con-centrations of harmful airborne par-ticles and gases produced by heavy traffic, particularly diesel exhaust, which has been classified by WHO as carcinogenic. The main concerns have been fine particulate pollution – PM2.5 and PM10 – and polycyclic aro-matic hydrocarbons (PAHs).*

The more dangerous and micro-scopic PM2.5 particles (tinier than 2.5 μm), which are exhaust and com-bustion particles or diesel particles from vehicles, are small enough to evade the body’s defence mecha-nisms and pass into the airways and the lungs and blood. There is a direct connection between fine particles (<2.5 μm) and increased mortality caused by cardiovascular and respira-tory illness. Breathing PAHs has been associated with cancer and are of the greatest concern with regard to po-tential exposure and adverse health effects on humans.

‘Live’ before-and-after testThe site for conducting the filtration test on Hornsgatan was an apartment building that had been refurbished with a new central air handling sys-tem equipped with a heat exchanger. Air handling units were fitted with the energy-saving City-Flo XL, a com-bined particle and molecular filter that is part of Camfil’s “City” series for polluted urban environments.

By measuring air quality in the apartment before and after the instal-lation of the new central air system, differences in IAQ could be thor-oughly documented. In Sweden and the other Nordic countries, air quality is based on the flow of outdoor air in litres per second (l/s) to supply fresh air to buildings. However, it is impor-tant to keep in mind that “fresh air” is not the same as “clean air”. Compare filling a jug with one litre of water and not caring if it was sewer water or tap water.

The 105-m2 apartment used for the

study was located on the second floor at a “critical level”, defined as 7-10 metres above the street, where most coarse dust tends to spiral up, and where the exteriors of buildings in inner city areas are often very dirty. During the measurement period, a family occupied the apartment to provide a realistic living environment for the trial. During the test, air sup-plied and filtered through City-Flo XL was approximately 70 percent cleaner than outdoor air.

Since one family member had a his-tory of asthma and allergy problems, the central air system was supple-mented with a Camfil room air puri-fier. This mobile unit has HEPA fil-ters that remove 99.7% of all airborne particles down to 0.3 μm in size.

ResultsAfter the central air system was installed, with City-Flo XL in air handling units, measured values in-doors fell radically, compared with outdoor air concentrations, despite an increased amount of supply air. Outdoor air had about 22 million par-ticles 0.3 μm in size per cubic meter, while supply air in the apartment had 8 million per m3 – a low concentra-tion and a very good level of IAQ for a residence in an inner city area.

The addition of the mobile air puri-fier proved that it is a good solution to supplement a central air system with an air purifier with HEPA filters for preventive purposes – for exam-ple, when residents are experiencing breathing problems due to allergies or asthma. A mobile air purifier of this class will provide very high IAQ, sometimes down to ISO Class 7-8 with regard to emission and particle levels and according to ISO Standard 14644-1.

The central system installed in the building supplied conditioned clean air. Before the installation, indoor air contained about 750 ppm of CO2, and after installation around 480 ppm of CO2, due to increased airflow and better air circulation.

After the central air system was in-stalled with City-Flo XL and a Camfil

air purifier, indoor air was 80 percent cleaner.

Cleaner air for urban dwellersThe filter duo proved to be beneficial to human health.

The study clearly showed that living on Hornsgatan, a street

with the worst air pollution in Stockholm,

does not have to be unhealthier than in other

areas of the city.

“The installation of a well functioning and sealed ventilation system, with good and effective filtration of parti-cles and some molecular gas filtration with activated carbon – for example, with City-Flo XL Class 7 with a mini-mum efficiency of 50-60% – solves many indoor air quality problems in cities with bad air pollution. When the system is supplemented with a mobile air purifier with HEPA fil-ters, IAQ will be improved even more to the benefit of human health and well-being,” says Anders Hedström, Camfil’s Global IAQ Manager.

*PAHs, one of the most widespread organic pollutants, are present in fossil fuels and are also formed by incomplete combustion of carbon-containing fuels.

Outdoor and indoor air after the installation

Values for outdoor and indoor air after central air was installed, as well as the cleanliness of the air after a Camfil air purifier with HEPA filters was installed in the living room. In a city like Stockholm, supply air should be maintained at 7 l/s per person and the filter class should be at least F7. A combined particle and molecular filter like City-Flo XL is also recommended to remove exhaust gases, smells and other pollutants.

Supply air with City-Flo XL filters in air handling units. Outdoor air concentrations. Living room air. Living room air with a City air purifier with HEPA filters.

Central air handling system with F7 filtration and City-Flo XL filters with 68% reduction in particles 0.3 - 0.5 µm in size. Difference between room air and supply air. Increase in the number of particles generated indoors. 80% cleaner air with the addition of City air purifier with HEPA filters and the central air system in operation.

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6 AirMail No. 2 2014

PORTRAIT – ANDERS FREYSCHUSS

Anders, 51, is born and raised in Stockholm. This is his 27th year in the heating, ventilation and air conditioning (HVAC) industry. His passion for technology and the envi-ronment emerged during childhood:

“My dad helped pioneer IT systems in the early 1960s, in-cluding the first computer-based business systems for large Swedish corporations. That influenced me. At the same time, I had a genuine love for math and structural order, combined with an interest in everything ‘green’ when I was a teenager in the Scouts,” Anders Freyschuss begins.

Energy resource management was also fascinating to young Anders. For his university studies, he wanted an en-gineering education that integrated energy conservation and sustainability aspects so he could work with environ-mental issues:

“I went for an M.Sc. in Engineering from the Royal Institute of Technology (KTH) in Stockholm, specializing in heat pump and ventilation technology, and graduated in 1987. Heat pump technology had become ‘hot’ and the energy savings aspects nabbed me. I did my thesis work on heat pumps for Fläkt (Fläkt Woods today), one of the larg-est HVAC companies in Europe. But surprise! During my studies, it was established that freon was hazardous and the entire heat pump market had a meltdown. How could I,

an environmentally friendly engineer, build environmen-tally harmful pumps that damage the ozone layer?”

He changed course. His academic connection to Fläkt led to a seven-year career with the company and a sharper focus on ventilation. Anders developed simulation soft-ware for calculating and designing commercial ventilation systems. “I had to learn about every single component. This gave me much knowledge and deep insight into the ventila-tion industry, which paid off later at Camfil,” says Anders.

Anders also spent 2.5 years as Fläkt’s technical manager in France, learning French quickly from scratch. He al-ready spoke English and German. “Being forced to adopt a new language – so you can communicate with colleagues, encourage teamwork and set things in motion – made me believe strongly in the value of good people-to-people com-munications,” Anders says. “You can be the best engineer in the world, but if you can’t communicate and interact with people, nothing will happen. My time in France also allowed me to develop a European network of contacts that has helped me immeasurably during my career.”

Fläkt’s huge project for AstraZeneca in Dunkirk (1992-93) – the cleanrooms and ventilation systems for a new plant – established a bridgehead for Anders to Camfil: “Camfil filters were the number-one choice for this plant and this was my first contact with the company.”

Joined Camfil in 1994Camfil scooped up Anders after he returned to Sweden in 1994 to settle down. Camfil’s marketing manager at the time, a former Fläkt employee, asked Anders if he was interested in becoming Managing Director of Camfil’s Swedish sales subsidiary in Trosa.

Humanist engineer and champion of clean airHe is a Swedish engineer and executive who manages

close to 400 people and all of Camfil’s filter business in

four Nordic countries, including two production units.

His name is Anders Freyschuss and he is Camfil’s

Executive Vice President Northern Europe. This

humanist engineer values the art of communication

and believes more in carpe diem than worrying

about the future.

“You appreciate the environment when you spend a lot of weekends in the woods, camping with your troop!”

PORTRAIT – ANDERS FREYSCHUSS

“I knew it would be a massive chal-lenge,” Anders says.” I was only 31. Suddenly, I was stepping from engi-neering to management. My reaction was a little like a ‘deer in the head-lights’ experience. Fortunately, I had completed a three-year management-training programme while at Fläkt. Challenges are tough to take, but they develop you as a person. Going to Camfil in 1994 was a very big step for me, but I was ready for it.”

The rest is history. The team at the Swedish subsidiary developed the Swedish after-market for filters, mod-ernized business systems and expand-ed sales in the fore- and after-market – the HVAC contractors and service companies Anders knew well from Fläkt. The filter replacement market was also built up and AHU manufac-turers became a new customer. In-ternal structural and organisational changes were made. Sales grew con-siderably in four years. Anders’s next big career move was Marketing Direc-tor of the Camfil Group at the end of 1998, a position that allowed him to leverage his international experience and contact network. “I had become an MD at an early age and this position provided some distance for trying new challenges,” he says.

“Then Camfil started to buy com-panies in rapid succession as part of a growth strategy, and while we rode this acquisition wave, we had to find effective ways to integrate these com-panies in the organisation, marketing and technical training,” says Anders.

Back on the home frontHe returned full-time to the home front in 2001. Camfil had just formed the Nordic region as a geographic area, which included sales and pro-duction in Sweden, sales companies in Denmark and Finland, and sales through an agent in Norway.

Anders: “It was great timing and made perfect sense to me to stay rooted on the home front – Lena, my life partner, gave birth to our son Edvin in 2001. Up to now, I had done the whole management bit with per-

sonnel and sales, then shifted to one area of focus – corporate marketing. At 38, I felt more mature to tackle a management role as head of Northern European operations.”

Programmes were launched to re-structure, improve efficiency, launch new filters and increase sales. Then in 2006, Anders Freyschuss faced his biggest mission yet: Camfil had ac-quired its main domestic competitor, IF Luftfilter AB, which had to be suc-cessfully integrated. “We engineered this business combination success-fully – normally you lose some market share when you buy your biggest local competitor. We didn’t lose a single customer and grew our sales instead.”

The chairpersonAnders Freyschuss is chairman and the longest serving board member of Swedvent, the trade organisation for the HVAC industry in Sweden. He is also chairman of Eurovent’s Certifi-cation Programmes and Policy Com-mission (CPPC), the highest authority for Eurovent certification in Europe for all ventilation-related products. “I’m really proud and privileged to have these roles. Eurovent, for exam-ple, is a natural international forum for Camfil to act in. More than 90% of our sales are outside Sweden. We have driven filter standards and our role as the industry leader allows us to leverage our experience to improve the industry as a whole.”

Nordic differencesAnders’s territory means he works with Swedes, Danes, Finns and Norwegians. Are Scandinavian bonds strong?

“Each market functions somewhat differently, but we all have a com-mon base and a common ‘Nordic’ style of management, meaning that we value our colleagues – the human element – and we emphasise people skills, teamwork and the delega-tion of responsibility,” says Anders. “You can’t be a director ‘high in the sky’. It doesn’t work here. There are clear cultural differences, too. There are four distinct countries and each

behaves and thinks in its own way. Geographies also impact the sales and competitive landscape and how we approach the market. In Norway, we only sell to HVAC contractors, while the other three Nordic units sell directly to service companies, con-tractors and end users.”

The Nordic area has always been an early adopter of computer technology and Camfil’s online store, introduced already in 2001, has been a huge success, generating a large part of re-gional orders. “This is quite substan-tial for an industrial company (see AirMail 1, 2014),” says Anders. “The site makes it easy for all our Nordic customers to deal with Camfil. They can order 24/7/365, select their filters themselves, manage them by build-ing site and do this anywhere they have an Internet connection. The concept is now being introduced in other European countries.”

Full resources to serve customers“The backbone of Camfil’s R&D resources, the Tech Centre in Trosa, is a super strength and advantage for us in the Nordic region and for other Camfil Group companies”, says Anders. “We have also rebuilt and modernised our first filter test rig in Trosa, which is now reserved exclusively for Nordic customers. This speeds up testing and solution finding. Then we have our Filter School for customers and Trosa, as our Nordic hub, is a highly efficient and top-notch automated production unit and distribution centre. Deliver-ies are 99% on time, which is fantastic support for the sales force through-out the region. When you have a well-oiled infrastructure, our sellers can focus on their most important task – serving the customer.”

He says Camfil’s technical know-how and long-term perspective are appreciated: “We’re always here for our customers. Also, many of our em-ployees are loyal and passionate about the business. They stay with us, which guarantees continuity in customer relations. We’re appreciated for our expertise and reliability. We’re also curious – we really want to know, understand and solve the customer’s filtration problem,” Anders says.

Building IAQ awarenessThe importance of indoor air quality is well established in the Nordic mar-ket – people spend more than 90% of their time indoors. Camfil promotes greater awareness of IAQ through its Road Show and Filter School chan-

nels – or through events in collabora-tion with Swedvent. These have been extended to encompass important political arenas, which has put filtra-tion and IAQ on the political agenda in Sweden. For example, some parties pushed the issue that the government should approve major investments to improve ventilation in schools in coming years. “Educating the cus-tomer, end users, government agen-cies and the market is an important part of our role,” says Anders.

He mentions the Hornsgatan pro-ject in Stockholm (page 4-5). “It is so important. We are proving how good ventilation and filtration make a dif-ference in people’s lives. We are show-ing what we can do ‘on the inside’ when you have the worst air pollution outside. We are showing residents how filtration theory translates into specific health benefits. Better venti-lation with effective filtration will be particularly important when Sweden starts to rebuild and modernise the million apartments that were built in high-rise buildings during the 70s as part of a government initiative,” ends Anders.

ANDERS FREYSCHUSS

AGE: 51

POSITION: Camfil’s Executive Vice President and Area Manager for Northern Europe. Member of Camfil’s global Group Management team. Chairman, Swedvent and Eurovent’s Certification Programmes and Policy Commission.

RESIDENCE: Stockholm, vacation home on the Baltic coast.

FAMILY: Lena and their son Edvin.

INTERESTS: Fishing and all kinds of boating, including kayaking.

ON WORKING FOR CAMFIL: “I work here for the people – our many fine colleagues all over the world. This gives me energy and a vital life force. Camfil also lets me real ise my personal goal to work with the environment and sustainability. We produce filters that use less energy and provide clean air for health, wellness and higher industrial productivity with the lowest environmental impact. I like our mindset. I love our purpose.”

MOTTO: “Think how you feel today. Don’t be too future- oriented. Think ‘now’ and enjoy living in the present.”

8 AirMail No. 2 2014

NEW & NOTEWORTHY

Grüner goes for Camfil Handte’s

Oil Expert separator and Heat-

SaverBox for combined filtra-

tion and heat recovery.

The automotive industry and auto-motive suppliers are major customers of Camfil Handte APC in Germany. An example is the Grüner Group, which uses a range of materials to produce supplier parts for vehicle engines, drive trains, steering systems and structural components.

Grüner, with two plants in Baden-Württemberg and Thüringen, builds its own machines to guarantee con-sistent production quality standards. The company also makes precision tools for customers, which use them to manufacture their own parts and components. Grüner’s customers in-clude the largest automotive producer in Southern Germany.

The Baden-Württemberg site in Ulm is a fully automated machining centre using the latest generation equipment to manufacture precision tools for gearbox cases, among other parts. Here, two brand-new produc-tion halls are being built, of which one was opened in the summer of 2014.

To meet goals for high operator safety, clean production and energy savings, Grüner needed a new ex-haust-air filtration system for the hall, where high-speed grinding, cut-ting and milling processes generate a lot of fumes and airborne ultrafine aerosols.

Combined solutionGrüner turned to Camfil Handte for the solution, which combines a very efficient oil mist separator – the Handte Oil Expert – with an industry-unique energy-saving system – the Handte HeatSaverBox.

The HeatSaverBox system, an in-house development by Camfil Hand-te, is the first system of its kind to recover heat from the exhaust air of machining processes. Utilizing ther-mal energy in process exhaust air, the Handte HeatSaverBox helps custom-ers cut electricity bills significantly for lower operating costs. The system is decentralized and flexible for easy installation in manufacturing plants. Handte Oil Expert is a separator with a mechanical post-filtration stage that is specially designed for machining processes using oil as a cooling lubricant.

At the Ulm site, the Camfil Handte APC-designed system is realizing considerable cost savings for Grüner by recovering energy from the ex-haust air of 11 machine tool systems using only two Handte Oil Experts and two Handte HeatSaverBoxes. The total air volume is 2 x 12,000 m3/h and Grüner’s realized energy savings is approximately 354,167 kWh per year.

Visit camfilapc.com for further in-formation about these products and Camfil Handte.

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AirMail No. 2 2014 9

NEW & NOTEWORTHY

Air should be sufficiently clean so that people can breathe it

without risk to health and the same applies to Camfil staff. This is

why the Paris headquarters of our French subsidiary uses several

Camfil filtration solutions to maintain high indoor air quality (IAQ)

and protect employees from air pollution.

Earlier this year, air pollution in the French capital actually forced the govern-ment to introduce alternate driving days. According to sources, pollution levels reached 180 μg of PM10 per cubic metre, more than double the safe limit of 80. Air pollution was also critical in Europe for days as a belt of smog stretched for hundreds of kilometres, from France’s Atlantic coast through Belgium and right into the territory of Germany.

Taking measures in ParisCamfil France’s head office, with 100 employees, is located just northwest of the Paris city limits in La Garenne-Colombes, one of the most polluted suburbs of the greater Paris region (La Défense).

To provide the best possible IAQ for staff, Camfil France launched an action programme this year to investigate and implement a solution. These measures included a complete analysis of outdoor/indoor pollutants and emissions. For example, outdoor particle concentrations were monitored with a particle coun-ter and measurements were continuously made to document carbon dioxide concentrations and emissions of volatile organic compounds (VOCs).

Using Camfil’s software, a life cycle cost (LCC) analysis was prepared for the facilities management company to document the energy savings and IAQ im-provements that could be achieved by upgrading the conventional G4 and F7 air filters in rooftop air handling units. These AHUs are now equipped with M-Pleat Green M5 and CityCarb™ F7 filters for both particle and molecular filtration. The CityCarb combines an effective carbon filter with a high-efficiency particle filter in the space of an ordinary compact filter.

Camfil air purifiersTo complement the air handling system, five mobile Camfil City air purifiers with an H13 filter and two activated-carbon filtration stages were installed in-doors on the two floors of Camfil France’s office. The carbon filters remove both heavy and light VOCs and have reduced formaldehyde emissions by 90%. The City air purifier is typically used as an effective air filtration solution to provide clean healthy air at the point-of-need with minimum use of energy.

Today, all IAQ indicators are green in Camfil France’s offices and employees are experiencing fresher and cleaner indoor air that has improved health and wellness.

Stepping inside for fresh air in Paris

Higher HVAC performance at lower costWhat does a hospital have in common with an ice cream manufacturer? The answer is effective low-energy filters that reduce overall heating, ventilation and air conditioning (HVAC) costs. Here are two examples from the United States:

Durable savings with Durafil® ES/Opakfil™ ES When a Detroit city hospital completed a major renovation to its facilities, the administration looked to save money in all areas and realised there were sig-nificant savings opportunities in the operation of their HVAC system. With the existing filter programme, the facilities team had to change out the pre-filters four times a year and the final filters at least once a year. But these filters failed to maintain their rated efficiency over their expected life and required frequent reordering and changing, as well as excessive filter disposal.

Camfil proposed replacing the filters with the 30/30® pre-filter and Durafil® ES/Opakfil™ ES final filter. A life cycle cost analysis based on three air handling units (AHUs) showed that the configuration would achieve significant savings, with the 30/30 lasting at least twice as long and the Durafil® ES/Opakfil™ ES at least three times as long.

After the conversion, the energy-efficient Camfil combination has resulted in savings of at least 40% in HVAC-related expenses, reduced energy costs 53%, filter costs 26% and labour costs 59%. The total savings is about USD 20,300 per year for the hospital’s three AHUs.

Hi-Flo™ ES/Hi-Flo™ XLT upgrade Faced with escalating energy costs and increased demands on maintenance personnel’s time, a major U.S.-based ice cream manufacturer required a clean air solution that would reduce air-filter life-cycle costs and maintenance expenses.

The producer already used Camfil’s AeroPac™ Rigid Filters and 30/30 filters to effectively deal with outdoor contaminants that caused a higher than normal pressure drop development in their pleated and box filters. But the process of changing filters still represented an additional maintenance cost.

Camfil’s solution was to replace the current combination of filters with a single-stage Hi-Flo™ ES/Hi-Flo™ XLT . After one year, the net energy savings for the ice cream manufacturer was USD 8,000, plus an additional USD 8,600 in filter cost savings. The lower frequency of filter changes and use of one-stage filtration reduced waste by 70%. The savings in total filter costs alone is 39% – a nice topping for this ice cream maker’s budget.

10 AirMail No. 2 2014

Taking the sting out of dust explosions

NEW & NOTEWORTHY

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W O R D F I N DCAMFIL PARTICLES

CARBON POLLUTED

EXPLOSION SEPARATORS

FANS SMOG

HEMIPLEAT SPRAY

URBANISATION

Camfil Air Pollution Control’s new Stinger™ valve isolates dust

collector explosions to prevent a deflagration from travelling back

through the inlet pipe of a dust collector into the workspace.

The Stinger is used with new or exist-ing Farr Gold Series® dust collectors where there is a risk of a combustible dust explosion. The valve can also be retrofitted onto most dust collection systems.

A key feature of the valve is its light-weight, patent-pending composite blade that reacts with the highest possible speed in the event of an ex-plosion. It closes faster than heavier steel blades typically used for dust collector inlet protection.

Because of its light weight, less pressure drop is needed to hold the blade open during normal flow, sav-ing on energy use. The composite material also has a smooth surface and does not use stiffeners, which can allow dust to build up on the blade to compromise performance.

The Stinger is the first American-made explosion flap valve to be certi-fied by an independent testing agen-cy to comply with the standards of the National Fire Protection Association (NFPA), a U.S.-based authority on fire, electrical and building safety.

Protects personnel and equipmentDuring normal operation, the airflow holds the blade open. If a deflagra-tion occurs in the dust collector, a pressure wave will travel through the pipe faster than the flame front and close the flap valve, protecting down-stream personnel and equipment from injury and damage.

When the valve is fully closed, a latching mechanism keeps it shut. The closed valve prevents the trans-mission of flame and keeps smoke, dust and burning debris from trav-elling through the inlet pipe into the factory. The blade is easy to replace, eliminating the need to change the entire valve after an explosion event. A wear-resistant liner also functions as a wear indicator, showing when the blade needs to be replaced.

For more product information and a video on the Stinger explosion valve, go to www.camfilapc.com/stinger. The new Stinger valve from Camfil APC is specially designed to prevent a dust collector explo-

sion from travelling back through the inlet pipe into the workspace. It features a new type of lightweight composite blade that responds to explosions much more rapidly than the heavier steel blades typically used for dust collector inlet protection.

AirMail No. 2 2014 11

NEW & NOTEWORTHY

Farr Gold Series® adds new layer of safety in coatingImpreglon UK, a globally renowned industrial

applicator of fluoropolymer, polyurethane,

anti-microbial and thermal spray coatings, has

installed state-of-the-art dust collectors from

Camfil APC Europe to replace existing dust

extraction systems that could no longer keep up

with the company’s growing production volume.

Two state-of-the-art Farr Gold Series® dust collectors were installed: a GS12S to control the dust from a lathe, and a GS48 to provide extraction from a large booth where Impreglon sprayed aluminium and zinc by way of arc wire, plasma and flame spray methods.

This safe and cost-effective solution handles the demand-ing requirements of Impreglon’s applications. To ensure compliance with ATEX – the EU directive for equipment in explosive atmospheres – the collectors were installed complete with vertical discharge explosion-relief panels and flame-retardant HemiPleat™ Gold Cone™ filter car-tridges. High efficiency filtration, extended filter life and easy maintenance are other key benefits of the cartridges.

Dust collector fans are fitted with variable speed drives to minimise energy usage, further improve filter life and meet Impreglon’s sustainability requirements for an effi-cient low-impact solution that helps shrink the company’s carbon footprint, requires low maintenance and gives employees a safer working environment.

IMPREGLON’S COLLECTOR COMBO

The GS48 and the GS12S are installed outside Impreglon’s factory in Tamworth, UK, to provide more space indoors, reduce noise and create a cleaner working environment. The high-efficiency fan is fitted with a discharge silencer and controlled by a variable speed drive for energy savings.

12 AirMail No. 2 2014

THE BIGsmoke

AirMail No. 2 2014 13

CITY POLLUTION

The shops and department stores on Central London’s Oxford Street draw visitors from all corners of the globe, but

levels of nitrogen dioxide pollution on Europe’s busiest shopping street are the “highest in the world”, according to the

air quality experts of the Environmental Research Group (ERG), part of the School of Biomedical and Health Sciences

at King’s College London (KCL).

ERG is a leading provider of air quality in-formation and research in the UK and the alarming news about Oxford Street was revealed at their recent scientific conference on air pollution.

Monitoring by SelfridgesResearchers from the university set up a monitoring station on Oxford Street near the entrance to the world-famous department store, Selfridges, which found a peak level of nitrogen dioxide at 463 μg/m3 (micrograms per cubic metre). This figure is more than 11 times higher than the European Union’s safe limit of 40 μg/m3.

The monitoring station also found that average levels of nitrogen dioxide were 135 μg/m3 – almost four times the EU limit – largely because of buses and taxis passing through the busy shopping street. The level recorded in Oxford Street is an average, in-cluding night-time when there is less traffic, so the figure experienced by shoppers and workers will be much higher than this.

“To my knowledge this is the highest in the world in terms of

both hourly and annual mean. Nitrogen dioxide concentrations

[on Oxford Street] are as high as they have ever been in the long history of air pollution,” commented KCL air quality

scientist Dr David Carslaw in the Sunday Times recently.

Diesel vehicles are main causeOxford Street is one-and-a-half miles from end to end. It is best known for the Selfridges department store and the other big name re-tail flagship stores, which are all found in the

section from Marble Arch to Oxford Circus. It is Europe’s busiest shopping street, and as of 2011 had approximately 300 shops. It can be-come congested both on the pavements, due to the large number of shoppers and tourists, and on the roadway as a result of the diesel-engine traffic in the street (buses and taxis). Experts say the pollution on Oxford Street is mainly caused by diesel vehicles.

Air pollution measurements are made con-tinuously in Oxford Street by Westminster Council, as part of the London Air Quality Network. In 2013 (the most recent full year for which statistics are available), the annual mean NO2 was 135 μg/m3 and there were 1,502 hours greater than 200 μg/m3. The EU sets limits for NO2 based on World Health Organisation Guidelines.

The news follows data released by the Mayor of London in June 2013, which revealed that Oxford Street was one of the most polluted roads in London for both nitrogen dioxide and particulate matter 2.5 (PM2.5) and one of the top 15 worst polluted locations in the capital for 2012.

Major health issueAcross London, around 4,000 deaths a year are attributable to air pollution. Poor air quality is considered to be one of the biggest public health issues now facing the UK. A report by the House of Commons environ-mental audit committee included evidence that showed pollution could be contributing to 50,000 deaths in the UK each year.

In high concentrations, NO2 can trigger asthma and heart attacks in people exposed to it for only a short period. NO2 concentra-tions in Oxford Street are as high as they have ever been in the history of air pollution. The toxic gas causes breathing difficulties and has been linked to increases in prema-ture deaths and hospital admissions.

In 2013, the UK’s Supreme Court ruled that the Department for Environment, Food and

Rural Affairs (DEFRA) had breached pollu-tion laws, because its strategy would only en-sure that 23 of the UK’s 40 air pollution zones would comply with EU legislation by 2015. Under the UK government’s plan, another 16 zones would not comply with the air pollu-tion limits until 2020, while London would not meet the targets until 2025.

Separately, the European Commission has revealed it is taking legal action against the UK for failing to adhere to the legal limits.

Growing public awareness“In the UK, public awareness of the health effects of poor air quality both indoors and outdoors is increasing and Camfil is work-ing with major organisations to protect the health of the people inside their buildings, in this case, shop staff and thousands of shoppers,” says Bill Wilkinson, Managing Director of Camfil UK.

“City centre air quality in the UK is typically above WHO annual warning levels for PM2.5 and NO2. One effective measure to reduce city workers and shoppers being exposed to this air pollution is to improve the clean indoor air quality (IAQ) inside the buildings. This means ensuring effective air filtration is fitted in offices and public buildings.”

Filtration solutionBill Wilkinson points out that a class F7 low-energy air filter like City-FloTM XL will remove a large part of PM2.5 from supply air as it is drawn into the building, as well as improve energy efficiency.

“Alternatively, Camfil’s range of air puri-fiers is used by building owners to clean the air inside buildings in highly polluted areas. They work as a supplement to existing venti-lation systems and deliver a healthier indoor environment by removing dust, contami-nants and harmful particles in department stores, industry, offices and homes,” ends Bill Wilkinson.

London’s Oxford Street is the most polluted in the world

PHOTO: elenaburn / Shutterstock.com

14 AirMail No. 2 2014

CAMFIL FILTER SCHOOL: MODULE 4

THE FOLLOWING MODULES ARE BEING OFFERED IN AIRMAIL:

Module 1: Airborne Pollutants – Why We Need Clean Air

Module 2: How Air Filters Function

Module 3: Test Methods and Standards

Module 4: Fans, Airflows and Energy Calculations

Module 5: Certification Systems

Module 6: Environmental and Energy Aspects

Module 7: Choosing the Right Filter and Filter Class

Module 8: Filter Replacement and Service

Several different factors affect the total effi-

ciency of an air handling unit (AHU) fan. In this

module, we explain how you measure efficiency,

how inefficiency impacts energy use, and how

you improve efficiency by using quality filters

with low pressure drop.

AHU fansIn the ventilation business, AHUs are equipped with differ-ent types of radial and axial fans. The fans differ in terms of their wheel design and whether or not the fan has a hood.

The B-wheel radial fan (1) has backward-curved blades, the highest efficiency and a low noise level. The F-wheel radial fan (2) has forward-curved blades and a lower effi-ciency than the B-wheel. It is used for moving high volumes of air at a low number of revolutions. The wheel of the axial fan (3) rotates within a cylindrical hood. The blades force air to move parallel to the shaft, along an “axis”. The axial fan utilizes less power than a radial and is also suited for transporting high air volumes with low resistance.

The fan speed has to be reduced to save energy in a fan drive, regardless of the design. When you use an air filter with a lower pressure drop at the same air volume, the fan uses less energy, but only if you reduce the speed. The efficiency of the fan assembly also depends directly on the electric motor, the frequency converter, the belt drive (unless it is a direct drive) and the aerodynamic design and the efficiency of the fan wheel.

Electric motorsThe most common electric motors are asynchronous induction motors and the Electronically Commutated Motor (ECM), also called the Permanent Magnet (PM) motor. Efficiency is normally somewhere between 70% and 90%. At smaller sizes (<1 kW), ECM (PM) motors are about 10-20% more efficient than asynchronous motors.

The efficiency factor defines the efficiency of motors when transforming electrical energy into mechanical energy. For many years low-voltage three-phase motors in the EU have been sold in three efficiency classes: EFF3, EFF2 and EFF1.

There have been international discussions in the industry about energy efficiency and a world-wide energy efficiency classification system for low-voltage three-phase asynchronous motors and the International Electrotechnical Commis-sion (IEC) has published an energy efficiency standard replacing all previous national norms.

The IEC has also developed and issued a new standard for determining motor efficiency. Worldwide, the IEC 60034-30:2008 standard defines and harmonizes the efficiency classes IE1, IE2 and IE3 for low-voltage three-phase motors in the power range 0.75 kW to 375 kW:IE1 = Standard efficiency (comparable to EFF2)IE2 = High efficiency (comparable to EFF1)IE3 = Premium efficiencyIE4 = This level is defined according to

IEC 60034-31:2010.

3. Axial fan.2. Fan with an F-wheel and hood.1. Fan with a B-wheel and hood.

It is very important to size each type of electric motor correctly to allow the motor to operate in its most efficient range. An undersized motor cannot be used and an oversized motor gives reduced efficiency, sometimes drastically.

Frequency convertersFrequency converters adjust the speed of the electric motor, based on the load from the venti-lation system. Reducing the motor’s speed saves energy. However, the converter also has an ef-ficiency rating that must be taken into account. The rating depends on the size of the converter and the frequency. The lower the frequency, the lower the efficiency, especially when using a converter smaller than 5 kW. When using pres-sure-controlled fans with constant air volume, the frequency converter automatically controls the fan speed to provide the desired air volume.

Fans, Airflows and Energy Calculations

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AirMail No. 2 2014 15

CAMFIL FILTER SCHOOL: MODULE 4

Total efficiency analysisTo determine the total efficiency of the fan assembly, you multiply the efficien-cies of all individual components using this formula:total = motor x frequency converter x belt gear x dynamic loss x fan wheel

You determine the total efficiency of the fan “as installed” by comparing meas-ured power usage to the fan’s measured performance. A modern ventilation system has a total fan system efficiency of roughly 50%. In older ventilation systems, the efficiency might be much lower.

In Sweden, for example, average total system efficiency is 33%, as measured and documented over a five-year period in buildings by ECiS (Energy Concept in Sweden AB). Camfil compiles the results, which indicate that only one-third of a ventilation system’s total energy use is actually for operating fans, while the remaining two-thirds are lost, mostly in the form of heat.

ECiS (Energy Concept in Sweden AB), average total fan efficiency.

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33

Measuring the actual efficiencyThe following formula is used: Pelectrical (W) =

ptotal (Pa) x V (m³/s)

total• Pelectrical is power measured in W (or Nm/s)• Ptotal is pressure measured in Pa (or N/m2)• V is air volume measured in m3/s• is total fan efficiency, expressed as a real number

Power is measured in W (Nm/s) on the input current cable of the fan motor. Use a meter that takes an accurate measurement next to the frequency converter. Always measure on the input side of the frequency transformer, never on the output side.

To measure the fan’s operation in terms of pressure (Pa), add the static negative pressure at the fan inlet to the positive pressure at the fan outlet. Adding these two pressures gives the total static pressure of the system. The air volume of the system is measured by using carbon dioxide (CO2) as a trace element.

How air filters impact energy useEurovent Certita certification programmes for air filters are used to determine how air filters impact a ventilation system’s energy usage. The energy classifica-tion is the amount of energy a fan uses in kWh to pull air through an air filter, which also depends on the filter class. The filter must be tested and approved according to EN 779:2012.

Calculation conditions according to Eurovent 4/11:Running time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6000 hours (h)Airflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3400 m³/h (0.944 m³/s)Fan efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5Average pressure drop Δp (Pa) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Calculated** The values are retrieved from graphs based on the dust load used for the test protocol, as specified in EN 779:2012:

• Coarse filter G4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350 grams• Medium filter M5-M6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250 grams• Fine filter F7-F9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 grams

Formula for calculating energy use:

Energy use (kWh) = Average pressure drop (Pa) x Airflow (m³/s) x Running time (h)

Fan efficiency () x 1000

Finally, the filter is classified by its calculated energy use.

What can building owners do?When AHUs are equipped with energy-efficient filters with low pressure drop, the energy used by existing and new ventilation systems can be reduced. As a bonus, building owners might also be able to discover if there are other in-efficiencies hidden in their ventilation systems. It has been documented that Camfil’s air filters are the most energy-efficient on the market. The pressure drop caused by the actual filter is a major part of the pressure drop in the whole venti-lation system. Since the duct system is more complex to change, changing filters is an easy way to reduce overall energy costs.

Belt drivesA belt-driven AHU fan reduces efficiency. The efficiency depends on the calculation of the belt gear, the type of belt and the com-plete gear adjustment. You can normally expect an efficiency of about 90% at medium power (about 3-15 kW), but it can easily slip to 60-70% if the gear adjustment is incorrect.

Fan wheelsThe last factor is the fan wheel. Efficiency will vary, depending on the type and design of the blades. The highest efficiency, up to 85%, has a Type B wheel with backward-curved blades.

Aerodynamic designThere will always be dynamic pressure loss in a fan. The aerody-namics of the fan hood or AHU chamber (if the fan does not have a hood) will dictate the size of the loss. The dynamic pressure loss is always lower with a well-designed fan hood than a chamber.

PURE, PARTICLE-FREE AIR FOR ROOMS UP TO 75 M2

The mobile City M air purifier, available in a black or white finish, is designed to purify air in rooms up to 75 square metres in area. It features a removable top for easy filter replacement and a display for setting the desired airflow. The display also indicates when it is time to replace the filters.

Polluted air passes through a pattern of holes on both sides and continues inside to be purified. Clean air – free of particles and harmful pollutants, gases and odours – is dispersed in all directions, 360 degrees.

The combination of a particle and molecular filter is so efficient that air would have to pass through the filters of an ordinary ventilation system three times to achieve the same level of air purification as it does in a single circulation through City M. The low-energy fan is the only moving part.

City M – the roommate everyone appreciatesImagine a mobile air purifier in

your room that reduces millions

of airborne particles and takes

care of molecular gases with the

latest HEPA filter technology to

make room air purer and safer to

breathe. It’s no fantasy – this is

possible today with Camfil’s new

City M air purifier with combined

particle and molecular filtration

in three stages.

City M is the perfect solution for ensur-ing high indoor air quality (IAQ) in build-ings in urban areas. The air purifier is used to supplement existing ventilation systems with inadequate filtration, to fil-ter room air when there is no central air handling system, or to eliminate numer-ous internal source pollutants. Typical application areas include commercial, retail, residential and public premises, such as offices, shops, apartments, schools and hospitals.

Consistently clean airThe City M air purifier comes with an Absolute™ particle filter (HEPA 13) and a molecular filter with activated carbon. The large filtration surface of the filter pack is 14 times denser than most com-mon brands for much higher capacity. The filters retain dust and particles with-out clogging and without compromising on their ability to let air pass through. The result is a highly effective filter pack that lasts longer and delivers consistently clean air with a high level of efficiency over its lifetime.

If you compare the filter of an ordinary room air cleaner with City M’s, it would be like comparing the load capacity of a normal size station wagon with a full-size truck.

City is also a greener and more sus-tainable solution because the filter is more energy-efficient and requires less frequent change-outs, which also means less filter waste.

Importance of good IAQMost people know that outdoor air pollu-tion can damage their health, but many do not know that indoor air pollution can also cause harm. Levels of pollutants can sometimes be many more times higher than outdoor air, which is of particular concern because most people spend up to 90% of their time indoors.

Indoor air pollution has been ranked among the top environmental health risks to the public by many governments. Much of the 25 kg of air we breathe daily is indoor air, and if IAQ is poor, it can have a range of negative effects. Studies have confirmed, for example, that poor IAQ can impact productivity and health in offices and even the learning environ-ment in schools.

The perfect complementCity M effectively removes particles and molecular gases. As a complement to existing or inadequate ventilation sys-tems, it takes care of pollutants from the outside and captures those on the prem-ises, such as emissions from furniture, wall paint, cosmetics, air fresheners, cleansers, carpets, aerosol propellants, building materials and office supplies and equipment.

The air purifier can also eliminate a range of symptoms caused by poor IAQ, including headaches, coughing, aller-gic reactions, respiratory problems, eye irritation, nausea and skin rashes. It can even reduce cleaning costs by removing a large portion of the dust that is gener-ated daily indoors.

www.camfil.com