Spider Power for Turbomachinery Operators

Slowly, a blue spider crawls across its spider web. When it reaches the center, it stretches, solidifying the self-woven structures. We are in the middle of a video scene. Only when the camera opens up and moves away from the scenery does it become clear. This is not a real spider, but a model from nature that was used to launch a brand-new product at Freudenberg Filtration Technologies: the spiderMaxx.

The cassette filter was developed for turbomachinery operators to achieve maximum performance and operational reliability (Figure 1). “We are proud of this product because it combines several positive features that offer clear added value for our customers,” explained Leon Strauss, Freudenberg Filtration Technologies’ turbomachinery sales executive for the southeastern U.S. In this context, inspired by nature—with the spider and its web—really does bring benefits for the users and is not just a great design gimmick. But everything in turn. The filter can be used where there is a lot of moisture, it rains a lot, snow occurs, or salty air attacks the machines, particularly in coastal onshore and offshore platforms.

Longer Runtime, Fewer Filter Changes

What matters? The intake air of gas turbines and compressors must be free of dust and moisture. This is the only way to avoid costly machine downtime and losses in efficiency and effectiveness.

The spiderMaxx can absorb more dust than comparable products on the market. It also enables a 15% to 25% longer runtime. Air pressure is noticeably reduced, resulting in higher energy efficiency, and thus, higher energy output from the system. By stopping salty air from reaching the turbine, less erosion and corrosion occurs.

In addition, the spiderMaxx performs at EPA (Efficient Particulate Air) filter class level and meets ISO 29461-1 specifications. “The exact impact depends very much on the environment. But we can calculate the benefit individually,” Strauss said. Using the electronic Freudenberg Filter Efficiency Calculation Tool (e.FFECT), possible solutions can be compared and individually optimized.

So far, so good, but let’s take another look at the unique design (Figure 2). The cassette filters achieve their performance through a series of refinements. Inspired by nature, the burst protection grids of the innovative filtration solution are characterized by extremely high dimensional stability and resistance. With their concentric spider-web design, the grids distribute the changing mechanical loads that occur during operation over the entire filter frame. This enables the filters to withstand extremely adverse ambient conditions, even in stormy coastal regions or offshore.

Risk of Leakage Approaches Zero

The filter frame itself has high torsional rigidity and mechanical stability. It consists of one-piece front and back plates. To prevent dust from penetrating, the frame is optimally sealed. The sophisticated design with a channel integrated in the front frame ensures the ideal fit of the foamed-on gasket—even in the critical corners. Water drainage slopes toward the air inlet side to ensure effective drainage.

In terms of sustainability, the aerodynamic guide vanes between the v-shaped pleat packs are special, too. On the downstream side, they create a low-turbulence airflow and effectively contain vortex formation. This ensures minimal flow resistance and reduced pressure losses, thus lowering CO₂ emissions during operation.

Better Results Thanks to Multistage

Turbomachines generally use multistage filter systems. In combination, they first filter moisture, then coarser particles, and finally fine dust from the supply air. The spiderMaxx would be the final stage. As a high-end filter, it is responsible for the efficient filtration of the finest particles.

Thanks to its water-repellent properties, it keeps moisture out, which makes it particularly predestined for use in regions with high humidity. The clip-on system from Freudenberg Filtration Technologies allows the individual filter stages to be connected easily and in a space-saving manner. Like the individual elements of a spider’s web, the parts come together in the end.

—This article was contributed to POWER by Freudenberg Filtration Technologies.