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Introduction
Filters are a critically important component in Pharmaceutical HVAC systems.
The majority of the following has been researched and compiled from many sources.
The intent is to bring together useful information to form one uniform article relating to
HEPA filtration with respect to particulate interaction with filter fibers.
Although Ashrae has partially covered some of the mechanics of particulate capture,
a more complete definition of these processes and concepts will be found within these pages.
This report is not a repetition nor an explanation of ASHRAE 52.1 or 52.2. It does not
identify or explain the usual dust-spot procedures for testing air filters. The reader will not find
any reference to MERV (minimum efficiency reporting values). What will be found is the
mechanics of filter fiber and particulate interaction, which will provide new insight to
filtration operational concepts.
General Considerations
A captured particle becomes part of the filter structure, increasing the pressure drop while at
the same time increasing the filter efficiency. A new filter will be less efficient than one that has
been in service for a while. Filters are changed because of reduced airflow due to increased
pressure drop, they are not replaced because of loss of capture efficiency unless they have been
punctured and leak. It should therefore be expected that recently replaced filters will pass more
particles than filters that have been in use for a while.
A time period of settling in or running of the system should be a standardized procedure after
filter replacement. Filter manufacturer’s charts indicate the pressure drop at a specified CFM,
filter charts never indicate the interception efficiency versus length of filter service or
interception efficiency versus loading capacity.
The rate at which a filter will become clogged is related to particle size, the finer (smaller)
the particle size the higher the rate of clogging.
Filter Structure
Filters should be considered as layers of fibers in an open three dimensional network.
Points of fiber to fiber contact are infrequent. If each layer of a (100) layer filter only captured
5% of the particles passing through it, the filter as a whole would capture 99.4% of the particles,
if there were (138) layers it would capture 99.9% of the particles, if the filter captured 7% with each layer
of the particles passing through it, the filter as a whole would capture 99.9% of the particles with
(96) layers, this same filter would capture 97.5% of the particles at it’s 51st layer. Particle size
not withstanding.
Thick fibrous filters are more efficient than thin filters. Layers are sparsely populated with fibers.
Packing Fraction
The “Packing Fraction” ( the fraction of the volume of filter media in relation to the
overall volume of the filter) is only a few percent. This could be readily seen by compacting
the filter media and comparing the filter volume to the media volume. Particle capture
throughout a HEPA filter is defense in depth or “Depth Filtration”. All packing fractions are
less than unity (1<). A packing fraction of one would simply be a solid mass which no air
could pass through. The lower the packing fraction the higher the dust holding capacity and the lower the
filter efficiency and initial pressure drop.
The probability of intersection (Int) of two fibers of length (L) drawn at random in a
square element with side (L) is:
If there are (Nf) fibers per unit area of filter the likely number of pores
produced by intersections, Np , is:
It would be difficult to measure the number of fibers (Nf) per unit area.
Predicting the number of intersections would not be useful unless the pore size could be calculated.
It is possible by statistical means to identify the pore size, but the accuracy of the procedures
may lie in statistical methods. Page 6 of 12 indicates a “Cell Theory” method of determining cell area.
The dimensional random fragmentation of the inside of a filter combined with particle distribution
and particle flow action can be treated with statistical theory.
Predicting the pore size does not lend itself to simple analytical procedures, pore areas will be
“skewed” and “unimodal”.
Note: Skewed = Probabilities which the median and the mean are not coincident.
Unimodal =
If x < y <c then f (x) < f (y) and If x > y > c then f (y) > f (x) or vice versa.
Function (f) possesses a single maximum or minimum in the interval.
It would be required to approximate pore size by one of the standard distributions, gamma, weibull
or lognormal. Constants for these distributions would have to be assumed. Because of the nature
of flow through a filter the influence of pores on airflow is governed more by hydraulic radius
than by cross-sectional area.
Characteristics and Forces affecting Airflow, Particulates and Fibers with respect to Air Filtration
The forces affecting fibers and particulates are:
Local Gravitational forces
Mass or inertia of the particulate
Viscosity of the air, particle and fiber
Elasticity of the particulate and fiber
Molecular action of the particulate and fiber
Ionization potential of the particulate
Surface tension (capillary) forces between particulate and filter fiber
Thermal energy Transfer Between Transport Medium (air) and the Particulate
Vibration and sound transferred to the filter fiber from the local environment
Velocity Pressure acting on captured particulates
William A. Greco 2007 Page 4 of 12
Capture by Diffusion
Small particulates are transported in the air stream. Particulates that are relatively small and have
low amounts of mass quickly achieve thermal equilibrium with the transport medium (air)
with which they have been entrained. Particulates suspended in a gas receive thermal energy
from that gas. A constant exchange of thermal energy between the transport medium (air) and
particulate results in microscopic motion of the particulate. This additional motion or wobble
of the particulate prevents it from traveling in a straight streamline course resulting in a
diffused trajectory, which aids in their capture. Capture by diffusional thermal motion
(known in physics as Brownian Motion) has a greater effect on very small particulates
than on large ones. Particulates captured by diffusion are often found on the back part of
the filter fiber with respect to airflow
Capture by Interception
Particles captured by pure interception depend strictly on the airflow velocity and generally
have a low inertia caused by a low mass and / or low velocity, Interception depends on conditions
close to the filter fiber surface. Air velocity at the fiber surface is close to zero and contact by interception
is a gentle process. A radial and tangential air component exists close to the filter fiber, both of these
components vanish at the fiber surface.
Particulate Escape
There must exist an energy level in which the fiber and the particulate contribute
the same adhesion energies and where the approach velocity becomes critical causing
sufficient energy for the particulate to escape capture or bounce off of the first fiber it encounters.
Particulates which either completely escape the filter or are captured deep within the filter
probably exhibit high mass relative to their size and are aerodynamically well suited to
high velocity and a low drag coefficient.
Vibration by sources outside of the filter media could cause loss of particulate adhesion
from the filter fiber, such vibrational forces can easily be found in most Pharmaceutical
production areas and processes, equipment vibration can be transmitted to the filter housing
through the building structure and ductwork system.
The size of particulates which either evade capture or are found buried deep within the filter
will have an increased diameter when the diameter of the filter fiber is increased and the
packing fraction and velocity are decreased.
Airflow around a captured particle provides an additional force which helps to encapsulate
the particulate within the surrounding flow streamlines. When airflow is shut down this
encapsulating force is deactivated, thereby allowing some of the previously captured
particles to become detached.
Those particulates that have been captured by inertial impact will be more difficult
to detach than those captured by other means.
Velocity increases in filters that have become clogged past their recommended
replacement pressure drop. A substantial increase in velocity may cause particulate
shredding or total detachment to occur.
Temperature change can cause the filter fiber to expand and actually release a captured
particle.
Some particulates are caught in the room by heat stratification or points of room
airflow stagnation which never reach the HVAC system and are a subject of space
airflow and not associated with filter dynamics.
Pin hole leaks are not as big a problem as might at first be expected.
A pin hole leak will exhibit a measure of size selection the same way that a filter
does. Since air passes through the leak faster than the air passing through the filter,
there will be a convergence of streamlines into the leak, this increased convergence increases
diffusional movement and particulate inertial impaction.
William A. Greco 2007 Page 6 of 12
A filter fiber cell area calculated in accordance with “Cell Theory” defines a reference surface
concentric with the fiber surface as shown in figure-4. The cell surface distance is such that the
packing fraction of the fiber within this cylinder is identical to that of the fibers within the filter.
The cell surface radius is equal to the fiber radius divided by the square root of the filter packing fraction.
See page 3 of 12 for example of statistical description of filter fiber structure.
Where:
R = Fiber Radius
c = packing fraction
Example-1:
For a 20 mm fiber radius and a filter packing fraction of 0.011 or 1.1%, the calculated
cell radius in accordance with Filter Cell Theory is:
Where:
20 = microns
Note:
Micron = symbol m A former name for the micrometer; 0.000001 meters
The following equation for pressure drop is from Happel, J. “Viscous flow relative to arrays of cylinders”,
American Institute of Chemical Engineers Journal, 1959 pp. 174-177.
Where:
DP = Pressure drop, pounds per square foot
R = Radius of the filter fibers, feet
c = Packing Fraction
h= Coefficient of viscosity of air at normal conditions (0.000004 lbs/square foot/sec.)
U = Average Velocity of airflow through filter media, feet per second
h = Filter Depth, feet
Note: Coefficient of viscosity of air as given by Baumeister, T.
Marks Standard Handbook for Mechanical Engineers, McGraw-Hill sixth edition, 1967
Pg. 3-50..fig. 2.
Example – 2:
Assume a packing fraction (c) of 0.011, an airflow of 100 feet per minute ( 1.67 feet per second)
and a filter depth of 6 inches (h = 0.5 feet) and a filter fiber radius of 40m microns .
The theoretical pressure drop for this filter is:
Canceling units:
Example – 3:
Assume the same filter as in example-2 with a clean packing fraction (c) of 0.011,
an airflow of 100 feet per minute ( 1.67 feet per second) and a filter depth of 6 inches (h = 0.5 feet)
and a filter fiber radius of 40m microns.
As the filter gets dirty the packing fraction will increase, and the filter pressure drop can be recalculated.
Assume a 20% particulate loading :
The new packing fraction will be:
0.011 + (0.20 x 0.011) = 0.011 + 0.0022 = 0.0132
The new velocity through the filter will be:
(100 feet per minute x 0.20) + 100 feet per minute = 120 feet per minute or 2 feet per second
On this particular filter an increase of 20% loading increases the packing fraction to 0.0132 and
causes the velocity to climb to 120 fpm which equals a pressure drop of 1.42 inwg.
Most HEPA filters are changed at a 2 inches water gage pressure drop. This particular filter would
require a 39% increase in the packing fraction prior to being changed. A 39% increase in the
packing fraction would increase the velocity to 2.31 feet per second and the packing fraction to
0.0153, the pressure loss would now equal 2 inwg thus:
or roughly 2 inwg
Please note that the packing fraction increase is by volume not by weight, an equal
volume of captured particulate will weigh considerably more than an equal volume
of filter packing media.
William A. Greco 2007 Page 9 of 12
Loading
Loading or clogging rate is very low for the inertial impact capture mechanism. Diffusional capture has
a very high clogging rate, while the capture rate by interception falls somewhere between inertial and diffusional.
The rate of clogging in HEPA filters is independent of velocity. The major capture mechanism for HEPA filter
particulate loading is interception. With high particulate inertia the likelihood of particle to fiber contact
without capture is higher for a clean filter than it is for a loaded filter.
Towards the end of life of a high efficiency filter there is a tendency to convert from depth filtration to
surface filtration where the leading surface forms a dust cake. This is usually the final behavioral mode of a
clogged filter.
A relationship exists between clogging rate and filtration efficiency. The best means of controlling the
loading rate is to use layered structures. A layered filter can be made from composite materials such that
the lowest efficient layer is first to capture the entering particulates. The entire filter would be made of
the same size fibers but the packing fraction made to vary with depth. This would promote depth filtration
and reduce the filter tendency to form a dust cake at the surface.
Calculation of Mean Thermal Diffusional Energy as it relates to Coagulation and filter clogging is
given by the theory of “Equipartation of Energy”. The theory states that the average energy of the
molecules of a gas are equally divided among the various degrees of freedom of the molecules and the
degree of freedom is equal to: ½ kT, where k is the Boltzmann constant and T is the absolute
temperature. Extending this to include mass and velocity gives: ½ mV2 = ½ kT where m = mass of the particle
and V = velocity. The thermal velocity then equals:
k = Boltzmann constant
Canceling units:
William A. Greco 2007 Page 10 of 12
Example-4:
Consider a spherical particle of dry soil (dirt) with a one micron diameter in an air mass of 70 degrees F. =
Volume of a sphere =
Where:
D = diameter of sphere
1 inch = 25,400 microns
therefore a one micron diameter has a volume of:
Architectural Graphic Standards _John Wiley & Sons –6th Edition – 1970 gives the weight of dry soil
as 76 pounds per cubic foot.
one spherical micron of dry soil weighs:
Velocity of a spherical particle of dry soil (dirt) with a one micron diameter in an air mass
of 70 degrees F. due to diffusional thermal movement (Brownian motion) = 0.00151 feet per second
This velocity represents the contorted vector movement which keeps the particle from moving
along the same path as the airflow streamlines.
The thermal energy which the particulate comes in contact with any surface which it encounters
is represented by:
Agglomeration
An indiscriminately formed cluster of particles can coagulate forming larger particles if they
have high adhesion properties. Certain forces could prevail in a space in which particles that are
below the minimum capture size pass through HEPA filtration, invade the protected space and
then proceed to join together and form larger particulates which could remain active in the space
if not captured by the HVAC system. A build up of such a process could cause the space to
eventually fail it’s classification rating.
Another term for agglomeration is flocculation. Particles below 0.1 microns in size exhibit
violent diffusional thermal movement as shown on pages 9 and 10, the mass of the particle is
divided into the Bolzmann constant, hence the smaller the mass the more violent the particulate
vector movement (Brownian Motion). This increases their collision frequency with consequent
formation of agglomerated masses or aggregate structures. Suspensions of such particulates
eventually achieve sufficient mass to succumb to gravity and settle. Settled particulate masses
tend to stick to vertical walls and surfaces with which they collide.
The time course of particulate agglomeration in a homogenous gas cannot be measured
by the decrease in the number of separate particles in the suspension because some of the particles
would have settled to vertical or horizontal surfaces. A theoretical method exists to measure the time
course of particulate agglomeration, however the theory and calculation is only useful for an infinite
space that is not bounded by surfaces and has no practical engineering value.
Aerodynamic Slip
Air molecules move by pushing against adjacent molecules. Air molecules travel a free path
distance at STP (standard temperature and pressure) of 0.065 microns before colliding with the
next air molecule. The effect of this free path is that the velocity of air at the fiber surface does not
vanish in the tangential direction, but approaches a minimum limit. If the air molecule waves travel
in a definite direction and the direction of the approaching molecules and reflected molecules make
equal angles with a line perpendicular to the filter fiber surface, the tangential velocity will equal the
approach velocity, causing the particulate to slip past the filter fiber. This process is termed
“Aerodynamic Slip”.
(m1)(v1)+(m2)(v2) = (m1)(V1)+(m2)(V2)
A slight loss of energy is given off to friction. Neglecting any losses due to coagulation forces,
frictional or aerodynamic drag forces and taking into account the coefficient of elasticity’s, the equation
becomes:
(m1)(v1)(e1)+(m2)(v2)(e2) = (m1)(V1)(e1)+(m2)(V2)(e2)
Conclusion
The information contained within these pages was an attempt to present the mechanics of
filter fiber and particulate interaction in a simple manner. Many intricate equations and concepts
pertaining to filtration mechanics exist, however individuals actively engaged in HVAC system
design would find this theoretical information’s usefulness inversely proportional to it’s complexity.
References:
Dorman, R.G. Dust Control and Air Cleaning, Pergamon Press, Oxford, 1974
Hudson, R.G. The Engineers Manual, John Wiley & Sons, 1917
Kaye, B.H. Describing filtration dynamics from the perspective of fractal geometry.
KONA Powder and Particle 1991, pp 218-236
Piekaar, H.W. and Clarenburg L.A. Aerosol Filters- pore size distribution in fibrous filtration
Chemical Engineering Science, 1967 1399-1408
Stafford, R.G. and Ettinger, H.J. Filter efficiency as a function of particle size and air velocity.
Atmospheric Environment, 1972 pp 353-362
Wake, D. And Brown, R.C. Filtration of monodisperse aerosols and polydisperse dusts
by porous foam filters. Journal of Aerosol Science, 1991 pp. 693-706