Hybrid Air offers the solutions to the challenges in today’s mist collection systems. 

Problems in a traditional central mist collection system:

• Coolant loss due to “sucking up” too much coolant at the machine.
• Duct leaks due to liquid coolant being carried inside ductwork.
• Plugged drains as a result of metal chips and other fines carried with the mist.
• Biological growth in ductwork, saturated filters, and collector sumps.
• Evaporation of coolants and oils within the mist collection system.

 

Problems solved with a Hybrid Air central mist collection system:

• Coolant loss. (At each machine, mist is captured, coalesced and separately returned to that machine.)
• Duct leaks. (Liquid coolant is no longer carried in the ductwork.)
• Plugged drains. (Metal chips and other fines are kept out of the ductwork.)
• Biological growth. (Coolant is kept out of the ductwork as well as any filters, and no sump is required.)
• Evaporation. (Mist is removed from the air right at the machine, rather than traveling all the way to the central collector while evaporating along the way.)

 

The Hybrid Air system accomplishes this tremendous improvement in performance by placing its very highly efficient first stage (the Hybrid Coil) right at each machine, rather than inside the central mist collector “box”. The Hybrid Coil is a passive mechanical separator with no moving parts, no filters and no electrical connections. It requires no maintenance. It simply becomes a “part of the duct”. The Hybrid Coil removes the mist along with any fines. The virtually clean and dry air is then ducted to the central collector, which in reality is now just a final filter box with a blower.  

The air discharged from a Hybrid Air central mist collection system will be much cleaner than air discharged from any other central mist collection system available today. 

Savings & Benefits

Comparing Hybrid Air to a Traditional System

Installation Savings

 

1. Smaller central collector footprint.
2. No sump installation.
3. No compressed air hook-up (for sump pump).
4. No water hook-up (for wash-down).
5. No duct drains.
6. Self-balancing – dampers are not necessary.
7. Ducting to outdoors not necessary.
8. Fire protection not necessary in ductwork.
9. Baffles/slots/capture boxes not required on machines.
10. U-Plenum allows easier/faster/more flexible installation.

Operational Savings

 

1. Lower coolant loss.
2. Lower make-up water usage.
3. No water needed for wash-down.
4. No coolants or water sent to Process Waste Treatment.
5. Airflow adjustable to only what’s required.
6. Regular ductwork & collector cleaning not required.
7. Duct leaks eliminated.
8. Longer filter life (6,000 hours minimum).
9. Heating/cooling savings (versus exhausting to outside).

Health & Safety Benefits

 

1. Cleaner discharge air.
2. Lower humidity in workplace.
3. Less oil vapors and other chemicals in workplace.
4. Fewer odors in workplace.
5. Much lower biological growth potential.

 
 
 
 
 
 

Other Applications for the Hybrid Coil 
 

The Hybrid Coil has an extremely high collection efficiency. Testing has shown that it collects all mist droplets down to 5 microns. This makes the Hybrid Coil ideal for use in applications where cyclone-type collectors, vane-type demisters, mesh demisters, and other collection devices are typically used. 

Potential applications are in the food processing, chemical, petrochemical, and other industries, in addition to the typical mist collection uses in the metalworking industry. 

The main advantages that the high efficiency of the Hybrid Coil provides are in two areas:

1. Maximize valuable product recovery.
2. Provide much cleaner exhaust.

 

In addition to being used in new systems, Hybrid Coils can also be added to existing collection systems. This type of retrofitting can significantly improve the performance of existing systems. 

Whether Hybrid Coils are part of a large central mist collection system, mated directly to blowers as individual collectors, or used as custom components within a larger product recovery or air pollution control system, their high efficiency, simplicity and maintenance-free operation will be a tremendous benefit to the end-user.

 

The following relates to water-based coolant (typically 5% to 12%
operating concentration levels).
Coolant loss in gallons per hour due to carry-off and evaporation
(% of total pumped GPM):
• Low pressure machining 2% – 4%
• High pressure machining 3% – 5%
• Grinding 3% – 5%
• Wash @ 120 deg F (intermittent spray) 4% – 8%

Around 40% to 70% of this coolant loss is due to evaporation
within Traditional mist collection systems.
The average evaporation rate in Traditional mist collection
systems is over 2 gallons per hour per 1,000 CFM. Just one
12,000 CFM mist collector will evaporate about 25 gallons per
hour, or 200 gallons per shift. (Based on actual measurements.)

Water is lost about 2 to 5 times faster than concentrate (concentrate
make-up is 1/2 to 1/5 of the operating concentration level).
Compared to a Traditional mist collection system, a Hybrid Air
mist collection system will save at least $0.50/CFM in annual
coolant costs for a one-shift operation, $1.00/CFM for a two-
shift operation or $1.50/CFM for a three-shift operation.
(Based on 8% operating concentration, 1.6% make-up
concentration and coolant concentrate costing $10/gallon.)

“In most cases, the greatest single impact on your annual coolant
costs is the type of mist collection systems you use.”