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Hydac develops new innovative filter element

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The new Hydac Optimicron features an innovative filter element technology for sustainable filtration.

Optimised for filtration and energy efficiency, the new Optimicron filter elements by Hydac offer the best combination of filtration efficiency and pressure drop. The innovative features of the new technology positively impact the differential pressure of the elements.

The high-performance micro glass media at the core of the filter element offers first class separation efficiency and a lower differential pressure over the entire service life of the element.

The Optimicron filter series has been expanded with the addition of 1 and 15 μm filtration ratings. The customer can now select the ideal filter element for any application from six different filtration ratings comprising of 1, 3, 5, 10, 15 and 20 μm.

Thanks to the graduated structure of the filter layers, the pore size becomes consistently finer from the contaminated side towards the clean side. Particles of varying sizes become efficiently embedded within the depth structure of the filter layers, with minimal impact on the flow characteristics. This outstanding depth filter effect in the main filter layers prevents premature blinding of the filter element and guarantees a low differential pressure over a long period.

The outer wrap in highly tear-resistant plastic features oval perforations in the Optimicron element with the shape of these patent pending pores improving the angle of incidence onto the filter pleats. Unlike round holes that completely cover the tip of the pleat, the oval pores leave cross-sections open so that the fluid can flow vertically to the pleat right down to the pleat base.

The oval shape of the pores additionally provides greater tear resistance in the outer wrap. According to the pipe formula on which the design of pressure vessels and pipes is based, the tangential stress on cylindrical bodies is twice the axial stress. With the oval perforation, the stress is distributed evenly, resulting in higher strength. The oval perforation makes the element immediately identifiable as an original Optimicron element. The wrap can also be customised using high quality multicolour printing.

The new pleat geometry, the patent pending Helios pleat is another innovation and features alternate high and low pleats. This special pleat geometry significantly increases the area for incident flow and reduces flow speed between the pleats resulting in improved flow and consequently reduced differential pressure. When the system is subject to high loads, the Helios pleating counteracts the resulting compression with the smaller pleats supporting the larger pleats and helping to maintain a gap between them. This produces a large surface area for incident flow even under high load conditions, consequently lowering pressure drops.

A new type of patent pending drainage layer is incorporated in the Optimicron filter element on the upstream side. The asymmetric design of this layer allows channels to develop and allow the fluid to flow uninterrupted, ensuring excellent drainage along the pleat.

Another innovation in the new Optimicron is the integrated drainage layer on the clean side of the filter element, ensuring that fluid flow is channelled into large flow cross-sections along the pleat. The combination of the integrated drainage layer and the tried and tested stainless steel wire mesh ensures free flow with very low differential pressure coupled with high pleat stability. The optimised and integrated drainage layers are produced for specific applications.

Key advantages of the Optimicron filter elements include up to 30% lower differential pressure (compared to Betamicron4) through innovations such as the Helios-pleat geometry, optimised filter media, drainage layer on dirt side, and integrated drainage layer; enormous energy and cost savings through lower differential pressure over a long element service life; first class filtration efficiency thanks to qualitatively high-grade micro glass media; and innovative outer wrap with increased robustness and improved diffuser effect.

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