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1、水溶于油的三个阶段油被水污染的三种形式.溶解水乳化水自由水EXTENDING YOUR ENERGY!溶解水对于轴承没有损害对于轴承没有损害EXTENDING YOUR ENERGY!乳化水对轴承有危害EXTENDING YOUR ENERGY!自由水对轴承的危害最大EXTENDING YOUR ENERGY!脱水技术聚结分离真空蒸馏颗粒过滤清漆去除EXTENDING YOUR ENERGY!聚结分离EXTENDING YOUR ENERGY!聚结分离柴油机燃料# 2 过程聚结滤芯乳化的燃料/水混合物水滴柴油机燃料# 2 (清洁干燥)分离滤芯水/燃料乳化EXTENDING YOUR ENERG
2、Y!聚结分离柴油机燃料# 2EXTENDING YOUR ENERGY!聚结分离柴油燃料# 2清洁燃料(出口)清洁燃料(出口)5. 分离水组阁2. 聚结水滴形成1. 聚结颗粒过滤形成3聚结水滴排干层4聚结水滴干层. 聚结水滴EXTENDING YOUR ENERGY!入口燃料& 水混合物聚结分离柴油机燃料# 2过滤精度 ISO 16/14/11水含量= 小于500 ppm水含量小于EXTENDING YOUR ENERGY!聚结分离汽轮机油过程聚结滤芯进水的乳化油分离滤芯水滴汽机润滑油汽机润滑油(干净和干燥)water/oil emulsionEXTENDING YOUR ENERGY!Coa
3、lescing聚结/Separating分离/Po作用预过滤过程聚结聚结分离/磨光器污染的汽机油前过滤屏干净&干燥的汽机油Turbo-TOC多阶段汽机润滑油净化作用过程EXTENDING YOUR ENERGY!Turbo-TOC聚结分离过程4 大水滴从聚结介质上释放到油流体3 小水滴聚合成大水滴在5 重力使得大水滴(50 4. 里面3. 小水滴聚合成大水滴在介质上5. 重力使得大水滴m) 降落到油里面并且被安置在容器的底部2. 油进入聚结滤芯水滴横穿聚结材料的6.油通过分离介质玻璃纤维.那些附加水滴相互碰撞结成小水滴油通过分离介质media小水滴试探通过分离介质但是最终还是降落在容器底部1.
4、 被污染的油进入系统,通底部7 干净的油通过出口阀门过入口阀门.7. 干净的油通过出口阀门流出设备(Click on video to play)EXTENDING YOUR ENERGY!Turbo-TOC汽机润滑油过滤精度 ISO 15/13/11总含水量= 小于100 ppm总含水量小于EXTENDING YOUR ENERGY!真空蒸馏EXTENDING YOUR ENERGY!真空蒸馏原理水沸点100C(212F)水沸点在100C (212F)如果水是在一个真空的空间里面沸点会变660 mm Hg (26” Hg)vacuum pump的空间里面,沸点会变低52C(125F)vacu
5、um chamberEXTENDING YOUR ENERGY!真空蒸馏原理160180sFWater will Distill from Oil in this Area140EDegrees100120ERATUREWater will Evaporate from Oil in this Area6080TEMP16 17 18 19 20 21 22 23 24 25 26 27 28 29 30Vacuum Pressure in Inches of Hg水蒸馏曲线EXTENDING YOUR ENERGY!真空蒸馏原理用蒸馏方式,从油中分离水,与其把水变成蒸汽再分离出来,倒不如水以
6、液体形式直接分离.这就是真空蒸馏的原理. EXTENDING YOUR ENERGY!基本的真空蒸馏过程external watercondenservacuum chamberelementwater/oil emulsionoil sealedvacuum pumpwater collectionwater (vapor phase)water dropletwaterwater (distilled)oil (with condensed water) oil with condensed water water/oil emulsionoil/water exiting system
7、EXTENDING YOUR ENERGY!Smart-VAC 真空蒸馏“C C过程hamber-in- hamber”disperserelementwater/oil emulsioninternal distilled water dropletwater (vapor phase)watercondensingcoilsinside chamberliquid ring (water sealed) vacuum pumpsighttubecooling waterclean oil outside chamberclean oil exiting system water/oil e
8、mulsionEXTENDING YOUR ENERGY!Smart-VAC脱水消除气陷消除气陷颗粒过滤颗粒过滤EXTENDING YOUR ENERGY!Smart-VAC过滤精度 ISO 15/13/11含水量= 小于25 ppm含水量小于EXTENDING YOUR ENERGY!颗粒过滤EXTENDING YOUR ENERGY!过滤介质微米级-玻璃纤维纤维素EXTENDING YOUR ENERGY!Source: Philip Johnson, Donaldson Company, Inc.,Matching Filter Element Design Features to Ma
9、chine Application. Machinery Lubrication Magazine. March 2003 过滤器的滤芯颗粒过滤Kaymax 系列微米级-玻璃纤维 KF 系列纤维素/聚酯纤维系列纤维素聚酯纤维KB 系列纤维素吸收水和颗粒过滤KQD6018-5 and KQD6036-5EXTENDING YOUR ENERGY!Kaymax主要竞争对Kaymax主要竞争对手的情况纵向打褶打褶金属保套无金属保温套无金属保温套热焊接打褶支撑金属丝支撑打褶支撑支撑EXTENDING YOUR ENERGY!Kaymax100001.5Kaydon 4000Kaydon = 1”Ple
10、at DepthKaydon= 1,000Ratio10001.0= 3,200Surface Area(square inches)3000Leading Competitor = 1/2”Leading Competitor= 801000.5 Leading Competitor = 1,8902000Pleat Depth Ratio at 12 micron100.0Filtration Area1000各类总计I, Kaymax 和主要竞争对手相比显示优秀的特点. EXTENDING YOUR ENERGY!过滤滤芯滤芯类型介质杂质吸纳Beta Ratio1Fiber Life S
11、helf Life滤芯类型介质杂质吸纳容量(Efficiency)Consistency Cycle Costs2(approx.)Kaymax玻璃纤维High高 = 1000 Most Low 3-5 years(99.9%)Consistent and UniformKF聚酯纤维/纤维混合物Good好 = 200(99 5%)Consistent and UniformMedium 2-4 years维混合物.5%)KB纤维素Poor差 = 2(50%)Random and Non-High 1-2 yearsUniformEXTENDING YOUR ENERGY!磁性过滤器EXTEND
12、ING YOUR ENERGY!Varnish定义 “一种稀薄的, 不容的涂层,沉淀在内部的零件上,由此产生油的劣化和聚合由此产生油的劣化和聚合” (source: Noria)EXTENDING YOUR ENERGY!Varnish描述 稀薄的橙色, 棕色或者黑色不溶涂层沉淀物产生在润滑油内部微小污染的构成是润滑油劣化的副产品;它的直径小于1微米Varnish(亚微粒粘滞物)的成分是不溶于油的Varnish(亚微粒粘滞物)成分是带有磁性的EXTENDING YOUR ENERGY!Varnish(亚微粒粘滞物)描述 varish形成于汽机轴承表面EXTENDING YOUR ENERGY!
13、Varnish(亚微粒粘滞物) 产生6汽机润滑油颜色变暗的表现汽机润滑油颜色变暗6油损量增高油损增高6增加轴承的磨损率6油温升高6阀门操作迟缓不灵活卡涩6酸值增高EXTENDING YOUR ENERGY!Varnish(亚微粒粘滞物) 如何产生的?炭化作用/聚合作用炭化作用聚合作用氧化作用EXTENDING YOUR ENERGY!Varnish(亚微粒粘滞物) 形成物微小污染物的状态Metal Surface微小的污染物带有磁性, 亚微米尺寸的微粒EXTENDING YOUR ENERGY!Varnish(亚微粒粘滞物) 形成物微小的污染物沉积在金属的表面Metal Surface微小的污
14、染物是带有磁性的,亚微米尺寸的微粒EXTENDING YOUR ENERGY!Varnish(亚微粒粘滞物) 产生的问题黏在阀门的内部并且形成阀门卡涩轴承注油孔堵塞轴承孔堵因为隔离层引起,热交换效率下降汽机润滑油劣化汽机润滑油劣化吸附其他的微小的坚硬的污染物增加旋转组件的磨损增加旋转组件的磨损EXTENDING YOUR ENERGY!Varnish解决方案 BCA* = Balance双向Charge充电 双向充电Agglomeration 结块EXTENDING YOUR ENERGY!* BCA - Trademark of ISO Pur Inc.Varnish (亚微粒粘滞物)解决方
15、案BCA净化技术858SystemK-4100TURBOTOCFilterorGeneral Electric Recommended Technology by GE TIL 1528-3EXTENDING YOUR ENERGY!BCA技术结果在BCA 使用前的状态油温: 67C (154F)在BCA 使用后状态油温: 63C (145F)75 daysEXTENDING YOUR ENERGY!BCA技术结果100 200 300 400500 600 7000Oil beforeBCAOil after BCA100 200 300 400500 600 700BCA - Hours of Operation0EXTENDING YOUR ENERGY!BCA技术益处 去除了氧化物污染的预防& 消除改良了汽机发动机的运行效率降低了油成本EXTENDING YOUR ENERGY!
