TEXTILES FOR

FILTRATION
Kavitha Rajan
 INTRODUCTION
• The current emphasis on environmental protection by governments and
ecologists has increased tremendously the scope for fabric filters.
• In dust filtration, where penetration has to be kept to a minimum, only
fabric filters can give the required efficiency.
• Fabric filters are used for various filtration purposes, which include dust
filtration, the purification of gases, and the removal of suspended
materials from liquids, and also for gas and liquid chromatography.
• In air and gas filtration, non-woven fabrics have made great inroads in
recent years and are preferred to woven fabrics for improved performance.
• In INDA's eighth technical symposium, the perspectives of non-woven
fabrics up to 1988 were reflected. In 1978,out of 340 million lb (154 221
tonne) of disposable non-woven fabric produced, 86 million lb (39 009
tonne) were used for filtration media '
 Definition of Filtration
• It is a mechanical or physical operation which is used to
separate solids from liquid/fluid/gases by interposing a
medium through which only any liquid can be passed.
• Filtration technique is used in any process to separate
particles from any fluid which can be a liquid, a gas or any
super critical liquid.
• The application of filter fabrics varies according to the end use
of the process involved.
• Filtration is widely used in the chemical engineering
processes.
• Permeability is an important factor in the filtration process.
• There are a various types of textile fibres, yarns including DREF yarns,
nonwoven fabrics with multifilament and monofilament yarns and some
cases blends or combination of more than one of these structures which
are involved in the filtration processes.
• The four major classes of nonwoven man-made fabrics used in the
filtration processes are
• (i) needle felt produce from staple fibres,
• (ii) wet laid fabrics produced from short-cut fibres,
• (iii) spun bonded fabrics and
• (iv) melt-blown.
• Needle felt fabrics are made from polyester and sometimes
polypropylene and other polymeric fibres including meta aramide and
PPS.
• Interception:
When a particle tries to pass the fibre surface from the distance smaller than the
radius of particle, it may collide with the fibre and may be stopped or arrested.
• Inertial disposition:
When heavy particles are carried in the flow, they may be thrown out from the
streamline flow due to its inertia. This may cause the particle to be trapped in the
fibres.
• Random diffusion (Brownian motion):
Due to random vibrations and zigzag movement of particles in the flow, particles
may follow zigzag route causing chances of trapping.
• Electrostatic disposition:
Micro particles are very difficult to capture with mechanical methods. Strong
electrostatic charges on the fibres increase filtration efficiency.
• Gravitational forces:
Under the influence of the gravity, a particle that is sinking may collide with the
fibres and get caught.
 Classification of filtration
Depending on the process of separation, filtration is classified as:
1) Particle filtration
Particle filtration is the separation of particles having size above 10 microns.
These can be filtered out easily without any usage of micro porous membrane.
2) Microfiltration
Microfiltration is a filtration process, which removes contaminants from a
fluid (liquid & gas) by passage through a micro porous membrane. A typical
microfiltration membrane pore size range is 0.1 to 10 microns (µm).
Microfiltration is fundamentally different from reverse osmosis and nano-
filtration because those systems use pressure as a means of forcing water to go
from low pressure to high pressure. Microfiltration can use a pressurised system
but it does not need to include pressure.
• 3) Ultra filtration
Ultra filtration (UF) is a variety of membrane filtration in
which hydrostatic pressure forces a liquid against a semi
permeable membrane. Suspended solids and solutes of high
molecular weight are retained, while water and low
molecular weight solutes pass through the membrane.
This separation process is used in industry and research for
purifying and concentrating macromolecular solutions,
especially protein solutions.
• Nano-filtration
• Nano-filtration is a relatively recent membrane filtration
process used most often with low total dissolved solids water
such as surface water and fresh groundwater, with the
purpose of softening (polyvalent cation removal) and
removal of disinfection by-product precursors such as natural
organic matter and synthetic organic matter.
• Nano-filtration is also becoming more widely used in food
processing applications such as dairy, for simultaneous
concentration and partial (monovalent ion) demineralisation.
• Nano-filtration (NF) is a cross-flow filtration technology
which ranges somewhere between ultra filtration (UF) and
reverse osmosis (RO). The nominal pore size of the
membrane is typically below 1 nanometer, thus Nano-
filtration. Nano-filter membranes are typically rated by
molecular weight cut-off (MWCO) rather than nominal pore
size.
5) Reverse osmosis
•Reverse osmosis is similar to the membrane filtration treatment
process. However, there are key differences between reverse osmosis
and filtration.
•The predominant removal mechanism in membrane filtration is
straining, or size exclusion, so the process can theoretically achieve
perfect exclusion of particles regardless of operational parameters
such as influent pressure and concentration. RO (Reverse Osmosis),
however involves a diffusive mechanism so that separation efficiency
is dependent on influent solute concentration, pressure and water flux
rate.
• It works by using pressure to force a solution through a membrane,
retaining the solute on one side and allowing the pure solvent to pass
to the other side.
• This is the reverse of the normal osmosis process, which is the
natural movement of solvent from an area of low solute
concentration, through a membrane, to an area of high solute
concentration when no external pressure is applied.
• Methods of filtration
• There are many different methods of filtration; all aim to attain
the separation of substances. Separation is achieved by some
form of interaction between the substance or objects to be
removed and the filter. The substance that is to pass through
the filter must be a fluid, ie, a liquid or gas. Methods vary
depending on the location of the targeted material, ie, whether
it is in the fluid phase or not.
• Solid Gas separation
• Eg, Filters used in cigars, filters used in AC systems.
• Solid Liquid separation
• Eg, Filters used in sewage disposal plants, filters in chemical
industries, water purifiers, etc.
Generally, for filtrations, synthetic fibres are used
because:
1) They have reduced fabric weight
2) They are having higher strength
3) Easier handling and replacement
4) Easier separation of filter cakes
5) Resistance to rot
6) Higher filtration rate
7) Higher fatigue resistance
8) Good dimensional stability
9) High temperature resistance
10) Better abrasion, corrosion and chemical resistance
• Advantages of nonwoven filter over the woven filters are:
• 1) High permeability
2) High filtration efficiency
3) Less blinding tendency
4) No yarn slippage as in woven media
5) Good gasketing characteristics
6) Good cake discharge
Application
 Dust Filtration
• A comparison of felts and various types of woven fabric showed that the
fabric structure influenced the performance of the dust-loaded filters.
Microfibres of average diameter less than 0.3 (JLTU sandwiched between
porous non-woven webs of polyester fibres. Carl Freudenberg KG has
produced a new filter medium, designated Viledon compact 'microfine'.
The fibres are 100% polycarbonate, with diameters between 1 and 10 fxm.
• For use in air filters, these fibres can achieve dust-removal rates of up to
99% and present a suitable alternative to glass fibres".
• The new filter is claimed to be suitable for air blows of up to 60 000 m/hr
and at operating temperatures of up to 135°C as standard.
• The fabric filtration medium is in the form of flat bags to provide the
maximum surface area within the minimum over-all size. The bags are
grouped in cells, which are isolated automatically from the process air
stream for cleaning, with reverse air pulses that create non-destructive
shock waves.
 Protective Masks
• Masks have been introduced for the protection of respiratory
tracts against pollutants.
• The use of special non-woven materials for use as the filter
elements in dust-resistant half-masks for short-term use.
• The requirements of non-woven fabrics for use in face masks,
with particular reference to protection from dust,smoke, and
the dispersion of chemicals,virus that may be toxic. The
resistance to penetration by molecules, methods of measuring
this coefficient, penetrability, and dust absorption are one of
the factors that have been considered.
• A special face mask for personal protection against inhalation
of dust .
• The mask is composed of a bonded non-woven material as a
filter support, a filtering element, and a non-woven obturating
fabric in direct contact with the face.
• The filter support is made from a 50-50 blend of polyester
fibres, of the same length (65 mm) but differing in linear
density, bonded with a latex.
• The obturating fabric is a non-woven fabric made from a 10-
30 blend of polyester fibre (65 mm, 3.33 dtex) and viscose (65
mm, 3.12 dtex).
 High-temperature
Filtration
• The advantages of high-temperature filtration of gases (at temperatures in excess of
150°C), and the limitations of textile fibres in this respect are indicated.
• Aromatic polyamide fibres permit the use of temperatures in excess of 200°C and
Teflon fibres the use of temperatures in excess of 250°C. Temperatures ranging
from 300 to 600°C can be used for mineral fibres.
• Use of currently available high-temperature fibres in non-woven fabrics for
filtration purposes. Teflon, mineral fibres, and steel fibres, and temperatures that
they can withstand are indicated.
• It is suggested that metal fibres have the greatest potential in this field. the
requirements of filter fabrics for use at high temperatures.
• Fabrics made solely from continuous-filament yams had low air-permeability and
poor filtering properties.
• A scrimless high-temperature needlefelt based on poly(w-
phenylene isophthalamide) and having a specified range
of felt density and air-permeability after heat stabilization
has been introduced.
• It is claimed that the felt may be formed into a bag and
used for the filtration of gases at 200°C or more.
• The new filter medium is heat-resistant to 220 C in
continuous operation and withstands peaks to 250°C. The
use of quartz as a filter medium in the temperature range
800-1000°C has been suggested.
• A new research disclosure reports a filter fabric produced
by needling a non-woven batt of PTFE staple fibres into a
woven scrim of textured continuous-filament PTFE yams.
• Purification and Separation of Gases
• A review of recent advances in membrane science and technology covers gas
transport, and the sorption and separation of gases. The use of coated porous fibres
for gas recovery and separation.
• A structured fibre having a three-dimensional reticulated structure and
chemisorption properties has been revealed .
• The fibre, used in the purification of gases, is composed of a polymer containing
vinyl pyridine groups or aliphatic amino groups, e.g., copolymers of acrylonitrile
and a vinyl pyridine, a copolymer of poly(vinylidene fluoride or chloride) or pvc
and a vinyl pyridine copolymer of polyethylene, polyamine, or polyimine and
poly(vinylidene chloride or fluoride) or pvc, or a copolymer of vinylidine fluoride
with Teflon.
• The fibres are prepared by wet or dry spinning after the addition of structuring
agents, such as hydrazine, peroxides, or epichlorohydrin. Halide-containing
polymers are aminated.
• The use of non-woven polypropylene-fibre-pvc-fibre fabrics bonded with
poly(vinyl emulsion and annealed at 90-100°C for the removal of particles from
industrial gaseous wastes.
• These fabrics have a high permeability to gases, low density, and good resistance to
acidic and alkaline fumes. Laminated filters have higher elasticity, filtration
efficiency, and density and lower gas-permeability than random-blend filters.
• A fibre filter produced by electrostatic spraying of a solution of polycarbonate in a
volatile solvent onto a conductive support, followed by evaporation of the solvent
to leave a fibre fleece with a porous surface structure to be used for filtering dust
particles from a gas. Lewcott Chemicals have developed a process for charcoal
impregnation of non-woven material known as the Activfilter.
• This activated-carbon-coated non-woven fllter is used in air-filtration applications.
The adsorption of CO2 gas on modified activated-carbon fibre. The maximum
adsorption capacity for CO2 at low partial pressures was studied for both
unmodified and modified fibres over a wide range of pressures.
• The maximum adsorption was obtained with fibres that had a 50-60% combustion
weight loss and was nine times as great as the capacity of granulated activated
carbon. The adsorption capacity was doubled by iodination of the fibres,
• chlorination. or amination.
 Cigarette Filters
• The production and properties of various types of cigarette filter. These include
filters made from paper, cellulose acetate, viscose, cotton, wool, and jute. An
investigation in which cigarette filters were fabricated from combed wool top and
two types of adhesive-bonded wool webs.
• The influence of variables such as fibre arrangement, fibre diameter, pressure drop,
and binder content on selected performance criteria was studied.
• More effective filtration was achieved by decreasing the fibre diameter and
utilizing a random-fibre arrangement.
• Higher pressure drops increased the retention of smoke particles but lowered the
collection efficiencies of the fibres. The filter performance was adversely affected
by increasing the binder content of the bonded webs.
• At low or medium pressure drops, filters prepared from a random web were more
efficient than conventional cellulose acetate filters. The random webs gave firm
filters, which retained their firmness during smoking.
• A cigarette filter that is made from a strip of a bonded non-woven fabric composed
at least partly of wool flbres.
 Solid-Liquid Separation

• Wet filtration or the separation of solids from aqueous or solvent mixtures has been
studied extensively. Of the filtration media available, e.g., sand-diatomaceous
earth, perforated plates and screens, sintered metals and ceramics, porous plastics,
fibre sheets, and textile fabrics, the last-named, and particularly woven fabrics,
have found the widest acceptance in the filtration industry.
• The flexibility of construction in the woven form offers the greatest possibilities in
meeting the necessary filtration-performance criteria.
• Examples of cloth applications and the chemical and physical characteristics of
fibres used in the manufacture of fabrics, respectively.
• The dependence of the weave pattem on the performance criteria quoted from the
same source.
• The development of synthetic polyester fibres with special properties has solved
several environmental and energy problems. In a new process for solid-liquid
separation, silo-shaped special fabrics made of Trevira, a high-tenacity polyester-
fibre yarn, have been used.
• The process is a combination of flocculation and filtration and is most suitable for
sludge dewatering and waste-water treatment in industry and municipalities.
Properties of polyester-fibre filter fabrics.
 Liquid-Liquid Separation
• The use of 'Reutlingen Mats', developed by the Institute for Textile Technology,
Reutlingen, for oil separation from refinery and power-station effluents.
• These non-woven needlefelt-type mats consist of 4—7-dtex synthetic fibres
(polyester, polypropylene, or polyethylene fibres) and weigh between 200 and 800
g/m.
• The mats form the basis of a continuous oil-separation process by the skimming
method. A method for separating adsorbable hydrocarbons from a carrier liquid that
contains plastics-material fibres or threads (or both) having hydrophobic and
oleophilic properties has been claimed in a patent.
• The fibres or threads (or both) absorb the hydrocarbons to produce an absorbent,
which circulates along an endless path of displacement.
• The absorbent is regenerated outside the carrier liquid by being squeezed out in an
upwardly running section, the separated hydrocarbons being caught in collecting
devices arranged on both sides of the running section. I.C.I, has patented a method
for the removal of oil from an oil-in-water emulsion.
• Use is made of a special fabric in the form of an area-bonded moulded fabric made
from fibres having a core of PET and a sheath of a copolymer of PET and
polyethylene adipate, which is passed through a dispersion of silane-coated silica