Autorin: Vanessa, 20. März 2025, Kategorie: Filtration verstehen

Ⅰ. The generation of industrial oil mist: an invisible byproduct of high-speed cutting

In the metal processing process of CNC machine tools, the generation of oil mist is the inevitable result of multiple physical effects:

1. High temperature of mechanical friction:

  • The temperature of the contact point between the tool and the workpiece can reach 600-1000℃, which instantly vaporizes the cutting oil (taking turning 45# steel as an example, the oil mist generation reaches 12L/h at a linear speed of 150m/min).
  • The diameter of oil mist particles is concentrated in 0.1-10μm, of which PM2.5 particles <2.5μm account for more than 60%.

2. Coolant spray atomization:

When the high-pressure cooling system (20-80Bar) sprays cutting fluid, the droplets are broken into micron-sized aerosols due to shear force.

3. Equipment seal failure:

When the seal gap of the old machine tool is greater than 0.1mm, the oil mist escape rate can reach 30% (ISO 8573-1 test data).

2. Metal cutting oil mist: “health killer” lurking in the factory

1. Human health hazards

Respiratory diseases:

  • Long-term inhalation of oil mist increases the risk of chronic bronchitis by 3.2 times (NIOSH study).
  • PM2.5 oil mist particles can penetrate deep into the alveoli and cause pneumoconiosis-like lesions.

Skin diseases:

– Sulfur and chlorine extreme pressure additives in oil mist cause contact dermatitis, and the incidence rate of workers in a gearbox factory is as high as 17%.

Carcinogenic risk:

When the content of polycyclic aromatic hydrocarbons (PAHs) exceeds 1.2μg/m³, the carcinogenicity level is IARC 2B (WHO standard).

2. Damage to the production environment

  • Oil mist sedimentation increases the wear rate of machine tool guide rails by 40% (GB/T 17421.3 test).
  • When the oil mist concentration in the workshop air is >5mg/m³, the fire risk level rises to Class II (OSHA standard).

III. Three-stage filtration mechanism: the “defense fortress” of oil mist filter element

First stage: mechanical pre-filtration (interception >5μm particles)

Technical principle: cyclone separation + wire mesh interception

Performance parameters:

  • Pressure loss <200Pa
  • Filtration efficiency >92% (ASHRAE 52.2 test)

Case: After a certain automobile cylinder production line was equipped with pre-filtration, the replacement cycle of the rear filter element was extended from 2 weeks to 6 weeks.

Second level: electrostatic adsorption (capture 0.3-5μm particles)

Technical principle: 12kV high voltage electric field charges the oil mist, and the dust collecting plate captures it

Performance parameters:

  • Ozone release <0.05ppm (UL 867 standard)
  • Energy consumption <0.5kW/1000m³/h

Advantages: Can handle high temperature (≤80℃) and high humidity (RH≤90%) oil mist.

Level 3: HEPA/activated carbon final filtration (removes particles <0.3μm and VOCs)

Technical solution:

Certification requirements:

  • Passed EN 1822 and GB/T 18801-2015 dual-standard certification
  • Emission concentration <1mg/m³ (GB 16297-1996)

IV. Actual case: economic and environmental benefits of three-stage filtration

Renovation project of a German bearing factory:

Before renovation:

  • Oil mist concentration in the workshop: 8.3mg/m³
  • Annual incidence of respiratory diseases among employees: 9.7%
  • Annual equipment maintenance cost: €120,000

After the three-stage filtration system was installed:

  • Oil mist concentration dropped to 0.8mg/m³ (a decrease of 90.4%)
  • The disease rate dropped to 1.2%
  • The annual consumables cost of the filter element is only €18,000
  • Certified by German DGUV, the insurance premium rate is reduced by 15%

Through scientific graded filtration and intelligent monitoring, modern oil mist filter elements are building an invisible protective barrier for the global manufacturing industry – this is not only a protection for equipment, but also a defense of the dignity of workers’ lives. By combining cutting-edge filtration technology with Industry 4.0 smart management, Trenntech is redefining the standard of machine tool protection – because every clean breath is worth protecting with the most stringent technology. Contact Trenntech Filtration to provide you with professional oil mist filter products and treatment solutions.

Vanessa

My name is Vanessa, and I am a content writer specializing in corporate content creation. With more than 10 years of writing experience, I am committed to providing companies with high-quality, impactful content to help them stand out in a competitive market. My background covers multiple industries, including technology, finance, marketing, etc. In the process, I have accumulated rich knowledge and skills, and can deeply understand the needs of audiences in different fields, so as to create more targeted articles and content. I am good at writing blog posts, white papers, case studies, product descriptions, etc., and I am familiar with SEO optimization strategies to ensure that the content gets good exposure in search engines. At the same time, I also have good project management skills and can complete high-quality works within a tight time frame. I believe that high-quality content can not only convey information, but also build customer trust and brand image.