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Centrifugal Mist Collector, Media Mist Eliminator, Electrostatic Precipitator Coolant Mist Separator & The MistBuster ESP Mist Collector

"An Analysis of The Four Different Technologies for Collecting and Reducing Industrial Oil Mist in The Work Environment..."

This article gives the reader the benefits and drawbacks for each type of industrial mist collecting technology and allows the reader to come to his / her own conclusion which is the best oil mist technology to use for their application.

MistBuster 500 - One Size Fits All!Mistbuster more efficient than centrifugal mist collector.
More information on MistBuster oil smoke & coolant mist eliminator

1.  Centrifugal Mist Collectors:
Centrifugal Mist Collectors were first designed and manufactured for to be placed on the gear boxes of nuclear submarines. This was the first modern day use for industrial smoke oil and coolant mist collection.

The idea behind the mechanics of how a centrifugal mist collector works is the rotating filter element forms the trapped mist back into larger droplets. The rotating centrifugal force then causes the droplets to be propelled free of the filter drum towards the inside wall of the casing. High velocity air (caused by the centrifugal rotation) forces the liquefied oil to traverse along the walls to an opening whereby all the excess oil is driven through an opening and into a drain.  Fresh pure air is delivered back to the industrial building by way of an exhaust grill, and the excess oil drains from the centrifugal mist eliminator unit for re-use or disposal.

One of the benefits of going with a centrifugal mist cooling system is that it does not depend on gravity for the smoke oil to drain allowing the centrifugal compressor oil mist eliminator to run 24 hours a day, without requiring it to be shutdown.

MistBuster 500

MistBuster 500 electrostatic precipitator mist collector.

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MistBuster 500 LINKS
  1. How The MistBuster Works

  2. Technical Specifications

  3. Customer Testimonials

  4. MistBuster - One Size Fits All

  5. Project Photos of Different Machines w/ MistBusters

  6. How To Install MistBuster 500

  7. OSHA & NIOSH Related Info

  8. MistBuster 500 FAQs

  9. MistBuster - FREE TRIAL

  10. MistBuster 500 - Main Page

The Prefilter trap- Is a required accessory for any centrifugal mist eliminator and is supposed to reduce the level of vibration caused by larger particles.

The HEPA filter final stage- The main compartment of the centrifugal oil smoke and coolant mist collector is usually about 97% efficient at one micron - An expensive HEPA filter that constantly needs to be replaced is required to elevate the efficiency rating to the industry standard 99.97% efficiency rating at .3 microns (this is the average size of an oil smoke droplet).  Many of these bulky HEPAs will last only a few months and as they become more worn the energy consumption of the centrifugal compressor oil mist collector increases which adds to the cost of operation.

Some common problems found with centrifugal compressor oil mist eliminator

  • Centrifugal oil smoke mist eliminators cannot collect smoke or fine droplets. In fact, these types of units actually create fine droplets by breaking up large drops in the high energy acceleration process.

  • Centrifugal mist collectors tend to have a very high siren-like screech.

  • Centrifugal mist separators require frequent cleaning to remove accumulated mist and dust that causes impeller damage.

  • Centrifugal oil mist collectors can have very high maintenance costs due to frequent cleanings that are required due to imbalanced impellers that cause machine tool vibration and loss of precision.

  • Energy costs for Centrifugal compressor oil mist eliminators can be very high: 700-2100 watts needed to run the system.

2.  Cartridge Mist Collectors:
Cartridge mist collectors also known as media filter mist eliminators usually include a HEPA type filter to filter out industrial mist and smoke oil.  The process of filtration is very simple; air is drawn into the cartridge media oil smoke and coolant mist collector by a fan or blower.  The air containing mist is then forced through a media type filer where the droplets, mist and particles are trapped or filtered out by the media material - usually a HEPA filter.  These cartridge media mist eliminators were first designed to handle an efficient consistent system that would reduce mist from wet grinding applications and other processes with combinations of liquid/solid, liquid/vapor, or solid/vapor.

Cartridge mist separators are some of the oldest technology and are therefore one of the most common systems found in industry.  The present state of the technology is modular and includes options for pre-filters, HEPA, activated carbon, as well as high-powered fans that can reach as high as 18,000 cfm.

The cartridge oil smoke and coolant mist eliminator systems have been used for all types of wet grinding, cast iron machining, and is also found throughout the die casting industry. Other applications the cartridge style of mist removal include rubber and plastics, food processing, and occasionally welding fume.

Some common problems found with cartridge media filtration.

  • Cartridge mist collector's cartridges / filters get clogged and tend to reduce airflow.

  • Cartridge media mist eliminators are usually big and bulky and can take up valuable floor space.

  • Cartridge media mist collectors can have expensive filters that need to be frequently replaced.

  • Cartridge media mist separators tend to get very loud as the media plugs up causing the fan to work over-time.

  • Cartridge media oil smoke and coolant mist collectors are costly to operate and suck up a tremendous amount of energy.

3.  Electrostatic Precipitator Mist Collectors
Electrostatic precipitator mist collectors use high voltage to charge and gather the smaller mist particles and droplets. This method of filtration has several advantages and is our choice of mist eliminating technology. Many of the benefits of using an electrostatic mist collector include;  a constant flow, low pressure drop, and efficient filtration of sub-micron smoke and fumes. Electronic cells are washable, and are normally dipped in solution and left to dry. Maintenance schedules are dependent on the amount of solids collected, since liquids will drain by themselves.

Electrostatic precipitator oil smoke & coolant mist collectors are perfect for petroleum based cutting oils, mist and smoke. Electronic collector cells are engineered to last forever use and their is substantial annual savings on not needing to purchase HEPA filters or any other type of media filters.  Electrostatic precipitator collector cells when used to filter mist caused by petroleum cutting oils keep the collectors clean of dust and smoke buildup because the petroleum cutting oils do not evaporate.

In days past cartridge mist filtration and centrifugal mist elimination was the only method of mist elimination.  Nowadays, electrostatic precipitation is the more efficient, lowest cost and preferred technology to handle industrial mist and coolant indoor air quality problems. How else can a company that manufactures unique “nano-powders”, whose particles can be as small as 0.003 microns in size ( a microscopic 3.0 nanometers!)  filter this material?  A well engineered electrostatic mist collector can easily and efficiently filter out these tiny particles.

As mentioned above electrostatic precipitator oil smoke and coolant mist systems are most often used to filter mist and oil smoke in industrial applications. This is where the system really shines. One customer of ours has 15 units filtering mineral oil smoke on a 3-shift basis. He drains over 1 gallon per week (per system) of collected oil, and has not had to service the filter cells for over 2 years! Needless to say, everyone is pleased.

4.  Introducing The MistBuster 500 Electrostatic Precipitator Mist Collector
The MistBuster 500 is a compact electrostatic precipitator which is available in single and double-pass configurations. This unique mist collection system is the OEM standard on many Swiss screw machines, and we have hundreds of installations on Citizen, Star, Tornos, B&S, and other popular automatics. In addition, the MistBuster 500 is equally at home on top of an enclosed machining center, mill, or lathe. There is not another mist collector that beats the 99.9% efficiency rating of oil smoke that does not need a HEPA final stage. The electronic filter cells continuously  drain, which makes the MistBuster 500 self-cleaning. Our custom plenums and mounting plates make installation easy, and the 110 volt power cord means no extra wiring. The MistBuster 500 is so compact that we can send it to you via UPS.

Cartridge mist collector louder than mistbuster.Rating - Excellent
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See our complete line of Coolant oil mist collectors eliminators & separators and Industrial Air Cleaners.

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