23 March 2016

How Does Your ESP Compare to PowerClean?

PowerClean-with-integral-wash-and-detergent-self-washing-system

PowerClean ESP systems installed in Melbourne Docklands Harbour Town precinct have given over a decade of reliable operation, and are still functioning as installed without any operational, mechanical or electronic failures.

Airepure Australia has supplied PowerClean large-scale auto wash ESP systems to the Australian market since our partnership with US Company Air Scrubbers Inc. was established in 2004. There is clear evidence to prove PowerClean ESP systems, manufactured by Air Scrubbers Inc. are the most efficient and reliable ESP’s in our marketplace today.

Ten (10) large-scale auto wash ESP systems up to 10,400 L/s were installed in 2004 to service the commercial kitchen exhaust emissions of the various restaurants, cafes and fast food dining venues at the Melbourne Docklands Harbour Town precinct.

  • 12 years of reliable, continuous operation, and still going strong.
  • Still operating on their original ESP cells.
  • No electronic component failure.
  • No requirement to replace ESP cells.
  • No complaints regarding performance.
  • Clean rooftop exhaust vents after 12 years operation.
  • Hundreds of thousands of dollars saved in operation costs and energy expenses compared to conventional filter solutions.

See attached project details for the Melbourne Docklands Harbour Town Precinct.

Longevity of PowerClean ESP Systems

Industrial, robust design is the key to the longevity of these large-scale auto wash ESP systems. A correctly sized PowerClean ESP delivers instant and constant specified efficiency of minimum 95% @ 0.3 micron throughout the lifetime of the system.

PowerClean SystemPowerClean large-scale auto wash ESP system

Durable Design of PowerClean ESP Cells

The PowerClean ESP cells are solidly constructed to endure the lifetime of the system and function correctly for its intended purpose – as a grease collector for kitchen exhaust.  A deeper cell depth compared to conventional ESP cells allow for greater efficiency and dust / grease holding capacity.

ESP-Cell-Depth-Comparison--PowerClean-V-Competitor
ESP cell depth comparison:
PowerClean (left) competitor (right).

PowerClean ESP cells also incorporate a unique long-lasting rigid ionising discharge electrodes made from 304 grade stainless steel. Conventional ESP cells often include less durable ionizer designs such as tungsten ionizing wires, which are prone to failure – subsequently short circuiting in their system, or spiked electrodes made from inferior materials – which erode after a period of time, losing efficiency.

ESP-Cell-Ioniser-Comparison--PowerClean-V-Competitor
ESP cell comparison:
PowerClean rigid stainless steel ioniser (left) competitor tungsten ionising wires (right).

The tracking distance between the electrical insulators of an ESP cell is extremely important, as it limits the potential arcing from the charged components to the grounded sections. Arcing affects the performance of the ESP cell by temporarily stopping power to the ESP cells, allowing contaminated air to flow through untouched at zero efficiency.  PowerClean ESP cells utilise industrial strength cordierite insulators installed with a 66mm tracking distance between them to effectively limit the potential for arcing.  The insulator tracking distance used by conventional ESP cells are typically 41mm or less.

The PowerClean electrical insulators are also configured to protect the face area from contaminated air. This eliminates insulator coating, electrical shorting and ultimately insulator or system failure.

Many conventional ESP cells require replacement every two years. In normal use, PowerClean ESP cells are designed to last the lifetime of the system and save on maintenance costs because they do not need to be replaced.

The ten PowerClean systems installed at Melbourne Docklands Harbour Town precinct in 2004 are still operating successfully with their original ESP cells.

Superior Performance of PowerClean ESP Cells

The 0.3 micron benchmark is used in efficiency ratings, because it approximates the most difficult particle size for a filter to capture.

PowerClean ESP systems designed and supplied by Airepure Australia are rated to;

  1. remove 95% of up to 17,000L/s for single pass (one pass) configurations @ 0.3 micron
  2. remove 95% of up to 20,000L/s for double pass (two pass) configurations @ 0.3 micron

No other provider of ESP’s in Australia is able to treat that quantity of air at the required efficiency in a single pass unit in day to day operation.

ESP Collection Efficiency V Face Velocity- PowerClean V Competitors

This graph provides a comparison of test reports created by the same testing authority and under the same testing conditions for the PowerClean ESP cells and two competitor ESP cells in both single pass and double pass systems. The following results are evident:

  • A correctly sized single pass (one pass) PowerClean ESP can achieve and maintain an efficiency of 95% @0.3 micron. These are genuine operational values that can be maintained over time in real installations.
  • Face velocities exceeding 2.0m/sec in a single pass (one pass) system cannot possibly maintain a collection efficiency of 95% or higher.
  • If space is not a concern, moving to a double pass (two pass) system provides no real benefit other than an increase in capital cost.

The ten PowerClean systems installed at Melbourne Docklands Harbour Town precinct in 2004 have provided 12 years of reliable and continuous operation.

These photos, taken in December 2015, show the rooftop exhaust vents connected to the exiting airflow of the PowerClean systems for various commercial kitchens which include fried chicken, burger, modern Asian, and charcoal chicken venues.  After 12 years of operation these vents are relatively clean, showing no blackened residue or grease build-up on or around the vents; providing visible proof of the effectiveness of the PowerClean systems in cleaning the exhaust air stream of various types of commercial kitchens.

Superior PowerClean Performance- Clean rooftop exhaust vents - fried chicken & burger venuesSuperior PowerClean Performance: Clean rooftop exhaust air vents for fried chicken & burger venues in Melbourne Docklands Harbour Town after 12 years of operation.

Superior PowerClean Performance- Clean rooftop exhaust vents - modern asian & charcoal chickenSuperior PowerClean Performance: Clean rooftop exhaust air vents for modern Asian & charcoal chicken venues in Melbourne Docklands Harbour Town after 12 years of operation.

Robust PowerClean Power Pack

Power loss to an electronic air cleaning system is typically caused by momentary arcing within the ESP due to heavily contaminated particles in the air stream, a broken ionizing wire in the ESP cell or an electronic component failure.

The power pack is a vital component in the successful operation of an electronic air cleaning system, as a cessation of power means the cessation of a working ESP, allowing contaminated air to flow through untouched at zero efficiency.

The PowerClean power pack comprises industrial duty components which are designed to last the lifetime of the system and provide immediate restart of the ESP system after a power short (cracking noise).

Many conventional power packs comprise light commercial duty components that restart after several seconds, which equates to several seconds of contaminated air flowing through the system, untouched, at zero efficiency.

The ten PowerClean systems installed at Melbourne Docklands Harbour Town precinct in 2004 have never had an electronic failure and are still operating with their original power packs.

Robust PowerClean Power Pack
Robust PowerClean Power Pack: Still operating in Melbourne Docklands Harbour Town after 12 years of operation.

Outstanding Inbuilt PowerClean Auto Wash System

The auto wash function of a large scale air cleaning system is designed to keep the ESP cells running effectively at their specified efficiency and extend manual cleaning intervals.

The PowerClean contains an integral water and detergent self-washing system that, due to its front and rear oscillating wash manifolds and specially formulated emulsifying detergent, provides the lowest water and detergent usage in the industry. This provides a significantly lower maintenance cost to the end user.  A programmable logic control (PLC) also allows complete control of the ESP system, including wash cycles, fan drying and alarms for low detergent levels.

Other conventional auto wash systems use a series of fixed spray nozzles in a flooding method, whereby the use of detergent and water is dramatically increased. This is an inefficient use of water and detergent that becomes costly for the end user.

The ten PowerClean systems installed at Melbourne Docklands Harbour Town precinct in 2004 have only required annual manual cleaning intervals for their ESP cells, which are still operating successfully after 12 years.

PowerClean-with-integral-wash-and-detergent-self-washing-system
One of the ten PowerClean units with integral water and detergent self-washing system, installed at Melbourne Docklands Harbour Town.

Premium Quality Carbon Filtration

Activated carbon filters are typically used within an electronic air cleaning system to remove cooking odours, as they offer adequate life and performance, and are generally recognised as cost effective.

Many conventional systems use “filled” carbon panels (panels filled with loose granulated carbon), which are prone to abrasion between particles of the carbon media. This creates carbon dust formation and channels between particles that allow contaminant bypass, lowering the odour removal efficiency of the filter.

The PowerClean system uses “bonded” carbon panels, whereby the carbon is bonded together to provide uniform density of sorbent media across the panel. This ensures high odour removal efficiency with no contaminant bypass or carbon dust formation.  The bonded carbon panels are also configured for low pressure drop to save on energy.

Bonded carbon panel filter installed in PowerCleanBonded carbon panel filter installed in PowerClean systems.

The ten PowerClean systems installed at Melbourne Docklands Harbour Town precinct in 2004 have operated with bonded carbon panel filters for 12 years without any odour complaints. These carbon filters are typically changed every 12 months to 2 years, depending on the odour level of the exhaust stream serviced by the system.

PowerClean Safety Filters for Peace of Mind

PowerClean is the only ESP system in the industry that includes safety filters to protect the odour removal efficiency of the carbon filters.

Located between the ESP cells and the activated carbon sections, the safety filter (F6 rated disposable pleated bag filter) is used to prevent the rapid soiling or coating of the activated carbon by contaminated exhaust air (smoke and grease particles) should there be a power outage in the ESP section.

F6 rated safety filter installed in PowerCleanF6 rated safety filter installed in PowerClean systems.

If a power pack failed in a conventional ESP system with no safety filter, the carbon panels would saturate within a few days. Carbon filters are significantly more expensive to replace than disposable pleated bag filters, so this type of system failure would result in unnecessary inconvenience and expense for the owner.

Unbeatable Operational and Energy Savings

PowerClean ESP Vs Conventional ESP Comparison

PowerClean process exhaust air cleaning systems are the perfect combination of durable materials, solid construction, robust electronics, performance reliability, premium quality filtration and cleaning consumables, and superior design engineering.

The Melbourne Docklands Harbour Town case study is typical of the cost effectiveness and reliability experienced by PowerClean clients in Australia and all over the world. This robust performance is delivered by the fundamental “heavy duty” design of the ESP, from materials of construction to the appropriate choice of operational airflows.

Every element of the PowerClean including housings, electrical systems and washing systems are designed with up-time at 95% extraction in mind – to deliver the specified performance – day–in, day-out AND last the lifetime of the system.

The PowerClean range is the wisest choice for facilities that require real value, cost effectiveness and performance.

Written by Shannon Roger (B.Ed) for Airepure Australia Pty Ltd 2016.

Airepure is a leading national air filtration company providing unique, powerful and integrated air filtration solutions, ranging from basic HVAC filtration and odour control right through to high end HEPA/ULPA filtration and airborne containment technologies. Not only can we assist you with all aspects of a compliant system (AS/NZS 1668.2), we design site-specific air quality regimes for commercial food outlets. We also supply the most effective range of commercial kitchen hood filters, in duct odour control and air cleaning units, duct mounted ESP’s (electronic precipitators) and multi-exhaust plant room ESP’s. For more information, call 1300 886 353.

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Airepure Australia
Phone: 1300 886 353
Email: info@airepure.com.au

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