Filtration performance of novel microfibrous media embedded with nanofiber flocs for aerosol particle removal

Ingestion and accumulation of sea salt and other impurities is a major challenge for high speed vessels, turbine engines, and other air breathing systems. The performance and reliability of filters are anticipated to be improved significantly after the rate of performance degradation is reduced via enhanced filtration media and well-designed filtration approaches. This study proposes to apply anionic surfactant to disperse the nanofibers thoroughly and employ cationic surfactant to flocculate the dispersed nanofibers into numerous small groups of nanofiber flocs. Using the wet-lay procedure in the lab, the novel porous microfiber media was then fabricated with small groups of nanofiber flocs together with activated carbon and polyester fibers. The unique nanofiber filter media was then evaluated for filtration performance using face velocity, pressure drop, and filtration efficiency parameters. Due to nanoflocced fiber inclusion, an anomalous region in the filtration efficiency versus pressure drop regime was observed where wall slip occurring at the nanostructured surface provided an unusually high level of filtration efficiency near the most penetrating particle size (MPPS) region of 0.1-0.4 μm with a concomitant reduction in the normally encountered levels of pressure drop. This anomalous increase in the filtration efficiency versus pressure drop is a novel phenomenon and it is highly beneficial to aerosol filtration. The enhanced filtration reveals that the quality factor near the MPPS region increases significantly due to the inclusion of nanofiber flocs. The unique porous filtration media is expected to increase the dirt holding capacity and prolong the lifecycle of the turbine air filter systems.