Cleanable high efficiency filter media structure and applications for use

A filter arrangement comprising a media pack having an element comprising first and second opposite flow faces and a plurality of flutes wherein in said media pack;

• (a) each of said flutes have a first end portion adjacent to said first flow face and a second end portion adjacent to said second flow face;
• (b) selected ones of said flutes being open at said first end portion and closed at said second end portion;
• and selected ones of said flutes being closed at said first end portion and open at said second end portion
• (c) said element comprising a nanofiber layer and a high efficiency substrate layer;
• the nanofiber layer comprising a polymer material and having a fiber diameter of 0.01 to 0.5 micron, a basis weight of about 3×10−7 to 6×10−5 gram-cm−2, an average pore size of about 0.01 to 10 microns and a thickness of about 0.05 to 50 microns;
• the high efficiency substrate layer comprising a non-woven layer comprising a basis weight of about 0.2 oz-yd−2 to 350 lb-3000 ft−2, a layer thickness of about 0.001 to 0.2 inch, the overall filter having a permeability of about 1 to 200 ft-min−1 at 0.5 inch (water) ΔP, an efficiency in removing a 0.1 micron particle at 10 ft-min−1 of about 35 to 99,99995% and an efficiency in removing a 0.76 micron particle at 20 ft-min−1 of about 80 to greater than 98%.

A method for filtering air, the method comprising;

• (a) directing air through a media pack at a rate of 5 to 10,000 cfm, the pack comprising a substrate having first and second opposite flow faces, the element comprising a plurality of flutes wherein in said media pack;
• (i) said flutes have a first end portion adjacent to the first flow face and a second end portion adjacent to the second flow face;
• (ii) selected ones of the flutes being open at the first end portion and closed at the second end portion;
• and selected ones of the flutes being closed at the first end portion and open at the second end portion;
• (iii) the element comprises a nanofiber layer and a high efficiency substrate layer;
• the nanofiber layer comprising a polymer material and having a fiber diameter of 0.01 to 0.5 micron, a basis weight of about 3×10−7 to 6×10−5 gram-cm−2, an average pore size of about 0.01 to 100 microns and a layer thickness of about 0.05 to 50 microns;
• the high efficiency substrate layer comprising a non-woven layer comprising a basis weight of about 0.2 oz-yd−2 to 350 lb-3000 ft−2, a thickness of about 0.001 to 0.2 inch, the overall filter having a permeability of about 1 to 200 ft-min−1 at 0.5 inch (water) ΔP, an efficiency in removing a 0.1 micron particle at 10 ft-min−1 of about 35 to 99,99995% and an efficiency in removing a 0.76 micron particle at 20 ft-min−1 of about 80 to greater than 98%.

An air filter assembly comprising:

• (a) a housing including an air inlet, an air outlet, a spacer wall separating said housing into a filtering chamber and a clean air chamber;
• said spacer wall including a first air flow aperture therein;
• (b) a first filter construction positioned in air flow communication with said first air flow aperture in said spacer wall;
• said first filter construction including an extension of a pleated filter media composite defining a filter construction inner clean air chamber;
• (i) said first filter construction being oriented with said filter inner clean air chamber in air flow communication with said spacer wall first air flow aperture;
• (ii) said pleated filter media composite comprising a nanofiber layer and a high efficiency substrate layer;
• the nanofiber layer comprising a polymer material and having a fiber diameter of 0.01 to 0.5 micron, a basis weight of about 3×10−7 to 6×1031 5 gram-cm−2, an avenge pore size of about 0.01 to 100 microns and a thickness of about 0.05 to 50 microns;
• the high efficiency substrate layer comprising a non-woven layer comprising a basis weight of about 0.2 oz-yd−2 to 350 lb-3000 ft−2, a thickness of about 0.001 to 0.2 inch, the overall filter having a permeability of about 1 to 200 ft-min−1 at 0.5 inch (water) ΔP, an efficiency in removing a 0.1 micron particle at 10 ft-min−1 of about 35 to 99,99995% and an efficiency in removing a 0.76 micron particle at 20 ft-min−1 of about 80 to greater than 98%;
• and
• (c) a cleaning system comprising at least one of a pulse-jet cleaning system oriented to direct a pulse of air through said filter construction into said inner clean air chamber or a vibration cleaning system oriented to vibrate said filter construction inner clean air chamber.

A method for filtering air, the method comprising;

• (a) directing the air through an inlet of a housing and into a filtering chamber;
• the housing including a spacer wall separating the filtering chamber from a clean air chamber;
• the spacer wall including a first air flow aperture therein;
• (b) after directing the air into the filtering chamber, directing the air through an extension of a pleated filter composite of a first filter construction and into a filter construction inner clean air chamber;
• the first filter construction being positioned in air flow communication wit the first air flow aperture in the spacer wall;
• the extension of a pleated filter media composite defining the filter construction inner clean air chamber;
• (i) the first filter construction being oriented with the filter inner clean air chamber in air flow communication with the spacer wall first air flow aperture;
• (ii) the filter composite comprising a nanofiber layer and a high efficiency substrate layer;
• the nanofiber layer comprising a polymer material and having a fiber diameter of 0.01 to 0.5 micron, a basis weight of about 3×10−7 to 6×10−5 gram-cm−2, an avenge pore size of about 0.01 to 100 microns and a thickness of about 0.05 to 50 microns;
• the high efficiency substrate layer comprising a non-woven layer comprising a basis weight of about 0.2 oz-yd−2 to 350 lb-3000 ft−2, a layer thickness of about 0.001 to 0.2 inch, the overall filter having a permeability of about 1 to 200 ft-min−1 at 0.5 inch (water) ΔP, an efficiency in removing a 0.1 micron particle at 10 ft-min−1 of about 35 to 99,99995% and an efficiency in removing a 0.76 micron particle at 20 ft-min−1 of about 80 to greater than 98%;
• and
• (e) after directing the air through an extension of a pleated filter media composite of a first filter construction and into a filter construction inner clean air chamber, directing the air into the clean air chamber and out of the housing.

A method for filtering air in a gas turbine intake system, the turbine operating at a temperature of about 120° F. to about 220° F., the intake air having an ambient temperature and a humidity of at least 50% RH, the method comprising the steps of:

• (a) installing a filter proximate an air intake of a gas turbine system, the filter comprising at least one filter element, the filter element having a media pack forming a tubular construction defining a open filter interior;
• the open filter interior being a clean air plenum, the media pack including a pleated construction of a media composite, the media composite, comprising a nanofiber layer and a high efficiency substrate layer;
• the nanofiber layer comprising a polymer material and having a fiber diameter of 0.01 to 0.5 micron, a basis weight of about 3×10−7 to 6×10−5 gram-cm−2, an average pore size of about 0.01 to 100 microns and a thickness of about 0.05 to 50 microns;
• the high efficiency substrate layer comprising a non-woven layer comprising a basis weight of about 0.2 oz-yd−2 to 350 lb-3000 ft−2, a thickness of about 0.001 to 0.2 inch, the overall filter having a permeability of about 1 to 200 ft-min−1 at 0.5 inch (water) ΔP, an efficiency in removing a 0.1 micron particle at 10 ft-min−1 of about 35 to 99,99995% and an efficiency in removing a 0.76 micron particle at 20 ft-min−1 of about 80 to greater than 98%;
• and
• (b) directing intake air into an air intake of a gas turbine system.

A method for filtering air in a gas turbine intake system, an intake air having an ambient temperature and a humidity of at least 50% RH,

• (a) directing intake air into an air intake of a gas turbine system having at least one filter element, the filter element having a media pack forming a tubular construction and construction defining a open filter interior;
• the open filter interior being a clean air plenum, the media pack including a pleated construction of a media composite, the media composite including a substrate at least partially covered by a layer of fine fibers, comprising a nanofiber layer and a high efficiency substrate layer;
• the nanofiber layer comprising a polymer material and having a fiber diameter of 0.01 to 0.5 micron, a basis weight of about 3×10−7 to 6×10−5 gram-cm−2, an average pore size of about 0.01 to 100 microns and a layer thickness of about 0.05 to 50 microns;
• the high efficiency substrate layer comprising a non-woven layer comprising a basis weight of about 0.2 oz-yd−2 to 350 lb-3000 ft−2, a layer thickness of about 0.001 to 0.2 inch, the overall filter having a permeability of about 1 to 200 ft-min−1 at 0.5 inch (water) ΔP, an efficiency in removing a 0.1 micron particle at 10 ft-min−1 of about 35 to 99,99995% and an efficiency in removing a 0.76 micron particle at 20 ft-min−1 of about 80 to greater than 98%;
• and
• (b) directing the air through the media pack of the filter element and into the open filter interior to clean the air.