Methods for filtering air for a gas turbine system

• US 6,875,256 B2
• Filed: 12/10/2003
• Issued: 04/05/2005
• Est. Priority Date: 09/05/2000
• Status: Expired due to Term

• Current Assignee: Donaldson Company Incorporated
• Original Assignee: Donaldson Company Incorporated
• Inventors: Gillingham, Gary R., Gogins, Mark A., Weik, Thomas M.
• Primary Examiner(s): Smith, Duane
• Assistant Examiner(s): Greene, Jason M.
• Application Number:
  US10/732,709
• Publication Number:
  US 20040226443A1
• Time in Patent Office: 482 Days
• Field of Search: 554/82, 554/86, 554/87, 555/27, 553/851, 553/853, 555/28, 555/29, 553/02, 555/21, 442/36, 952/73, 952/80
• US Class Current: 95/273
• CPC Class Codes: B01D 2279/60 for the intake of internal combustion engines or turbines intake systems for vehicles comprising filters F02M35/024
• CPC Class Codes: B01D 39/1623 of synthetic origin
• CPC Class Codes: B01D 46/0001 Making filtering elements
• CPC Class Codes: B01D 46/2411 Filter cartridges
• CPC Class Codes: B01D 46/521 using folded, pleated material
• CPC Class Codes: B01D 46/546 using nano- or microfibres
• CPC Class Codes: B01D 46/71 with pressurised gas, e.g. pulsed air
• CPC Class Codes: D01D 5/0007 Electro-spinning non-woven fabrics produced by electro-spinning D04H1/728
• CPC Class Codes: D01F 6/90 of polyamides
• CPC Class Codes: D01F 6/92 of polyesters

Abstract

Methods for cleaning air intake for a gas turbine system include utilizing filter arrangements that include a barrier media, usually pleated, treated with a deposit of fine fibers. The media is particularly advantageous in high operating temperature (140 to 350° F.) and/or high humidity (greater than 50 to 90% RH) environments.

Claims

1. A filter structure for filtering air in a gas turbine intake system, the turbine operating at an intake air demand greater than 8000 ft³-min⁻

1, the intake air having an ambient temperature and a humidity of at least 50% RH, the structure comprising, in an air intake of a gas turbine system, 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 including a substrate at least partially covered by a layer of fine fibers, the fine fibers comprising a polymeric composition comprising an addition polymer or a condensation polymer other than a copolymer formed from a cyclic lactam and a C_6-10 diamine monomer or a C_6-10 diacid monomer combined with an additive material.

2. The structure of claim 1 wherein the substrate comprises a cellulosic fiber, a synthetic fiber or mixtures thereof.

3. The structure of claim 1 wherein the additive comprises an oligomer having a molecular weight of about 500 to 3000 and an aromatic character free of an alkyl moiety wherein the additive is miscible in the condensation polymer.

4. The structure of claim 1 wherein the polymer comprises a polyalkylene terephthalate.

5. The structure of claim 1 wherein the polymer comprises a polyalkylene naphthalate.

6. The structure of claim 1 wherein the polymer comprises a polyethylene terephthalate.

7. The structure of claim 1 wherein the polymer comprises a nylon polymer.

8. The structure of claim 7 wherein the nylon copolymer is combined with a second nylon polymer, the second nylon polymer differing in molecular weight or monomer composition.

9. The structure of claim 8 wherein the nylon copolymer is combined with a second nylon polymer, the second nylon polymer comprising on alkoxy alkyl modified polyamide.

10. The structure of claim 8 wherein the second nylon polymer comprises a nylon copolymer.

11. The structure of claim 8 wherein the polymers are treated to form a single polymeric composition as measured by a differential scanning calorimeter showing a single-phase material.

12. The structure of claim 11 wherein the copolymer and the second polymer are heat-treated.

13. The structure of claim 12 wherein the copolymer and the second polymer are heat-treated to a temperature less than the lower melting point of the polymers.

14. The structure of claim 1 wherein the additive comprises an oligomer comprising tertiary butyl phenol.

15. The structure of claim 14 wherein the additive comprises an oligomer comprising:

16. The structure of claim 1 wherein the additive comprises an oligomer comprising bis-phenol A.

17. The structure of claim 16 wherein the additive comprises an oligomer comprising:

18. The structure of claim 1 wherein the additive comprises an oligomer comprising dihydroxy biphenyl.

19. The structure of claim 18 wherein the additive comprises an oligomer comprising:

20. The structure of claim 1 wherein the additive comprises a blend of the additive and a fluoropolymer.

21. The structure of claim 1 wherein the additive comprises a fluorocarbon surfactant.

22. The structure of claim 1 wherein the additive comprises a nonionic surfactant.

23. The structure of claim 1 wherein the condensation polymer comprises a polyurethane polymer.

24. The structure of claim 1 wherein the condensation polymer comprises a blend of a polyurethane polymer and a polyamide polymer.

25. The structure of claim 24 wherein the polyamide polymer comprises a nylon.

26. The structure of claim 25 wherein the nylon comprises a nylon homopolymer, a nylon copolymer or mixture thereof.

27. The structure of claim 1 wherein the condensation polymer comprises an aromatic polyamide.

28. The structure of claim 1 wherein the condensation polymer comprises a reaction product of a diamine monomer and poly(m-phenylene isophthalamide).

29. The structure of claim 28 wherein the polyamide comprises a reaction product of a diamine and a poly(p-phenylene terephthalamide).

30. The structure of claim 1 wherein the condensation polymer comprises a polybenzimidazole.

31. The structure of claim 1 wherein the condensation polymer comprises a polyarylate.

32. The structure of claim 31 wherein the polyarylate polymer comprises a condensation polymerization reaction product between bis-phenol-A and mixed phthalic acids.

33. A method for filtering air in a gas turbine intake system, the turbine operating at an air intake demand of at least 8000 ft³-min⁻

1, 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 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, the fine fibers comprising a polymeric composition comprising an addition polymer or a condensation polymer other than a copolymer formed from a cyclic lactam and a C_6-10 diamine monomer or a C_6-10 diacid monomer combined with an additive material; and

(b) directing intake air into an air intake of a gas turbine system.

34. The method of claim 33 wherein the additive comprises an oligomer having a molecular weight of about 500 to 3000 and an aromatic character free of an alkyl phenolic moiety wherein the additive is miscible in the condensation polymer;

and comprising the step of directing the air through the media pack of the filter element and into the open filter interior to clean the air.

35. The method of claim 33 wherein the polymer comprises a polyalkylene terephthalate.

36. The method of claim 33 wherein the polymer comprises a polyalkylene naphthalate.

37. The method of claim 33 wherein the polymer comprises a polyethylene terephthalate.

38. The method of claim 33 wherein the polymer comprises a nylon polymer.

39. The method of claim 33 wherein the nylon copolymer is combined with a second nylon polymer, the second nylon polymer differing in molecular weight or monomer composition.

40. The method of claim 33 wherein the nylon copolymer is combined with a second nylon polymer, the second nylon polymer comprising an alkoxy alkyl modified polyamide.

41. The method of claim 39 wherein the second nylon polymer comprises a nylon copolymer.

42. The method of claim 39 wherein the polymers are treated to form a single polymeric composition as measured by a differential scanning calorimeter showing a single-phase material.

43. The method of claim 42 wherein the copolymer and the second polymer are heat-treated.

44. The method of claim 43 wherein the copolymer and the second polymer are heat-treated to a temperature less than the lower melting point of the polymers.

45. The method of claim 43 wherein the additive comprises an oligomer comprising tertiary butyl phenol.

46. The method of claim 45 wherein the additive comprises an oligomer comprising:

47. The method of claim 33 wherein the additive comprises an oligomer comprising bis-phenol A.

48. The method of claim 47 wherein the additive comprises an oligomer comprising:

49. The method of claim 33 wherein the additive comprises an oligomer comprising dihydroxy biphenyl.

50. The method of claim 49 wherein the additive comprises an oligomer comprising:

51. The method of claim 33 wherein the additive comprises a blend of the resinous additive and a fluoropolymer.

52. The method of claim 33 wherein the additive comprises a fluorocarbon surfactant.

53. The method of claim 33 wherein the additive comprises a nonionic surfactant.

54. The method of claim 33 wherein the condensation polymer comprises a polyurethane polymer.

55. The method of claim 33 wherein the condensation polymer comprises a blend of a polyurethane polymer and a polyamide polymer.

56. The method of claim 55 wherein the polyamide polymer comprises a nylon.

57. The method of claim 56 wherein the nylon comprises a nylon homopolymer, a nylon or copolymer mixtures thereof.

58. The method of claim 33 wherein the condensation polymer comprises an aromatic polyamide.

59. The method of claim 33 wherein the condensation polymer comprises a reaction product of a diamino monomer and poly(m-phenylene isophthalamide).

60. The method of claim 58 wherein the polyamide comprises a reaction product of a diamine and a poly(p-phenylene terephthalamide).

61. The method of claim 33 wherein the condensation polymer comprises a polybenzimidazole.

62. The method of claim 33 wherein the condensation polymer comprises a polyarylate.

63. The method of claim 62 wherein the polyarylate polymer comprises a condensation polymerization reaction product between bis-phenol-A and mixed phthalic acids.

64. The method according to claim 33 wherein, said step of directing air into an air intake of a gas turbine system having at least one filter element includes directing air into an air intake of a gas turbine system having a plurality of filter element pairs, each of the filter element pairs including a first tubular filter element with the media pack sealed against an end of a second tubular filter element with the media pack;

each of the first and second tubular filter elements defining the clean air plenum.

65. A method according to claim 64 wherein said step of directing air into an air intake of a gas turbine system having a plurality of filter element pairs includes directing air into the first tubular filter element and the second tubular filter element;

wherein the first tubular filter element is cylindrical and the second tubular filter element is conical.

66. A method according to claim 64 further including directing a pulse of air into each of the clean air plenums of each of the filter element pairs to at least partially remove particulates collected on each of the media packs.

67. A method for filtering air in a gas turbine intake system, the method comprising, in a turbine operating at an air intake demand greater than 8000 ft³-min⁻

1, 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, the fine fibers comprising a condensation polymer, other than a copolymer formed from a cyclic lactam and a C_6-10 diamine monomer or a C_6-10 diacid monomer, and a resinous additive comprising an oligomer having a molecular weight of about 500 to 3000 and an aromatic character wherein die additive miscible in the condensation polymer; and

(b) directing the air through the media pack of the filter element and into the open filter interior to clean the air.

68. The method of claim 67 wherein the condensation polymer comprises a polyalkylene terephthalate.

69. The method of claim 67 wherein the condensation polymer comprises a polyalkylene naphthalate.

70. The method of claim 67 wherein the condensation polymer comprises a polyethylene terephthalate.

71. The method of claim 67 wherein the condensation polymer comprises a nylon polymer comprising a homopolymer having repeating units derived from a cyclic lactam.

72. The method of claim 67 wherein the nylon copolymer is combined with a second nylon polymer, the second nylon polymer differing in molecular weight or monomer composition.

73. The method of claim 67 wherein the nylon copolymer is combined with a second nylon polymer, the second nylon polymer comprising an alkoxy alkyl modified polyamide.

74. The method of claim 73 wherein the second nylon polymer comprises a nylon copolymer.

75. The method of claim 73 wherein thy polymers are treated to foam a single polymeric composition as measured by a differential scanning calorimeter showing a single phase material.

76. The method of claim 74 wherein the copolymer and the second polymer are heat treated.

77. The method of claim 74 wherein the copolymer and the second polymer are beat treated to a temperature less than the lower melting point of the polymers.

78. The method of claim 67 wherein the additive comprises an oligomer comprising tertiary butyl phenol.

79. The method of claim 78 wherein the additive comprises an oligomer comprising:

80. The method of claim 67 wherein the additive comprises an oligomer comprising bis-phenol A.

81. The method of claim 80 wherein the additive comprises an oligomer comprising:

82. The method of claim 67 wherein the additive comprises an oligomer comprising dihydroxy biphenyl.

83. The method of claim 82 wherein the additive comprises an oligomer comprising:

84. The method of claim 67 wherein the additive comprises a blend of the additive and a fluoropolymer.

85. The method of claim 67 wherein the additive comprises a fluorocarbon surfactant.

86. The method of claim 67 wherein the additive comprises a nonionic surfactant.

87. The method of claim 67 wherein the condensation polymer comprises a polyurethane polymer.

88. The method of claim 67 wherein the condensation polymer comprises a blend of a polyurethane polymer and a polyamide polymer.

89. The method of claim 88 wherein the polyamide polymer comprises a nylon.

90. The method of claim 89 wherein the nylon comprises a nylon homopolymer, a nylon copolymer or mixtures thereof.

91. The method of claim 67 wherein the condensation polymer comprises an aromatic polyamide.

92. The method of claim 67 wherein the condensation polymer comprises a reaction product of a diamine monomer and poly(m-phenylene isophthalamide).

93. The method of claim 92 wherein the polyamide comprises a reaction product of a diamine and a poly(p-phenylene terephthalamide).

94. The method of claim 67 wherein the condensation polymer comprises a polybenzimidazole.

95. The method of claim 67 wherein the condensation polymer comprises a polyarylate.

96. The method of claim 95 wherein the polyarylate polymer comprises a condensation polymerization reaction product between bis-phenol-A and mixed phthalic acids.

97. The method according to claim 67 wherein, said step of directing air into an air intake of a gas turbine system having at least one filter element includes directing air into an air intake of a gas turbine system having a plurality or filter element pairs, each of the filter element pairs including a first tubular filter element with the media pack sealed against an end of a second tubular filter element with the media pack;

each of the first and second tubular filter elements defining the clean air plenum.

98. A method according to claim 97 wherein said step of directing air into an air intake of a gas turbine system having a plurality of filter element pairs includes directing air into the first tubular filter element and the second tubular filter element;

wherein the first tubular filter element is cylindrical and the second tubular filter element is conical.

99. A method according to claim 97 further including directing a pulse of air into each of the clean air plenum of each of tho filter element pairs to at least partially remove particulates collected on each of the media packs.