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Oil mist separtion for BOSCH MAHLE Turbo Systems

Turbocharger cells are manufactured at Bosch MAHLE Turbo Systems (BMTS) in the St. Michael / Austria plant. This is a customer of Filtration Group Industrial. Two-spindle machining centres are used in turbocharger production. During machining, the cleanliness of the components plays an important role. Combination tools are used here, which can machine several mould elements in one operation and which are precisely matched to the multi-spindle machining centres. High aerosol concentrations at the production sites can be hazardous to the health of employees and cause expensive damage to the machines. For an optimal economic solution, electrostatic filters, centrifugal separation systems and mechanical filters were compared with each other.

With its highly efficient coalescer principle, the LGA 600 FUW achieved the best separation values for non-water-miscible cooling lubricants and cooling lubricant emulsions compared to devices on the market, which were far below the legally required limit values for air pollution control. Filtration Group was able to ensure optimum performance and function here with an optimally designed filter system, which convinced the customer accordingly.

Challenge

PROBLEM

  • Oil drops settle in the factory hall and on the machines
  • High maintenance, downtime and service costs as well as large expenses for police-filter stages (H14) at classical separators
  • Machine operators and other employees have to breath in harmful oily aerosols
  • Short lifetime and frequent downtime of tooling machines

Target

  • Increased separation rate with significantly reduced remaining oil
  • Residual oil < 200 µm on components
  • Reliable, low maintenance requiring oil mist separator system
  • High protection of employees through clean air in production line
  • High machine availability through online-operation
  • Compliance with prescribed values of German Federal Imission Control Act

Solution statement

Overall 40 Filtration Group LGA type 600 FUW oil-mist separators have been installed, piped, configured and launched per production line by Filtration Group service engineers.

Results

  • A significant increase of the separation rate was achieved
  • Secured separation and recovery of finest oil aerosols through the maintenance free coalescer principle
  • Compliance with correct extraction volume and required values of German Federal Imission Control Act

Customer value

  • Profitability through low maintenance and service costs
  • Reduction of machine downtime to a necessary minimum
  • The issue of intensive cleaning efforts for the removal of oil films in the production hall and in the tooling machine centers has been eliminated completely
  • Total recovery of the separated oil
  • Nearly no wasted material in the LGA-system
  • Reliable protection of the employees’ health

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