In the machining workshop, behind the splash of welding flowers, there is an "invisible killer" that threatens the health of workers. Long-term exposure to metal oxide particles, ozone and nitrogen oxides from welding and grinding processes can lead to a 30% increase in the incidence of respiratory diseases. Traditional dust removal equipment has low efficiency and high energy consumption, which has become the bottleneck of the green transformation of the manufacturing industry. Henan Xinxiang Lifelte Filter Co., LTD. (hereinafter referred to as "Lifelte") research and development of the third generation of filter cylinder dust removal system, through technological innovation to solve this problem, open up a new path for industrial pollution prevention. The problem of welding workshop pollution: The game between efficiency and environmental protection "In the past, the workshop was always filled with choking smell, wearing a mask can smell metal dust." An auto parts factory welding workshop director Master Wang admitted. In the high-temperature flue gas produced by welding arc, 90% of the particle size is less than 1 micron, and the traditional bag dust collector is difficult to intercept, and the wet dust removal faces the problems of secondary pollution and high energy consumption. Data show that the annual emission of PM2.5 in China's welding industry is equivalent to the exhaust gas of 150,000 diesel trucks, and the contradiction between environmental protection pressure and production costs has become increasingly prominent. Zhang Jianmin, general manager of Liffert, pointed out that the dust removal technology must take into account "filtration accuracy" and "operation economy". The filter cylinder dust removal system developed by the company for 5 years has achieved a balance between efficiency and cost through the two-way breakthrough of nanomaterials and intelligent control. Technical breakthrough: The "twin engine" of nanofiltration membrane + pulse ash cleaning core innovation one: PTFE nanofiltration membrane, the interception rate of 99.7%. Liffert uses a plasma spraying process to form a 0.3 micron PTFE film layer on the surface of the filter cartridge, like a "nano-screen" for the dust removal system. This film not only improves the filtration accuracy by three times compared to the traditional filter material, but also has hydrophobic and oil-proof characteristics to avoid the viscous particles in the welding smoke blocking the filter hole, and the service life is extended to 36 months. Core innovation 2: Intelligent pulse cleaning, energy consumption reduced by 40%. The system is equipped with PLC intelligent differential pressure monitoring, when the pressure difference of the filter cartridge exceeds 1500 pa, the high-pressure pulse air is sprayed with 180° rotation, and the single cleaning efficiency is 95%.
Compared with the regular cleaning mode, the technology can reduce the ineffective energy consumption by 60% and save more than 100,000 yuan in electricity bills annually. In the welding workshop of a large steel structure factory in Henan Province, the Lifeldt system has been running stably for 18 months. Data show that when the air volume is 12,000 cubic meters/hour, the export particle concentration is reduced from 32 mg/cubic meters to 1.2 mg/cubic meters, far better than the national standard limit (5 mg/cubic meters). The person in charge of the factory calculated an account: "Although the initial investment is 15% higher than the traditional equipment, the filter cartridge replacement cycle is extended by three times, coupled with the reduction in energy consumption, the total cost in three years is saved by 28%." Intelligent operation and maintenance + Resource recovery: The "evolution" of dust removal technology Liffert's innovation does not stop at dust removal. The Internet of Things module equipped with the system can upload operational data in real time, and the AI algorithm can accurately predict the life and maintenance cycle of the filter material. The "Flue gas reuse module" launched in 2024 will also circulate the purified air to the workshop, and with the heat recovery device, the heating energy consumption of the workshop in winter will be reduced by 18%. This combination of technologies not only reduces pollutant emissions, but also builds a green closed loop of "dust removal - energy saving - carbon reduction". "In the future, dust removal equipment will be 'environmental stewards' rather than pure purification tools." Zhang Jianmin revealed that the company is developing laser scanning automatic ash cleaning technology to further reduce manual maintenance costs. Industry insiders believe that Liffert's technological breakthrough marks the shift of industrial dust removal from "passive governance" to "active prevention and control", providing a replicable solution for the green transformation of manufacturing.
