CJCTM Fine Filter Technology
Cleaning of thermal oil systems
Applications:
food industry
raffineries
timber and paper industry
coating industry
rubber and plastics industry
etc.
Maintenance of thermal oil in heat transfer systems
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2 Thermal Oil - Function and Requirements
Typical Problems:
• Deposits in the Tube System
• Contaminated Coolers
• Instable Processes
• Increasing Energy Consumption
Oil degradation products are the major cause of these problems which can be avoided with a
continuous fine filtration of the thermal oil.
Different Applications - Same Problems
Thermal oil is used in many industrial sectors. In heat transfer systems with operating temperatures of 140 - 310 °C these special oils
substitute water or steam as transfer medium, for example in the petrochemistry, electrical industry, paper and timber industry, in rubber
and plastics processing, in the shipping sector and not least in the food industry.
High Thermal Stress - Accelerated Oil Degradation Process
Thermal degradation activated by the high temperatures as well as oxidation processes stress the thermal oil. As a consequence, oil
degradation products are generated and transported throughout the whole system by the oil so that they deposit at the tube walls and in
the heat exchangers.
Clean Tube Wall
Deposits on the inner tube walls of a thermal oil system reduce the flow-cross section
of the tubes. The rough surfaces increase the internal resistance and lead to a loss
of energy. At restart after an operating stop the warm-up phase is prolonged, energy
Contaminated Tube Wall consumption increases and reaction times on control signals are much longer.
This extended reaction times lead to variations in temperature during the production. In
order to compensate these delays the thermal oil has to be exposed to even more heat
which further accelerates the oil degradation process.
TF = Film temperature
Tbulk = Bulk temperature
Especially in the heat exchangers, significantly more oil degradation products are deposited due to the temperature gradients. The charac-
teristics of the heat transfer deteriorate, the energy efficency decreases and the process parameters need to be adjusted frequently.
Productions Stops = Breakdown Costs
Processes with thermal oil are normally designed for continuous operation.
Especially here, downtime leads to considerable costs.
3 CJC™ Fine Filter Inserts
Continuous removal of oil degradation products
Carbonization / Oil degradation products
Oil degradation products due to oil ageing are generated in every
thermal oil system. Main reason is pyrolysis (thermal degradation
at high temperatures). Oil degradation products like oxidation
residuals, resin / sludge and varnish deposit on metal surfaces in
the system, reduce the free flow-cross section and deteriorate the
heat transfer.
Removal of oil degradation products
Oil degradation products can be removed with CJC™ Fine Filter
units before they deteriorate further and sediment as sludge or
resins.
CJC™ Fine Filter inserts are depth filters made of cellulose
with an immense inner surface area. Since filtration efficiency
generally depends on the contact time of the fluid with the filter Oil degradation products deposit at The CJC™ Fine Filter Insert purifying
material, CJC™ Fine Filter inserts are designed so the fluid has to the cellulose fibres (combination of the oil until the cellulose fibres are
adsorption and absorption) completely saturated.
pass the large volume of the insert.
The degradation products are removed from the oil by a combination of adsorption and absorption processes. The degradation products
deposit at the cellulose fibres and are absorbed into them.
• Coke number:
Removing oil degradation products leads to a reduction of the coke number (important indicator for the residual oil life time).
• TAN (Total Acid Number):
Existing acid components can also be neutralized and removed from the oil, the acid number (TAN) decreases.
Material: Cellulose Because of their structure CJC™ Fine Filter inserts are comparable
with a labyrinth-like, extremely close-meshed volume sieve with
finest, countlessly branched channels. The total volume of cavities
of the filter insert amounts to 75% which explains the particularly
high dirt holding capacity.
Used CJC™ Fine Filter inserts can be disposed off according to waste code 150202 (EWC, version
January 2002). They exclusively constist of natural ingredients so that they have not to be separa-
ted by material types. For that reason they fulfill also the requirements of DIN EN ISO 14001:2005
„environmental management systems“ and the German Life-Cycle Resource Management Act.
Up to 56 kg dirt
Sectional view of Depending on the size CJC™ Fine Filter Units absorb up to 56 kg of dirt, before the fine
a used CJC™ Depth Filter insert filter insert have to be replaced.
4 Functional Principle and Installation
Large Amount of Space for Contaminants depth filter (cross-section)
While crossing the filter insert microfine particles
and cracking products are retained in the depth flow direction
of the filter material. Depending on type and
volume of the particles each filter element can
absorb up to several kilograms of dirt until the
clean oil
element is saturated.
The filter insert also removes water from the oil.
It should be noted that during installation of the CJC™ Fine Filter unit, the
CJC™ Fine Filter insert may not come in contact with oil of a temperature
exceeding 150 °C. That implies a maximum inlet temperature of 300 °C
before it enters the heat exchanger of the filter system.
The fluid pressure in the CJC™ Fine Filter unit should be kept as low as
possible.
In order to keep the heat loss low the filtered thermal oil is, before it is
reverted to the system, reheated in the heat exchanger by the oil that has to
be filtered.
Installation
Ideal installation of the CJC™ Fine Filter
system is at the point in the system with the
lowest pressure and temperature conditions.
If necessary the temperature can be
lowered with a heat exchanger and a cooler to
a level that complies with the filter require-
ments.
Best conditions for installation are to be found
at the upstream side of the main or booster
pump.
If an installation is not possible at this point
the oil can also be drawn from the discharge
or expansion tank.
Another option is an installation in a secon-
dary circuit (with low temperature) or at the
tube to the expansion tank with oil return into
the heating circuit.
Whenever oil is exposed to high temperatures it generates problematic oil degradation products.
5 CJC™ Fine Filter units - Advantages
heat increased
energy input
declined
heat transfer
heat oil
deposits
cracking
decreased
thermal stress lower
energy input
improved
heat transfer
filtration oil
fewer
deposits
redissolving
deposits
• prevents the clogging of tubes and heat exchangers
• prolongs the oil life time
• stabilizes the process via constant heat transfer
• reduces deposits in the heating circuit
• saves energy
• lowers the coke number
• reduces the total acid number (TAN)
• reduces maintenance and downtime costs
The degradation process is catalysed by:
Oxygen High temperatures Water Wear particles Cu, Fe, Al
6 Dimensioning
CJC™ Fine Filter units
Dimensioning the optimum size of the
filter unit mainly depends on the oil
volume and the amount of contaminants
in the system.
The modular design allows a precise
dimensioning of the unit adapted to the
respective application.
Optional accessories
For filtration of thermal oil with an opera-
ting temperature >150 °C a version with
heat exchanger and cooler is recommen-
ded.
Further obtainable accessories are for
example tanks, base plates, leckage
sensors, pressure switches and tempera-
ture monitors. Signals and reports can be
transmitted externally.
Dimensioning
Oil volume CJC™ Fine Filter CJC™ Fine Filter Insert Holding capacity Pump flow Power consump-
max. Type Volume Surface Dirt Water Content [ L/min ] tion motor
[L] [L] [ m² ] [ kg ] [L] [L] [ kW ]
3.000 27/27 12 1.13 2.0 1.2 18 1.5 - 4.5 0.12 - 0.18
6,000 27/54 24 2.26 4.0 2.4 35 3.0 - 6.0 0.18 - 0.25
9,000 27/81 36 3.39 6.0 3.6 60 4.5 - 9.0 0.18 - 0.25
12,000 27/108 48 4.52 8.0 4.8 80 6.0 - 13.0 0.25 - 0.37
25,000 2 x 27/108 96 9.04 16.0 9.6 160 13.0 - 24.0 0.37 - 0.55
50,000 3 x 27/108 144 13.56 24.0 14.4 240 24.0 - 32.0 0.55
80,000 427/108 192 18.08 32.0 19.2 385 32.0 - 65.0 0.55 - 1.1
200,000 727/108 336 31.64 56.0 33.6 621 65.0 1.1
Please, contact us!
We will be pleased to help you dimensioning.
7 CJC™ Fine Filter Tecnology
Automatic separation of water / Removal of particles and oil degradation products,
Removal of particles and oil degradation products Absorption of water Neutralizing acids, Reducing TAN
CJC™ Filter Separators CJC™ Fine Filter Units CJC™ Oil Maintenance Unit
Removal of large amounts of water from
emulsified oils
CJC™ Desorber
Removal of particles and oil degradation products,
absorption of water
CJC™ Fine Filter Units
Automatic separation of water /
Removal of particles and oil degradation products
CJC™ Filter Separators / Thruster Units
For cleanliness analysis
CJC™ Fine Filter Units
For every application a suitable solution!
8 Our Energy for Your Oil
Whether at the maintenance of gear, lubrication or hydraulic oil or whether in wind power plants, plastic or metal processing, quenching
plants, at test benches, turbines, transformers or combined heat and power stations, in nearly all industrial and maritime sectors we have
firmly established ourselves as a competent partner for oil treatment and maintenance of oils.
Today our CJC™ Fine Filters, CJC“ Filter Separators and CJC™ Maintenance Units are used in various industrial sectors.
Karberg & Hennemann GmbH & Co. KG
Founded in 1928 in Hamburg, where we have developed and produced fine
filter technology since 1953. With our substantiated know-how and our own
in-house analysing and testing equipment we are today experts for the treat-
ment of oils and fuels.
Karberg & Hennemann srl
Because of the constantly increasing success of our CJC™ Fine Filter Units in the Italian market we have founded a subsidiary in Modena
in the year 2000. Karberg & Hennemann srl services our Italian customers, assisted by regional distributors.
Quality
Competent advice and indivual solutions for our customers even for difficult filtration problems - that is our
daily work, based on our experience and our products: Fine Filter systems of highest longevity and a filtration
degree down to < 1 μm. The Certification of our company according to DIN EN ISO 9001:2008 is both a
confirmation and a motivation for us.
CJC™ world wide
All over the world CJC™ Offline Fine Filter Units are available via our subsidiaries and local
sales partners. To reach an optimum oil cleanliness for an individual application, our sales
partners and the whole global intranet are at your disposal.
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Karberg & Hennemann GmbH & Co. KG
Marlowring 5 22525 Hamburg Phone: +49 (0)40 855 04 79 - 0 P.O. Box 54 01 40 22501 Hamburg Fax: +49 (0)40 855 04 79 - 20 www.cjc.de
[email protected]
