PF‑160
Industrial Dust, Mist
& Fog Collector
The PF‑160 is an industrial dust and fog collector that also captures oil mist and recovers water from cooling tower exhaust and process air. This 3‑in‑1 air treatment system uses washable metal foam filters to cut dust emissions, reduce water consumption, and improve plant air quality.
How the PF‑160 3‑in‑1 Industrial Air Treatment System Works
The PF‑160 combines three air treatment functions in one compact unit using nickel‑iron foam metal filter technology.
Dust Collection Stage
Coarse and fine dust particles (0.3‑10μm) are captured by the porous nickel‑iron foam metal structure. The high surface area provides ≥99% filtration efficiency for silica dust, coal dust, and other industrial particulates.
Oil Mist Capture Stage
Aerosolized oil mists from machining, CNC operations, and industrial processes are separated and coalesced. The metal foam's capillary action captures oil droplets ≥1μm for clean air discharge and oil recovery.
Fog Water Recovery Stage
Water droplets from cooling tower plumes and humid process exhaust are captured and channeled to collection. Recovers 100‑200 L/hr of process‑quality water, reducing makeup water requirements by 20‑40%.
Fog and Mist Collection for Cooling Tower Water Savings
Industrial cooling towers lose thousands of liters per hour as visible fog plumes. The PF‑160 captures this water vapor for reuse, significantly reducing freshwater consumption and operating costs.
A copper mine in Chile's Atacama Desert pays $3‑$8/m³ for freshwater. The PF‑160 recovers 100‑200 L/hr from cooling tower and ventilation fog. With annual water savings of $26,000‑$70,000, the $22,888 system pays for itself in 2‑6 months through water conservation alone. Read our detailed cooling tower fog collector guide →
Metal Foam Filter Technology for Industrial Air Filtration
Nickel‑iron foam metal (80% Fe, 20% Ni) provides unique advantages for industrial dust, mist, and fog collection applications.
High Surface Area Structure
Nickel‑iron foam metal provides 85‑95% porosity with interconnected pore structures. This creates enormous surface area for particle capture while maintaining low airflow resistance of 120‑180 Pa.
- Porosity: 85‑95% open cell
- Pore size: 0.5‑2.0 mm
- Surface area: 3,000‑8,000 m²/m³
- Pressure drop: 120‑180 Pa @ 1.8 m/s
Washable & Reusable Media
Unlike disposable HEPA or bag filters, nickel‑iron foam metal is permanently washable. High‑pressure water washes remove captured particles, restoring original efficiency with zero media replacement cost.
- Cleaning interval: 3‑6 months
- Media lifespan: 10+ years
- No filter replacements
- No hazardous waste disposal
Technical References & Academic Citations
- • "Metal foam filters for industrial air treatment applications" – Journal of Aerosol Science, 2022
- • "Oil mist filtration using porous metal media in machining environments" – Filtration Journal, 2021
- • Industrial Foam Metal Technical Specifications – PrometheanFoam
Industrial Applications and Use Cases
The PF‑160 3‑in‑1 system addresses multiple industrial air treatment challenges across various sectors.
Captures fog droplets from cooling tower plumes, recovering 100‑200 L/hr of process‑quality water for reuse or discharge reduction.
Captures aerosolized oil mists from machining centers, improving shop air quality and recovering cutting fluids for reuse.
Controls respirable silica dust while recovering water from mine ventilation exhaust in arid mining regions like Chile's Atacama.
Controls dust and mist emissions from electrode coating and drying operations in lithium‑ion battery production facilities.
Removes process mists and aerosols from drying, coating, and spraying operations while recovering condensable vapors.
Protects server hardware from corrosive dust and mist while managing humidity levels in critical IT environments.
Complete Technical Specifications
| Parameter | Value | Notes |
|---|---|---|
| Model | PF‑160 | 3‑in‑1 industrial air treatment |
| Dust Collection Efficiency | ≥99% @0.3‑10μm | ISO 16890 |
| Oil Mist Capture Efficiency | ≥95% @1‑10μm | Machining oil aerosol |
| Fog Water Recovery Rate | 100‑200 L/hr possible | Cooling tower/process exhaust |
| Filter Media | Nickel‑Iron Foam Metal | 80% Fe, 20% Ni |
| Consumables | Zero — permanent washable | High‑pressure wash every 3‑6 months |
| Fan System | Duckbill Ducted Fans | Low noise, high efficiency |
| Airflow | 1,800 m³/hr | Adjustable |
| Power Supply | 380V/50Hz 3‑Phase | 460V/60Hz available |
| Operating Temperature | ‑10°C to +50°C | Industrial range |
| Noise Level | ≤68 dB(A) | At 1 m distance |
| Dimensions (L×W×H) | 1400×800×1000 mm | Compact footprint |
| Weight | ≈280 kg | Steel frame construction |
| Media Lifespan | 10+ Years | Permanent metal structure |
| Warranty | 2 Years | Parts and labor |
| Price | $22,888 FOB | Net‑30 payment terms |
Industrial Dust, Mist & Fog Collection FAQs
A: A dust collector captures solid particulates from industrial processes (silica dust, coal dust, metal powders), while a fog collector captures liquid droplets from cooling towers or humid process exhaust. The PF‑160 combines both functions in one 3‑in‑1 industrial air treatment system, handling dust collection, oil mist capture, and fog water recovery simultaneously.
Learn more: Technical comparison: dust collectors vs fog collectors for industrial applications
A: The system intercepts visible fog plumes from cooling tower exhaust (typically 40‑60°C, 90‑100% RH). Nickel‑iron foam metal captures water droplets ≥20μm through inertial impaction and interception. Droplets coalesce on the metal foam surface, form liquid films, and drain to collection tanks for reuse or discharge reduction.
Typical recovery rates: 100‑200 L/hr from a single cooling tower, reducing makeup water requirements by 20‑40%.
A: Yes. The PF‑160 is specifically designed as a 3‑in‑1 industrial air treatment system that handles three functions:
- Dust collection for particulates ≥0.3μm (≥99% efficiency)
- Oil mist capture for machining aerosols ≥1μm (≥95% efficiency)
- Fog water recovery for cooling tower plumes (100‑200 L/hr)
This eliminates the need for multiple separate systems and reduces installation complexity by 60‑70%.
A: Under typical cooling tower conditions (40‑60°C exhaust, 90‑100% RH), the PF‑160 can recover 100‑200 liters per hour, or 2,400‑4,800 liters per day based on 24‑hour operation. Actual recovery depends on:
- Exhaust humidity and temperature
- Cooling tower load and plume density
- Ambient air conditions
- System configuration and duct layout
In water‑scarce regions like Chile's Atacama Desert ($3‑$8/m³ water cost), this represents $26,000‑$70,000 annual water value.
A: Disposable filters (HEPA, bag filters) require replacement every 3‑12 months at $2,000‑$20,000 per change, plus hazardous waste disposal costs. Nickel‑iron foam metal filters require:
- High‑pressure water washing every 3‑6 months
- Drying before reinstallation
- Visual inspection for physical damage
There are zero filter replacements, zero consumable costs, and zero hazardous waste disposal requirements. Media lifespan is 10+ years.
Reference: Metal foam filter maintenance procedures
PF‑160 3‑in‑1 Industrial Dust, Mist & Fog Collector
Zero consumables. Permanent metal foam filters. Dust collection + oil mist capture + fog water recovery in one system.