The article presents experimental results and theoretical analysis of aerosol nanoparticle penetration through fibrous filters with a broad fiber diameter distribution. Four fibrous filters were produced using the melt-blown technique. The analysis of the filters’ SEM images indicated that they had log-normal fiber diameter distribution. Five kinds of proteins and two types of silica particles were generated by electrospraying and were then classified using a Parallel Differential Mobility Analyzer to obtain well-defined, monodisperse, singly charged challenge aerosols with diameters ranging from 6.3 to 27.2 nm. Particle penetration through the filters was determined using a water-based CPC. Experimental results were compared first with predictions derived from the classical theory of aerosol filtration. It is demonstrated that it is inappropriate to apply it to the arithmetic mean fiber diameter, as this results in turn in a huge underestimation of nanoparticle penetration. A better, but still unsatisfactory agreement is observed when that theory was used together with the pressure drop equivalent fiber diameter or when the Kirsch model of nonuniform fibrous media was applied. We show that the classical theory applied to any fixed fiber diameter predicts a stronger dependence of nanoparticle penetration on the Peclet number as compared to experimental data. All these observations were successfully explained by using our original partially segregated flow model that accounts for the filter fiber diameter distribution. It was found that the parameter of aerosol segregation intensity inside inhomogeneous filters increases with the increase in particle size, when the convective transport becomes more pronounced in comparison to the diffusive one.

This study proposes utilising the solution blow-spinning process (SBS) for manufacturing a biodegradable filtration structure that ensures high efficiency of particle filtration with an acceptable pressure drop. The concept of multi-layer filters was applied during the design of filters. Polylactic acid (PLA) was used to produce various layers, which may be mixed in different sequences, building structures with varying filtration properties. Changing the process parameters, one can create layers with diverse average fibre diameters and thicknesses. It enables the design and creation of optimal filtration materials prepared for aerosol particle filtration. The structures were numerically modelled using the lattice Boltzmann approach to obtain detailed production guidelines using the blow-spinning technique. The advantage of this method is the ability to blow fibres with diameters in the nanoscale, applying relatively simple and cost-effective equipment. For tested PLA solutions, i.e., 6% and 10%, the mean fibre diameter decreases as the concentration decreases. Therefore, the overall filtering efficiency decreases as the concentration of the used solution increases. The produced multi-layer filters have 96% overall filtration efficiency for particles ranging from 0.26 to 16.60 micrometres with a pressure drop of less than 160 Pa. Obtained results are auspicious and are a step in producing efficient, biodegradable air filters.