Cleanroom Testing and Validation Instruments

Thermal Aerosol Generator

A controlled condensation aerosol generator that heats test liquid and forms a dense, repeatable aerosol for high-capacity filter challenge applications.

Dense repeatable condensation aerosol for large filter systems.
Independent thermal and flow control for adjustable output.
Insulated stainless construction with safety shutdown.

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Product Introduction

This thermal aerosol generator heats a compatible aerosol liquid under controlled conditions, carries the vapor into a cooler region and forms a stable condensation aerosol. Independent temperature and carrier-flow controls allow output to be adjusted for demanding filter systems while maintaining repeatability. Insulated hot surfaces, over-temperature protection and a drainable stainless flow path support safer field use and straightforward maintenance.

Key Features

Controlled heating produces dense aerosol without relying solely on compressed-air atomization.

Separate temperature and carrier-flow settings provide repeatable output adjustment.

Fast thermal response reduces stabilization time after a new setpoint is selected.

Insulated housing and over-temperature shutdown protect operators and internal components.

Stainless liquid path supports cleaning and compatible test-liquid changeover.

High-output configuration suits large air-handling units and demanding filter banks.

Customer Product Concerns

Thermal aerosol generation requires stable heat transfer, safe handling and controlled output across changing filter-system demands.

Heating can degrade test liquid or change output if temperature drifts.Closed-loop temperature control and a defined operating range stabilize vaporization without unnecessary overheating.

Hot external surfaces present a handling risk during field testing.Thermal insulation, guarded surfaces and cool-touch handles separate the operator from the heated core.

Condensed residue may accumulate in the outlet after shutdown.A controlled purge and drainable stainless path clear residual vapor before storage.

Large concentration changes can overload downstream measurement equipment.Independent carrier-flow and temperature settings allow output to be increased gradually to the required challenge level.

Typical Applications

Challenge testing of large HEPA filter banksAir-handling unit integrity testingFilter loading and separator-development studiesGeneration of controlled condensation aerosols in laboratoriesHigh-output qualification work where atomizer capacity is insufficient

Technical Parameters

Typical configurable construction values are listed below; final thermal, flow and dimensional specifications depend on the selected generator capacity.

Core Material	Insulated stainless-steel saturator, heated vapor path, condensation section and regulated carrier-gas circuit
Panel Thickness	Typically 1.0–1.5 mm for the stainless protective enclosure
Effective Width	Approximately 250–450 mm according to thermal-output configuration
Maximum Length	Approximately 450–750 mm including outlet and protective handle
Steel Facing Thickness	Typically 1.0–1.5 mm stainless steel
Core Density	Approximately 80–140 kg/m³ for the high-temperature mineral-fiber insulation surrounding the heated section
Thermal Conductivity	Approximately 0.035–0.050 W/(m·K) for the high-temperature insulation layer
Surface Finish	Fine-brushed stainless steel with heat-resistant dark controls and insulated grip surfaces
Joint Type	Threaded fill port, regulated carrier-gas inlet and high-temperature stainless aerosol outlet
Customization	Available based on the intended application and operating environment.

Available Options

Adjustable heating and carrier-flow rangesDEHS, PAO or other compatible liquid configurationIntegrated compressor or external inert carrier gasHeated outlet hoseRemote control and data interfaceInsulated transport frame

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