Hello, my partner! Let's explore the mining machine together!

[email protected]

magnetic separator oil

magnetic separators | polytech filtration systems

magnetic separators | polytech filtration systems

Magnetic separators can substantially reduce filter cartridge consumption and element changes when used in grinding, honing and lapping operations where filter cartridges are used. They can reduce the concentration of small fines left in the coolant by chip conveyors in broaching, milling and drilling operations that can settle in tanks and reduce machine tool life.

The magnetic drum is made up of alternating permanent magnets and steel discs. The magnetic field is extended by the magnetized steel discs to maximize effectiveness without resorting to more costly high strength or rare earth magnets. A comb type scraper and adjustable discharge chute optimizes sludge removal.

magnetic filtration applications and benefits

magnetic filtration applications and benefits

Oil filtration in automotive and industrial machinery is essential to achieving optimum performance, reliability and longevity. Lubricant cleanliness is highly important and lubrication practitioners are provided with numerous options for filtering and controlling contamination, including disposable filters, cleanable filters, strainers and centrifugal separators.

This article discusses the mechanism of particle separation and reviews the many applications of magnetic filters and separators in the lubrication industry today. A brief guide to commercial filtration products is also presented.

From its origin in the beneficiation of iron ores, the magnet has played a prominent role in the separation of ferrous solids from fluid streams. Even in the control of contamination from in-service lubricants and hydraulic fluids, magnetic separation and filtration technology has found a useful niche.

Car owners, car mechanics, equipment operators, maintenance technicians and reliability engineers know the importance of clean oil in achieving machine reliability. Tribologists and used oil analysts are also aware that in some machines as much as 90 percent of all particles suspended in the oil can be ferromagnetic (iron or steel particles).

While it is true that conventional mechanical filters can remove particles in the same size range as magnetic filters, the majority of these filters are disposable and incur a cost for each gram of particles removed.

There are other penalties for using conventional filtration, including energy/power consumption due to flow restriction caused by the fine pore-size filter media. As pores become plugged with particles, the restriction increases proportionally, causing the power needed to filter the oil to escalate.

While a large number of configurations exist, most magnetic filters work by producing a magnetic field or loading zones that collect magnetic iron and steel particles. Magnets are geometrically arranged to form a magnetic field having a nonuniform flux density (flux density is also referred to as magnetic strength) (Figure 1).

Particles are most effectively separated when there is a strong magnetic gradient (rate of change of field strength with distance) from low to high. In other words, the higher the magnetic gradient, the stronger the attracting magnetic force acting on particles drawing them toward the loading zones. The strength of the magnetic gradient is determined by flux density, spacing and alignment of the magnets.

Various types of magnets can be used in these filters (see sidebar). Magnets used in some filters can have flux density (magnetic strength) as high as 28,000 gauss. Compare this level to an ordinary refrigerator magnet of between 60 and 80 gauss. The higher the flux density, the higher the potential magnetic gradient and magnetic force acting on nearby iron and steel particles.

While there are many configurations of magnetic filters and separators used in process industries, the following are general classifications for common magnetic products used in lubricating oil and hydraulic fluid applications.

The most basic type of magnetic filter is a drain plug (Figure 2), where a magnet in the shape of a disc or cylinder is attached to its inside surface (typically by adhesion). Periodically, the magnetic plug (mag-plug) is removed and inspected for ferromagnetic particles, which are then wiped from the plug.

Today, such plugs are commonly used in engine oil pans, gearboxes and occasionally in hydraulic reservoirs. One useful advantage of mag-plugs relates to examining the density of wear particles observed as a visual indication of the wear rate occurring within the machine over a fixed period of running time.

The appearance of these iron filings on magnets are often described in inspection reports using terms such as peach fuzz, whiskers or Christmas trees. If one normally sees peach fuzz, but on one occasion sees a Christmas tree instead, this would be a reportable condition requiring further inspection and remediation. After all, abnormal wear produces abnormal amounts of wear debris, leading to an abnormal collection of debris on magnetic plugs.

While magnetic plugs are inserted into the oil below the oil level (for example, drain port), rod magnets may extend down from reservoir tops (Figure 3), special filter canisters (Figure 4) or within the centertube of a standard filter element.

These collectors consist of a series of rings or toroidal-shaped magnets assembled axially onto a metal rod. Between the magnets are spacers where the magnetic gradient is the highest, serving as the loading zone for the particles to collect.

Periodically the rods are removed, inspected and wiped clean with a rag or lint-free cloth. A conceptual example of a particular rod magnet filter is shown in Figure 1. When the rod is removed, the sheath or shroud can be slid off the magnet core to remove the collected debris. This debris can then be prepared for microscopic analysis to aid in assessing machine condition.

As fluid passes through the slots, ferromagnetic particles accumulate in the gap between the plates. However, they do not interfere with flow (clogging), or risk particles being washed off by viscous drag.

One advantage of flow-through magnetic filters is the large amount of debris they hold before cleaning is required. The cleaning process typically involves removing the filter core and blowing the debris out from between the collection plates with an air hose.

There are several suppliers of magnetic wraps, coils or similar devices intended for use on the exterior of spin-on filter canisters (Figures 7a-c). Spin-on filters are commonly used in the automotive industry but are also utilized in a number of low-pressure industrial applications.

These wraps transmit a magnetic field through the steel filter bowl (can) in order for ferromagnetic debris to be held tightly against the internal surface of the bowl, allowing the filter to operate normally while extending the service life. Unlike the conventional filter element, the magnetic filter wrap can be used repeatedly.

There are a variety of magnets and ways in which magnetic filters and separators can be configured in a products design. In fact, there is much more to their performance than simply the strength or gradient of the magnetic field.

For instance, the size and design of the flow chamber, total surface area of the magnetic loading zones, and the flow path and residence time of the oil are all important design factors. These factors influence the rate of separation, the size of particles being separated and the total capacity of particles retained by the separator.

The magnetic force acting on a particle is proportional to the volume of the particle, but is disproportional to the diameter of the particle (magnetic force varies with the cube of the particles diameter). For instance, a two-micron particle is eight times more attracted to a magnetic field than to a one-micron particle. This means large ferromagnetic particles are disproportionately easier to separate from a fluid compared to smaller particles.

The separating force is proportional to the magnetic field gradient and also to the particle magnetization (magnetic susceptibility). Particle magnetization relates to the degree to which the particles material composition is influenced by a magnetic field.

The most strongly attracted materials are particles made of iron and steel, however, red iron oxide (rust) and high-alloy steel (for example, stainless steel) are weakly attracted to magnetic fields. Conversely, some nonferrous compounds such as nickel, cobalt and certain ceramics are known to have strong magnetic attraction. Materials that cannot be picked up with a magnet (such as aluminum) are called paramagnetic substances.

There are also competing forces which resist particle separation from the fluid. One such force is oil velocity which imparts inertia and viscous drag on the particle in the direction of the fluid flow. Depending on the design of the magnetic filter, the fluid velocity may send the particle on a trajectory toward or away from the magnetic field or perhaps in a tangential direction.

The competing viscous force is also proportional to both the particles diameter and the oil viscosity. If the particles diameter or the oils viscosity doubles, then the hydrodynamic frictional drag doubles accordingly (resistance to separation).

Complicating the situation further, as mentioned above, the magnetic attraction increases by a factor of eight when a particles diameter doubles, while the competing viscous drag sees only a 2X multiple. This further emphasizes the fact that larger particles are more easily separated than small particles, even in an environment of considerable viscous drag.

The fluid conditions that best facilitate the separation of magnetic particles are low oil viscosity (ISO VG 32 vs. ISO VG 320 for instance) and low oil flow rate (2 GPM vs. 50 GPM). Even extremely small, one-micron particles can be separated from the oil if both of these fluid conditions exist concurrently.

The decision to use magnetic technology in a given application depends on various machine conditions and fluid cleanliness objectives. These include the expected concentration of ferrous particles, type of oil used, operating temperature, surge flow and shock and machine design.

Because of the numerous commercial products, configurations and applications, certain items on the lists of advantages and disadvantages may not apply. Nonetheless, this list can serve as a starting point for making the decision whether magnetic technology is a good choice in a given application:

Limited Flow Restriction Unlike conventional filters, most magnetic filters exhibit little to no increase in flow restriction (pressure drop) as it loads with particles. While conventional filters can go into bypass when they become plugged with particles, magnetic filters (including mag-plugs and rods) continue to remove particles and allow oil flow. For instance, most diesel and gasoline engines provide no indication of a filter that has gone into bypass. In such cases, the oil may go for an extended period of time without being filtered. Common causes of premature plugging of engine filters include coolant leaks, poor combustion, poor air filtration and overextended oil drains.

Extended Life of Conventional Filters When used in conjunction with conventional mechanical filters (Figure 8), an increase in effective filter service life may be experienced. In certain cases, two to three times life extension may be experienced.

Improved Reliability of Electro- hydraulic Valves Servovalves and solenoid valves are adversely affected by particles that are magnetic (iron and steel) due to the electromagnets deployed when actuating these valves. The continuous and efficient removal of these particles by magnetic filters can substantially enhance the reliability of these valves.

Lower Risk of Oil Oxidation Iron and steel particles are known to promote oil oxidation by their catalytic properties. Premature oil oxidation can lead to varnish, sludge and corrosion. Everything else being equal, the continuous and efficient removal of iron and steel particle by magnetic filters should have a positive impact on oil service life, and over time, reduce oil consumption if oil is changed on condition.

Enhanced Wear Particle Identification Traditionally, wear particle identification is performed microscopically by examining particles extracted from oil samples (analytical ferrography). Those particles that have evaded filters have often been reworked (comminution) by traveling through heavily loaded rolling and sliding dynamic machine clearances. Once ground up, crushed and pulverized, they are more difficult to analyze to determine the source location, cause and severity of wear. However, particles removed from mag-plugs, magnetic rods and magnetic filters are often in their original virgin state which can greatly enhance the accuracy of machine condition analysis.

Quick Wear Metal Inspections Mag-plugs and rods can be removed for visual inspection (daily, weekly, etc.) without stopping the machine or removing a filter. They provide a dual service of contaminant removal and condition monitoring (from the density of wear particles observed).

Oil Flow Not Required Many machines are lubricated by oil splash, bath, flingers, slingers and paddles. Without access to a pump and oil flow, conventional onboard filters cannot be used to keep the oil clean and optimize machine reliability (reduce wear) and lubricant service life (reduce oil oxidation). However, magnetic plugs and rods do not require oil to flow in pipes and lines. They require the oil only to agitate and circulate in a sump, reservoir or oil pan. This movement causes these particles to migrate to a loading surface of the magnetic separator.

Can be Used in Gravity Flow Drain Lines Most wear metal production comes from the business end of a machine (bearings, gears, cams, etc.). Oil often returns to tank down drain lines and headers (flooded or partially flooded) by gravity. Due to the lack of oil pressure, it is nearly impossible to locate fine filtration on gravity drains to catch wear debris before it enters the reservoir. However, magnetic filters, rods and plugs generally do not restrict flow, enabling these particles to be quickly and conveniently removed directly in oil drains.

Detached Particle Agglomerations A common risk associated with using magnetic separators is the possibility of particles becoming detached from the magnet and washed downstream in mass, potentially entering a sensitive component. This concern is reduced if the magnetic separator is located on a drain line or if a conventional filter is positioned downstream to trap migrating debris. Risk of debris being washed off is highest under surge flow conditions, cold starts, shock, high oil viscosity and/or high oil flow rates.

Magnetized Transient Particles Adding to the risk of particle washoff is the chance of these particles becoming magnetized while they were attached to the permanent magnet. After floating downstream, they might adhere magnetically to frictional surfaces such as bearings, causing wear. They could also lodge into narrow flow passages, orifices, glands and oilways, thus restricting flow.

Nonmagnetic Particles Remain Unchecked Indeed, magnetic separators will have little effect on controlling nonferrous particles composed of silica, tin, aluminum or bronze. Other types of filters and separators must be used.

Cleaning Requirement Unlike conventional filter elements that are thrown away after becoming plugged, magnetic filters are reusable and therefore must be cleaned. The cleaning procedure varies but typically is messy and involves the use of an air hose. Specific cleaning safety precautions must be taken. Magnetic rods and plugs generally need to be wiped clean only at each service interval.

Separation is not by Size-exclusion Mechanics As previously discussed, separation is based on physics considerably different from size-exclusion the method which defines the performance of conventional mechanical filters. Instead, the capture efficiency of magnetic separators is based on many factors including the collective influence of particle size, magnetic susceptibility, flow rate, viscosity and magnetic field gradient.

As such, magnetic filters are not known for having well-defined micronic particle separation capability. Therefore, it is important to determine what micron filter rating is needed by the tribological components in the system, considering the oil viscosity, fluid flow rate through the filter, the properties of the challenge particles, etc.

Experience shows that most modern hydraulic components need protection of at least five microns or greater. Studies conducted some 20 years ago at the Fluid Power Research Center at Oklahoma State University for the Office of Naval Research showed that no magnetic filter at that time could satisfy this requirement when used alone. In such cases, the best choice might be a combination of conventional and magnetic filters.

NdFeB (Neodymium-Iron-Boron) This is the strongest in magnetic strength of all the magnets known to mankind. Neodymium, with a number 60 on the periodic table, was first thought to be a rare earth element, due to its inclusion in the rare earth elements between 57 and 71 on the periodic table. NdFeB was first developed and commercialized in the mid 1980s. Over the years, the strength of this composition has increased due to new developments.

SmCo (Samarium Cobalt) Also being one of the rare earth elements, Samarium Cobalt can produce magnetic strength near that of NdFeB. It became available in the 1970s but was rarely used. Due to its expensive composition, fragility and difficulty to manufacture, it is used only for its benefits of being able to withstand high temperatures and corrosion.

Ferrite (Ceramic) Todays refrigerator magnet - ceramic magnets with Barium or Strontium Ferrite - is the most common of all magnets. It is considerably inexpensive but it contains a lower strength compared to the other magnets. Developed in the 1960s, it was the useful magnet, used everywhere. This type of magnet is cost-effective and resistant to corrosion and demagnetization.

AlNiCo (Aluminum-Nickel-Cobalt) One of the first magnets developed after plain steel, this magnet has a lower strength rating. It is sensitive to demagnetization and can be destroyed if stored incorrectly or if it comes in contact with Neodymium-Iron-Boron. It has excellent machinability and has about half the strength of a ceramic magnet. Reference: www.wondermagnets.com

It is logical that the leading applications for magnetic separators are those where a high percentage of the particle contamination is ferromagnetic and the conditions favor a successful performance of a properly selected and installed magnetic filter or separator. As previously discussed, low oil viscosity combined with low flow rate help to facilitate the separation process (where applicable).

Its a good idea to review the lists of advantages and disadvantages in regards to each application and separator type (mag-plug, rod, flow-through, wrap) considered. Possible uses for magnetic technology include the following:

Many commercial products and suppliers of magnetic technology for contamination control of lubricating oils are listed in the sidebar. Specific questions regarding applications and these products should be directed to these suppliers.

magnetic separators | prab

magnetic separators | prab

Remove ferrous material, including sludge and chips, from both water soluble and neat oils with high intensity ferrite or rare earth magnets. This unit is used as a pre-filter to limit contaminants from reaching subsequent industrial filtration equipment. Typical applications include centerless and heavy stock removal grinding machines, honing, and gear cutting machinery.

PRABs line of magnetic separators employ high-intensity ferrite or rare earth magnets within a fully energized rotating drum to continuously remove ferrous particles from the flow of liquid. These systems are often used as a pre-filter to limit contaminants reaching subsequent filtration equipment.

Magnetic separators are well suited to processes where ferrous and non-ferrous contaminants are mixed with water-based coolants or straight cutting oils. They can also be used to enhance chip processing tasks and help you get the most out of your industrial filtration equipment.

Magnetic separators employ high-intensity ferrite or rare earth magnets within a fully energized rotating drum to continuously remove ferrous particles from the flow of liquid. These systems are often used as a pre-filter to limit contaminants reaching subsequent industrial filtration equipment. PRAB offers 4 models depending on your application needs including MCA, MCA-J, SS, and MSK.

Rare earth models are used when there are large amounts of ferrous fines (smaller than 40 micron), large amounts of sludge accumulation in a machines coolant tank, or when the coolant has a high viscosity rating such as straight oil.

Magnetic separators employ high-intensity ferrite or rare earth magnets within a fully energized rotating drum to continuously remove ferrous particles from the flow of liquid. This scrap metal equipment is often used as a pre-filter to limit contaminants reaching subsequent filtration equipment and are well suited to processes where ferrous and non-ferrous contaminants are mixed with water-based coolants or straight cutting oils. PRAB offers 4 models depending on your application needs.

Product Brochures Product Brochure: Magnetic Separator Product Family Product Brochure: Magnetic Separators MCA Product Brochure: Magnetic Separators Model MCJ-A Product Brochure: Magnetic Separators Model MSK Product Brochure: Magnetic Separators Model SS

Other Downloadable Content PRAB Fluid Filtration Solutions Product Selection Chart Brochure PRAB Fluid Filtration Systems and Wastewater Treatment Brochure PRAB Filtration Spectrum Brochure PRAB Builds Equipment for the Toughest Jobs in Manufacturing and Metalworking

PRAB completes comprehensive sample testing to establish an accurate understanding of the unique characteristics of your mixed solution and its industrial applications. This test determines the correct centrifuge system design and capacity to optimizes the filtration process within your facility.

Proven to Decrease Fluid Disposal Costs By Up to 90% Documented Results Achieved by PRAB Customers: REDUCED COOLANT COSTS We have seen around a 75% savings on new coolant purchases. Alexandre Blinov, Koss Aerospace INCREASED OIL SAVINGS Over $212,000 a year in oil savings. I am in shock along with everyone else in my []

Metalworking operations are often faced with unavoidable costs that are beyond their control. Two of the largest this year have been tariffs, and the cost of cutting fluids. Fortunately, there are many back-end solutions to help offset these costs that will add more value to metal scrap and spend fluids, and move profit margins in a positive direction. Machine []

Product Selection Chart Model # Flow Filtering Efficiency Application Tramp Oil Separator 3-150 gpm (11-568 lph) Coolant Guardian Coolant Recycling Systems 90-1,500 gph (341-5,678 lph) Coolant High Pressure Coolant Filters Coolant Magnetic Separator 5-265 gph (19-1,003 lph) 50-100 micron Coolant Paper Bed Filter 5-250 gpm (19-946pm) 15-50 micron Coolant/Wastewater Magnetic Separator & Paper Bed Filter 5-265 []

in line magnetic separator | ilms - coal handling plants

in line magnetic separator | ilms - coal handling plants

Feeding of power supply to ILMS done before starting of conveyor belt. As power supply to ILMS ON, electro magnet is energized and self-cleaning belt of ILMS start rotating. After stating of ILMS, conveyor belt started. As the tramp iron comes along with conveyer material in magnetic field area which is created by electro magnet, the tramp iron is attracted towards the electro magnet. The ILMS self-cleaning belt will carry the tramp iron beyond the edge of the conveyor with the help of aluminium angle fitted in the ILMS self-cleaning belt. As the tramp iron gets beyond the magnet field it will drop off. Position of adjustable divider ensure that the trap iron does not fall back on the main conveyor. Finally, the trap iron discharge into a hopper through the divider.

eriez magnetic separation

eriez magnetic separation

Eriez Permanent Magnetic Separators require no electric power. With proper care, they can last a lifetime with very little loss of magnetic field strength. Eriez permanent magnets are supplied for a wide range of applications including dry bulk materials, liquids or slurries and even high temperature applications. Select Eriez Permanent Magnetic Separators are available with the Xtreme RE7 Magnetic Circuit - the industry's strongest magnet!

Eriez Permanent Magnetic Separators require no electric power. With proper care, they can last a lifetime with very little loss of magnetic field strength. Eriez permanent magnets are supplied for a wide range of applications including dry bulk materials, liquids or slurries and even high temperature applications.

Electromagnetic Separators use wire coils and direct current to provide a magnetic field which can be used to separate ferrous material from non ferrous products. Electromagnetic separators offer greater flexibility and strength as well as different magnetic fields for specific applications.

Related News
  1. working principle of magnetic separator in coal handling plant
  2. mining equipment gold separating machine small gravity separator earthquake shake table
  3. low price medium copper mine spiral chute separator price in medan
  4. magnetic separator for mine in indonesia
  5. large supply stainless steel magnetic separator manufacturer
  6. spiral chute separator character
  7. high quality hydro cyclone classifier separation machine for non ferrous minerals
  8. spiral chute separator adalah
  9. magnetic 0png
  10. what is the core meaning of magnetic separation
  11. portable iron ore crusher for sale malaysia
  12. jaw crusher jc 400x600
  13. mineral processing ball mill images
  14. portable gravel crushers monterrey uttar pradesh
  15. thu new machine of m2 stone crushers in india
  16. bandung efficient coal spiral classifier sell
  17. roll mills triple
  18. trommel screen 8600ms
  19. graphite flotation processing plant
  20. jaw crusher small stone jaw crusher for mining