The cause of 80% of all equipment failure is directly attributed to wear contamination on all manner of rotating, cooling & heating equipment. This leads to great production and money losses.
While filtering the fluids with the magnetic technology there are competing forces that resist particle separation from the fluid. Oil velocity is one such example, 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. This competing viscous force is proportional to both the particle’s diameter and the oil viscosity. If the particle’s diameter or the oil’s viscosity increases, the hydrodynamic frictional drag will increase proportionally.
The magnetic attraction increases by a factor of eight when a particle’s diameter doubles, while the competing viscous drag sees only a 2X multiple. This is important to note and further demonstrates how traditional full flow filtration is challenged to clean wear contamination under 10 microns in size because custom filtration for below 10 micron capability is expensive and requires frequent change out. Over the past 40 years, it has been realized that wear particulate under 4 microns is the most damaging. Also, standard analysis programs such as spectrographic and ferrographic analysis do not identify wear contamination under 4 microns and below 1 micron. All this place traditional filter’s efficiecy into question.
One of the factors of the particle capture efficiency by magnetic technology is particle characteristics.
The larger the particle, the easier it should be to separate, at least for the traditional filters. Our filtration technology is unique in that it filters contamination to sub-micron level with minimal flow restriction, maximizing efficiency. Additionally, only ferrous contamination are subject to a great capture efficiency when it comes to traditional filters. Our innovative technology captures non-ferrous particles because of cross-contamination. All particulate contamination becomes electrostatically charged due to physical interactions with other particles and surfaces, such as in pipelines or in hydrocarbon processing applications. This electrostatic charge causes negatively and positively charged ferrous particles to adhere to positively and negatively charged non-ferrous particles. The ferrous particle in this particle pair is then drawn to the magnetic element within the magnetic separator system.
There are other forms of adhesion that also cause the pairing of ferrous and non-ferrous particles, including embedding and capillary forces, although static pairing is the largest contributor to this process.
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