Magnetic filtration system - Automating and Improving Filtration in a Washing Process

A metalworking company operates a washing machine in which hydraulic parts made from cast iron are washed to remove oil and grease as well as particle contamination consisting of iron and carbon after a thermal grinding process.

Situation

Despite the use of a filtration system, large amounts of particles still accumulated in the washing bath, forming sludges at the bottom of tanks and reducing the effectiveness of particle removal in the washing process.

Solution

As a large amount of the particles in the system are cast iron, the company was informed that a magnetic filtration system could help solve their problems, as cast iron is extremely magnetic and can be removed very easily with a magnetic filter. In order to test this, a rental unit was placed at their facility for a few months, so that they could see the results first-hand. A model ASMF 3 was used during this test, as the customer wanted to have an automated system that did not need constant checking, but could run on its own.

magnetic filtration system

automated magnetic filtration system ASMF 5

As the system was to run as independently as possible, a connection between the electrical cabinet of the system and the control system of the factory was established, in order to monitor the magnetic filter system, so that errors could be detected remotely.

Customer ordered an automated magnetic filtration system ASMF 5

After having seen the results achieved by the test unit, the customer ordered an automated magnetic filtration system ASMF 5, including a cleaning system for the backwash liquid.

As the washing liquid used by the customer was fairly expensive, they did not want to throw it away in large quantities due to the flushing cycle of the model ASMF. To prevent this, a reclaim unit was attached to the model ASMF, that would separate the magnetic particles from the discharge fluid used in the flushing of the magnetic filter system.

Due to the aggressive nature of the washing fluid, all components in contact with the fluid needed to be made from stainless steel. Although most parts of the ASMF are already made from stainless steel standardly, the piping and the valves needed to be exchanged for the higher grade material.

Results

Having installed the system and being in use for several months, the customer analysed the system and found the following results:

in order to monitor the magnetic filter system
  • Per internal washing cycle, about 3-4 kg of iron was removed from the washing fluid. The service life of the washing fluid was increased by about 15%.
  • The washing result is now much more predictable and regular, and has improved in quality. This makes overall production easier to plan and therefore runs more efficiently.
  • It has been found that important washing additives stay in the bath for longer.
  • Overall this reduced the cost of operation for the customer while simultaneously improving production quality, which in itself leads to more savings.