A Powerful Ally for Gearbox Protection: Power Plant Edition - Special Magnetic Filter -
Magnet Filter MAGNOM (Magnum)
Achievements developed in the harsh and demanding environment of F1 racing. Please see the field report on the gearbox of a coal pulverizer operating in a power plant.
"Magnum" was originally developed to improve the durability of transmissions in the harsh conditions of F1 racing. It was later proven to make a significant contribution to the protection of large gearboxes used for the pulverization mills of coal, which is the fuel for coal-fired power plants. Amid calls for the abolition of coal-fired power plants in pursuit of a decarbonized society, these plants continue to operate actively as electricity consumption expands worldwide. Naturally, unexpected system failures can lead to significant losses. The introduction of "Magnum" was motivated by reasons such as the ineffectiveness of conventional barrier-type filters, including: - Generation of pressure loss - High viscosity index of the lubricating oil used - Insufficient removal of tiny iron-based particles that can damage the system In any system, it is essential to quickly remove the increasing contamination to prevent a wear chain. Since the installation of "Magnum" at the Didcot A power plant 18 months ago, it has been reported that there have been no issues with the pulverization mill gearbox, which previously occurred about four times a year. The earlier "Magnum" is installed, the more effective the protection of the mill, leading to reduced losses!
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basic information
■Removal of fine particles is possible Magnum can capture fine magnetic particles (submicron: 10μm to 0.07μm) that cannot be removed by filters using filter paper or mesh, such as cartridge filters. ■No clogging Due to its special structure, where magnets are sandwiched between special plates, it does not block the flow path in the area where iron powder is captured. Therefore, it does not experience any clogging or pressure loss. Even when the capture capacity limit is reached, it does not hinder the operation of the device. ■Powerful capturing ability The magnets enhance the magnetic flux due to their special arrangement, resulting in a significant difference in the capturing ability of iron powder compared to simple magnets. Unlike conventional magnet filters, which can only capture contaminants from liquids close to the magnets, this structure greatly improves the cleanliness of the fluid. ■No re-release Captured contaminants are accumulated in a strong collection area separate from the flow path. The dangerous phenomenon that can occur with regular magnet filters, where the magnetic force weakens as the distance from the magnet increases, causing once-captured and solidified contaminants to re-release as a mass, does not happen at all.
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Applications/Examples of results
By Industry ■ Hydraulic Systems Hydraulic power units for factories / Hydraulic devices for processing machines, etc. / Hydraulic testing equipment / Construction machinery / Ships Mining machinery / Agricultural machinery / Railways / Large transmissions / Transmissions for wind power generation systems / Transmissions for coal pulverizers in thermal power plants / Transmissions for kilns and coal pulverizers in cement plants / Transmissions for feed roller drives in factories / Transmissions for stirring and calendar machines in factories / Transmissions for crushing, grinding, and refining processes in mines and metal manufacturing plants / ■ Automobiles and Motorcycles Transmission oil / Power steering / Engine oil ■ Water Cooling and Heating Systems Cooling systems for injection molding molds / Industrial and power generation cooling lines Industrial and power generation steam lines (liquid only) / Cooling fluids for steelmaking lines Quenching fluids / Cutting fluids for processing machines and machine tools / Lathes, milling machines, etc. Processing oils for electrical discharge machines / Various cleaning fluids / Hardening cooling fluids
Detailed information
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Magnets have been used for a long time. However, a standalone magnet has a limited range of magnetic force, and trying to increase efficiency leads to new problems such as clogging and reflow. To overcome these issues, Magnum was developed. It is a groundbreaking magnet filter core technology that leverages the advantages of conventional filters while overcoming their disadvantages. By installing it within a circuit, it efficiently removes fine wear particles without causing clogging or reflow. Its performance is recognized worldwide, maintaining the performance of aircraft, racing vehicles, and various hydraulic and lubrication equipment.
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Historically, OEMs and end users of hydraulic systems have recognized the issue of iron and have attempted to address it using some form of magnetic device. For example, consider a simple magnetic drain plug. After regular equipment repairs or system failures, when the magnetic drain plug is removed, there is always a state where iron contamination is "attached" to the magnet. Dirt adheres to the surface of the magnet. Magnetic energy decreases in strength as the distance increases, following the inverse cube law (the inverse square law of distance). This means that unless one is close to the magnetic field lines, it is clear that contaminants cannot be adsorbed or removed. In other words, the more particles come into contact with the magnet, the further they move away from the magnet (or energy source), and as the contaminants move away from the energy source, they ultimately get washed away. Because the particles were exposed to the magnetic field, they remain as weakly magnetized clumps. When parts concentrated with high-carbon steel are the first to arrive, it is natural that they often suffer from catastrophic failures.
Line up（5）
| Model number | overview |
|---|---|
| Clear Series (for low-pressure general liquids) | ・Features Model for aqueous solutions Transparent housing Easy maintenance with T-type design High-capacity integrated model As a final filter for cutting fluids For scale removal in cooling water such as chillers ・Applications Machine processing cutting fluids Cooling fluids Cleaning fluids (caution regarding resin resistance for hydrocarbon-based fluids) |
| Model CP (for hydraulic circuits) | ・Features Compact model that can be directly installed in hydraulic circuits Housing that can withstand high pressure Upstream of important components in hydraulic circuits Model CP photo ・Applications Hydraulic lines Small transmissions Engine fuel lines |
| Model M (for hydraulic devices) | Versatile model High capture capacity Balances pressure loss and capture efficiency Simple and compact Model M photo ・Applications Main piping for hydraulic devices Medium transmissions Engine various lines |
| Process Unit (large models for lubricating oils, etc.) | Large diameter and high-capacity model Compatible with high flow piping Ensures protection for critical systems that cannot afford failures Maximum preventive maintenance Process Unit photo ・Applications Main piping for large hydraulic devices Large transmissions |
| Suction Filter Type | Features Model as a suction filter inside the tank of hydraulic devices Effectively captures iron powder particles down to 0.07 microns A model to protect pumps from clogging A significant protection solution for hydraulic devices Pump Mate photo ・Applications Suction line for hydraulic devices |
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