A Critical Imperative for Maximizing Production Efficiency
- KG International
- Whitepaper
- 16 June 2024
Abstract
In today’s highly competitive industrial landscape, maximizing production efficiency is of paramount importance for all industries. A critical factor influencing operational performance is the quality of fuel and oil. This white paper meticulously explores various contamination types, highlighting their implications and the imperative of sustained operational efficiency. By focusing on bulk filtration, it showcases the versatility of KG Filter Carts in enhancing performance and cost-effectiveness. This paper underscores the significance of filtration system in achieving seamless industrial operations, ensuring longevity and reliability.
Type of contamination and its effects
Effective fuel and oil management is vital to ensure the smooth operation of machinery and equipment in every industry. Failure to maintain clean fuel and oil can lead to numerous detrimental effects. This section delves into the key consequences of using contaminated fuel and oil.
| Type of Contaminants | Effects on Fuel and Oil | Effects on Engine Life | Effects on Environment |
|---|---|---|---|
|
Particulate |
Potential clogging in
fuel injector |
Likelihood of short
engine life |
Likelihood of short
engine life |
|
Water |
Corrodes metal parts |
Forms oxidation |
Basis of acid rain and
pollution |
|
Chemical |
Alteration in fuel
properties |
Corrosion of engine
components |
Responsible for air pollution and contributes to climate change |
|
Metal Particles |
Decrease fuel efficiency |
Engine overheat, damage to fuel injectors |
Risks to soil, crops and live stocks |
Understanding clean fuel and oil
Contaminant free fuel and oil is paramount to overall efficiency of engine and prolonging the lifespan of machinery. The ISO 4406 and NAS 1638 cleanliness codes offer standardized methods to evaluate fluid cleanliness. ISO 4406 provides three numerical values detailing the particle quantity in specific size ranges: 4 μm and larger, 6 μm and larger, and 14 μm and larger. In contrast, the NAS 1638 method differentially counts particles in size intervals of 5-15μm, 15-25μm, 25-50μm, 50-100 μm, and >100 μm.For many equipment, an incoming cleanliness adhering to the ISO standard is typically 22/21/18. This indicates, for a 100ml fuel sample at an ISO level of 22, that there are between 2 to 4 million particles present. However, optimal machinery operation often requires a cleanliness closer to an ISO standard of 14/13/11. Utilizing KG Filter Carts guarantees high filtration efficiency, ensuring NAS level 4 clean oil. Ensuring such cleanliness levels significantly reduces wear and tear, providing optimal equipment performance and longevity.
| ISO 4406 Cleanliness Code | ||
|---|---|---|
|
ISO Code Number |
No of Particles per 100ml |
|
|
More Than |
Up to and
including |
|
|
24 |
8,000,000 |
16,000,000 |
|
23 |
4,000,000 |
8,000,000 |
|
22 |
2,000,000 |
4,000,000 |
|
21 |
1,000,000 |
2,000,000 |
|
20 |
500,000 |
1,000,000 |
|
19 |
250,000 |
500,000 |
|
18 |
130,000 |
250,000 |
|
17 |
64,000 |
130,000 |
|
16 |
32,000 |
64,000 |
|
15 |
16,000 |
32,000 |
|
14 |
8,000 |
16,000 |
|
13 |
4,000 |
8,000 |
|
12 |
2,000 |
4,000 |
|
11 |
1,000 |
2,000 |
|
10 |
500 |
1,000 |
|
9 |
250 |
500 |
|
8 |
130 |
250 |
|
7 |
64 |
130 |
|
6 |
32 |
64 |
BEFORE FILTERATION
AFTER FILTERATION
What is bulk filtration and how does it work?
Bulk filtration is a comprehensive solution designed to remove contaminants from large quantities of fuel and oil, ensuring their cleanliness and optimal quality. This process involves the use of advanced filtration systems specifically designed for high-capacity applications. The bulk filtration process typically consists of multiple stages, each targeting different types of contaminants. KG Filter Cart uses SINGLE PASS FILTRATION technique to remove all contaminants and can be utilized in both in-plant machinery and mobile equipment. Below are the stages of KG Bulk Filtration systems:
- Main filtration in this stage, the fuel or oil flows through fine filtration media, such as high-quality filter cartridges. This stage consists of particulate filter designed to capture smaller particles, including those invisible to the naked eye, ensuring the fuel or oil is thoroughly purified.
- Water absorbing technology Water contamination is a common issue in fuel and oil systems. KG Filter Carts incorporate specialized technology to separate and remove free water from the fuel or oil.
Bulk filtration streamlines and expedites the cleaning process, offering a remarkably efficient solution. Traditionally, users would invest nearly half a day in cleansing equipment or storage tanks, incurring substantial labor expenses while grappling with operational downtime, untidy premises, and unsafe work conditions. KG International has ingeniously engineered systems for uninterrupted operation. These systems seamlessly integrate into prevailing fuel or oil storage and distribution frameworks, ensuring a smooth implementation devoid of any disruptive factors. The procedure of flushing is remarkably simple: insert the suction end of the hose at the tank’s inner base and the delivery end at a midpoint within the tank, initiate the pump and clean the entire tank within minutes.
Product range and use cases
KG Bulk Filtration solutions offer a diverse range of products that cater to unique demands, ensuring clean fuel and oil, improving equipment performance, and reducing overall maintenance costs. Every product in our range is meticulously crafted to fulfil these objectives.
The use of premium-grade filter media guarantees high filtration efficiency and consistency in performance across multiple applications by effectively capturing particulate, water, and other contaminants. The pump used in the system is manufactured by an Italian company, PUS. With the capacity of 25 LPM, the pump can be used to filter Diesel, Lube Oil, Hydraulic or Gear Oil. A point to remember is when the liquid is changed, the filter needs to be changed as well.
The filters used in filtration systems are made in collaboration with the HIFI Filters, known for being leaders in filtration solutions.
| Products | Description | Operating Pressure | Burst Pressure | Media | Use Cases |
|---|---|---|---|---|---|
|
SHR
536F04 V |
β(4μ) ≥ 2000 |
24 bar |
55 bar |
FiberGlass |
Automotive, Industrial, Commercial
vehicles, Construction and Mining |
|
SHR
536F07 V |
β(7μ) ≥ 2000 |
24 bar |
55 bar |
FiberGlass |
Automotive, Industrial, Commercial
vehicles, Construction, Mining and
Steel
|
|
SHR
536F25 V |
β(25μ) ≥ 2000 |
24 bar |
55 bar |
FiberGlass |
Automotive, Industrial, Commercial
vehicles, Construction, Mining and
Steel
|
|
SNR
536AB0 V |
Water
absorbing |
|
Absorbent |
Coupled with all the filters to
remove free water from fuel and oil |
|
Features of KG Filter Carts
- Single Pass Filtration: The KG Filter Cart cleans the fuel in a single pass, significantly reducing the time spent in flushing oil. This ensures that filtration is only required when putting fuel or oil into service, thus minimizing additional cleaning time.
- Highest Beta Ratio in the market: Beta ratio is a crucial aspect of filtration systems as it determines the filter’s efficiency. KG Filter Carts boast an impressive beta ratio of ß2,000-ß10,000 while market alternatives only achieve around ß200, making them 10 times less effective.
- Reduced spending on oil: Clean oil increases the life of equipment and dramatically reduces any maintenance cost.
- Increased engine life: Engines are the most expensive part of your machines, and they require constant protection. Clean lube oil/fuel reduces chances of damage, thus reducing maintenance / replacement costs and increasing uptime.
Fuel filtration for Industry 4.0
As the world embraces the era of Industry 4.0, bulk filtration plays a vital role in revolutionizing industrial processes and driving greater efficiency, sustainability, and reliability.
With advancements in sensor technology, real-time data analytics, and artificial intelligence, KG Filter Carts offer integrated monitoring and online connectivity. The numerous benefits of using IOT enabled KG Filter Carts are:
- Track filtration performance and proactive system maintenance capabilities.
- More predictable downtime with custom configuration possibilities.
- Integrated monitoring allows users to identify performance issues.
- Support compliance with environmental regulations.
Appendix: Measuring fuel quality in industrial plant (Case Study)
Test Facility: Industrial Manufacturing Facility
Sample Tank Size: 1000 L
Sample Tank Size: 1000 L
First sample was collected from the bottom of hydraulic oil tank. The ISO level found in the sample was 23/22/20 equals to NAS Level 12. The contamination contained metal particles upto the size of 80μm along with some particles of silica, rust, and fiber.
Post first sample collection, KG Filter Cart was installed with the hydraulic oil tank and flushing was initiated. Another sample was taken after running KG Filter Cart and ISO 4406 analysis was done using Manual Patch Test kit.
Observation Recorded: Hydraulic oil sample after going through KG Filter Cart achieved an ISO level of 14/11/8 equals to NAS Level 4 in a single flushing cycle. KG Filter Cart successfully attained 99.95% efficiency level in filtration in a single pass.
Fig: Sample Before Filtration
Fig: Sample After Filtration
(It is highly recommended to flush the system for 3-4 cycles to capture contamination settled on the bottom of oil tank and stuck on side walls as the life of filters depends on the level of contamination.)
In this dynamic landscape of modern operations, the significance of bulk filtration in maximizing efficiency cannot be overstated. From maintaining clean fuel and oil to optimizing engine performance and extending equipment life, the advantages of implementing high-quality filtration systems are clear and compelling. By adopting KG Filter Carts industries can gain access to cutting-edge technology, unparalleled expertise, and a comprehensive range of filtration solutions tailored to their specific needs. With a proven track record of delivering high-quality and reliable filtration solutions, KG Filter Cart ensures not only cleaner fuel and enhanced operational efficiency but also offers responsive customer support, ensuring seamless integration and sustainable success.
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