Superb results with Disc Centrifuge Filters

Disc Centrifuge Filter

 

What is a disc centrifuge filter?

A disc centrifuge filter utilizes the cleaning capabilities of a centrifuge. The disc centrifuge filter is installed as a bypass system, working in conjunction with the standard full-flow filter elements. A disc centrifuge filter can also be used with a self-cleaning automatic backwash filter. The engine’s lubricating oil pressure or external feed pump (kidney loop system) drives the disc stack centrifuge filter. The spinning action of the centrifuge bowl provides the centrifugal force to separate solids particles from the contaminated oil. 

A disc centrifuge filter functions as a clarifier centrifuge. A clarifier is a centrifugal separator for solid-liquid separation. A disc centrifuge filter is designed to separate solid particles (dirty/impurities) from a liquid phase (engine lubricating oil). When the denser solids are subjected to centrifugal forces, the denser solids are forced outwards against the rotating bowl wall, while the less dense liquid phase moves towards the centrifuge bowl center. The centrifuge conical discs increase the surface settling area, which speeds up the separation process. The concentrated denser solid particles collect against the disc stack centrifuge rotating bowl wall and are removed by hand during cleaning.

The oil-driven disc centrifuge filter is one of the industry’s most reliable and economic oil-cleaning technologies. Disc stack centrifuge filters are more environmentally friendly than utilizing disposable filter elements. Cleaning the conical disc centrifuge filter eliminates the expense of replacement filter elements and the cost of hazardous waste disposal. Disc stack centrifuge filters can effectively remove contaminants with a particle size removal below 1 micron. The filtration and separation efficiency of a disc stack centrifuge filter does not deteriorate with time.

 

How does a disc centrifuge filter work?

The engine lubricating oil pressure introduces the lube oil into the centrifuge bowl through holes drilled in the vertical spindle and via the accelerator channels in the bearing distributor. The centrifuge bowl then fills up, and oil overflows into the top turbine, where it exits the centrifuge bowl via the four-speed turbine channels and then out via the nozzles. This, in turn, rotates the centrifuge bowl, generating the centrifugal force required to remove the contaminants from the oil.

The contaminants migrate toward the outside of the centrifuge bowl, where they are deposited on a removable oil-resistant insert. The cleaned lubricating oil migrates towards the center of the centrifuge bowl, where it is expelled by the nozzles in the top turbine, thus perpetuating the cycle.

Increased efficiency with a disc stack centrifuge filter over traditional centrifuge filters!

Unlike conventional centrifuge filters, IOW Group disc centrifuge filters use bowl discs to increase the separation efficiency, dramatically reducing the time that contaminants can stay in the lubricating oil. IOW Group has improved the sealing between the dirty oil inlet and the cleaned oil outlet. This ensures that there is minimal cross-contamination between the two. IOW Group disc stack centrifuges have dirt/sludge monitoring technology, which informs the operator when the centrifuge system needs cleaning, saving valuable personnel time on otherwise unnecessary cleaning. The system is both MODBUS and CANBUS compatible and can be easily connected to your existing alarm systems.

When considering a disc centrifuge, you need to consider the technology’s features, advantages, and benefits. What makes the IOW Group disc stack centrifuges the market-leading disc centrifuge filter?

• • Bowl Disc Technology – Increasing efficiency by removing even more contaminants. The only pressure-powered centrifuge of their size to use bowl disc – usually associated with much larger centrifuges – allows the IOW disc centrifuges to remove significantly more small particles than any other competitor.
  • Fully Sealed Centrifuge Bowl – Reduced risk of cross-contamination between cleaned and dirty oil.
  • Remote Monitoring – Provides operators and systems with valuable insight into its speed, cleaning, and service requirements. The IOW disc centrifuge is the only product on the market that provides operators with a choice of remote monitoring. Remote monitoring helps the operator ensure that the disc centrifuge runs optimally. This reduces servicing man hours and increases productivity.
  • Distributor Impeller – Eliminates back pressure by drawing in contaminated oil. Oil enters the disc centrifuge at the base of the oil cleaning centrifuge and, while spinning, draws the oil into the centrifuge by the distributor impeller. This reduces the risk of back pressure causing cross-contamination and increases the centrifuge bowl (rotor) speed.
  • Increased Centrifugal Force – Higher centrifugal force produces a higher separation efficiency.

 

Engine Oil Filtration using a Disc Stack Centrifuge Filter

 

A power plant customer was interested in the potential cost savings of the new IOW Group MP600 disc stack centrifuge filters over their existing Mann+Hummel FM600 bypass centrifuge filters. The main objective was to increase the oil change intervals by maintaining insoluble levels, including soot below 1%, and by protecting the oil’s TBN (Total Base Number) level.

The power plant has a capacity of 20.4 megawatts. This power plant has Hyundai Himsen 9H21/32 engines (1800 kW power output at 900 rpm engine speed) running on heavy fuel oil (HFO). The lube oil tanks are 350 gallons (1,324.8 liters). The inlet pressure to the centrifuge filter is 63.8 PSI (4.4 bar). They are using SAE 40 lubrication oil.

Mann+Hummel FM600 bypass centrifuge filters were previously installed on the engines; therefore, the process was straightforward because the centrifuge interfaces are identical to the IOW Group MP600 disc centrifuge filters. The disc centrifuge filter is mounted on the inspection platform with a flange and a large gravity elbow pipe back into the sump. The flexible inlet hose has an isolation valve and pressure gauge to supply the pressurized oil to the centrifuge filter inlet directly from the engine’s pump.

 

Results:

With the Mann+Hummel FM600 centrifuge filter, the bypass centrifuge filter collected on average 400 grams (0.88 lbs) every 300 hours at a 1.3 grams/hour removal rate. The oil change interval was between 500-700 engine run hours depending on the amount of soot and insoluble.

With the IOW Group MP600 centrifuge filter, the disc centrifuge filter collected 1,722 grams (3.80 lbs) in 300 hours at a 5.7 grams/hour removal rate. The IOW MP600 centrifuge filter ran at approximately 4,300 RPMs using the 4.4 bar pressure from the engine’s lube oil pump.

The IOW MP600 disc centrifuge filter retains more soot, 3-to-4 times more than the Mann+Hummel FM600 centrifuge filter!

The power plant typically changed lube oil filters every 500 hours with 20 PSI differential pressure; now, the filter’s differential pressure is 17.5 PSI at 820 hours. By extending the oil life (oil change interval) and lowering contaminants in the lube oil, the IOW conical disc centrifuge filter achieves cost savings by consuming less engine oil and protecting the engine components from excessive and unnecessary wear. These cost savings mean that less operating budget is required for maintenance.

 

Conclusion:

The IOW Group disc centrifuge filter exceeded the customer’s expectations. Based on oil analysis, TBN levels remained acceptable, with only a 10% reduction in new oil levels. With new lube oil, the objective was to assess the capability of extending the existing 700-hour oil change intervals (when insoluble levels previously reached the condemnation limit with the Mann+Hummel centrifugal oil filter). By installing the IOW MP600 disc centrifugal oil filter, the lube oil reaches 1,500 hours before insoluble levels reach the 1% limit.

The IOW disc stack centrifugal filter more than doubled the engine oil change intervals!

By more than doubling the engine oil change intervals, the customer will save on engine downtime and labor rates. Still, ultimately the annual savings on an average of 7,000 operating hours can be calculated as follows:

Per the customer’s calculations, they projected to save over $17,360 per engine on lubrication oil. The calculation does not include the cost savings of extending the life of their inline filters and the cost savings of labor. IOW Group centrifuge filters allow you to maximize performance, extend maintenance intervals, and reduce the total cost of ownership (TCO) for engine systems and auxiliaries. IOW disc stack centrifuge filters come standard with Bowl Disc Technology and External Monitoring for greater efficiency. The new standard for performance in oil separators!

 

 

In addition to the engine lube oil filter, Hyundai Himsen recommends installing a purifying device for the lubricating oil. A build-on centrifuge filter is recommended for Hyundai Himen engines running on marine diesel oil (MDO). Continuously centrifuging with heated lubricating oil for lower viscosity is recommended for more effective purifying. It is recommended to centrifuge the lubricating oil on the engine while operating. If your looking to replace or upgrade your current Hyundai Himsen A67000 centrifugal oil filter, the IOW Group centrifugal oil filter is the better choice.

The superior centrifugal separation power (centrifugal force) of the IOW Group disc stack centrifuge filters will maximize savings and productivity throughout the power plant. Following fantastic feedback from the customer, they are installing IOW MP600 disc stack centrifuge filters on all their Hyundai Himsen 9H21/32 engines onsite to maximize savings throughout their power plant. To learn more, visit our IOW Group’s disc centrifuge filters webpage or visit IOWGroup.com.