iCerMax™ Ceramic Depth Medium

iCerMax™ offers ceramic sustainable cleanliness levels through dept filtration with a vast contamination holding capacity. It is significantly superior to paper/cellulose or synthetic filtration medium. When liquids, gas & air flow through iCerMax™ its cleanliness levels are guaranteed to improve as the medium just simply can’t be compromised as is the case with conventional filtration medium.

Filter Performance Monitoring –Cellulose & synthetic medium “break” due to an excess of dirt, surges, pressure, water, Biodiesel, surfactants, alcohol, heat etc. - Ceramics aren’t compromised by any of these factors

Ceramics enable sustainable cleanliness levels even with a single passing through of the liquid gas or air that is being filtered - this is achieved a 100% of the time throughout the Filter’s lifecycle

Summery on iCerMax™ Ceramic Depth Medium Filtration

Particle and water contamination in fuels and oils
iCerMax™ ceramic filtration is depth filtration with sustainable cleanliness levels. iCerMax possesses characteristics that ensure a market advantage over other medium. Nowhere is this more apparent than when one applies ceramics as a filter medium. This is not a new concept, as it is used extensively in water (capacity) and air (efficiency) filtration. iCerMax™ however saw the potential to use ceramics for the filtration of hydrocarbons (fuels – diesel & petrol, oils-lubrication and hydraulics) - a new concept application in the global market.

With efficiency and cost, over the entire volume filtered at sustainable cleanliness levels, with no media collapse, no surge sensitivity, no channel formation or water sensitivity we are setting a new bench mark in FILTRATION with this non flexible, vast dirt holding capacity medium.

Especially when taking into consideration the versatility of the ceramic medium.
iCerMax™ filter medium cannot be compromised; therefore “bad particle contamination” will lead to only filter blockage, not injector wear / failure or even engine failure. Normal filter medium will be compromised through various factors, most common on excess capacity and this will lead to contamination surges. There is a whole range of ceramics custom designed for various applications and cleanliness levels.

A ceramic fuel & oils depth filtration medium does not have any of the following depth filtration constraints:

• No water sensitivity at all (most depth filtration medium block with water instead of particle contamination)
• No channel formation or medium collapse
• Structural integrity - handles surges, pressure and heat with ease
• Ultra low resistance to flow and differential pressure
• Vast dirt holding capacity and high efficiency
• Physically separating clogging of hydrocarbons

And iCerMax™ offers:

• Absolute surety of sustainable filtration – 100 % medium integrity
• Dirt remains in filter – non flexible / non channel formation medium - in other words no dirt surges or any seepage
• Higher pressures obtainable and filter integrity not compromised on pressures exceeding 1.3 bar - ceramics can handle high pressure, multiple surges, hammering effects, vibrations and high flow rates
• With higher pressures and its vast dirt holding capacity, bulk filtration is totally in a league of its own – setting new standards. With its high capacity it holds much more than current mediums do – thus it is ideal for refineries or bulk fuel tank installations
• Lower maintenance, less call outs, fewer resources required
• Wet start – no medium crunch or ripping due to initial flow surges
• Ideal for kerbside pump applications due to its low pressure and high surges nature
• Economical as it lowers cost per liter filtration with total confidence of sustainability

Depth filtration is closer to the perfect filter as it conforms closer to filter performance criteria. The effective repeatable micron beta rating is substantially higher than surface filtration and the ultra important beta stability (see ref) uncompromised with our filter media. Therefore capable of continually removing micron contaminant at higher efficiency with vast increase in contaminant holding capacity

Surface Filtration	Depth Filtration

Both hard and soft contaminants penetrate into the depth media. Captures contaminants within its structure, as opposed to on the surface. Allowing for long life with minimal increase in pressure drop

Depth filtration – the General preferred technology – uses a relatively large volume of porous filtering media to capture contaminants at various depths deep within the filter element as the fuel and oil passes through. Depth filters featuring this type of construction provide maximum contaminant loading and long service life with a greater filter efficiency over a variety of particle sizes.

Semi-solid contaminants will penetrate the media and not glaze-over the surface as per surface filtration.

”if it flows through iCerMax™, the cleanliness levels are improved and sustainable, with depth filtration cleanliness levels”. The Ceramic medium simply can’t be compromise and thus it provides surety on sustainable filtration

• Depth Filtration not surface filtration
• Sustainable cleanliness levels with a single pass-100%
• High flow rates even with surges
• No channel formation or medium collapse
• Structural integrity – handles surges and contamination caking with ease
• High or low pressures, no element collapse
• Ultra low resistance to flow and differential pressure
• High efficiency - 100% sustainable
• Non flexi medium – improves filtration efficiency
• Vast dirt holding capacity -Long filter life: No water sensitivity
• No water or chemical sensitivity
• very small pores in the media are not blocked by large particles
• Physically separating clogging of hydrocarbons
• Even porosity throughout the medium
• Heat shock resistant –hot/cold/hot/cold etc
• Temperatures of 1500 c
• Manufactured to ISO 12000, ISO 12001 and ISO 14000 standards
• Excels in all of the eight main filtration criteria

Benchmarking sustainable cleanliness levels in filtration of:

• Fuel (diesel, petrol & biodiesel)
• OIL (hydraulic, gearbox & engine)
• Coolant, Air, (liquid or gas)
• Industrial filtration

It is structurally sound and can’t do the following:

Filter Performance Monitoring –Cellulose & synthetic medium will “break” due to excess contamination and dirt -holding capacity limitations, surges, pressure variances, water, bio diesels, surfactants, alcohol, heat, biocides, etc. – iCerMax™ ceramics simply can’t and don’t break as they are not subject to these limitations. iCerMax™ ensures sustainable filtration even on a single pass.

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Leading world independent test centre IFTS, where all the "leading brands in filtration" are tested

Below is the actual test screen as per IFTS in France, a world renowned independent test facility, which illustrates that our iCerMax™ simply is a superior filtration medium that sets new market standards in sustainable efficiency in filtration.

Determination of Filtration efficiency and the retention capacity in diesel fuel
According to SAE J 1985 Single pass test
Online particle counting by light extinction

Please note that at 7.8 bar there is absolute no medium compromise and there is a 98.54 % efficiency at ≤4 micron.
Efficiency unmatched when 245 699 particles less than ≤ 5 micron is injected on a single pass and only 3515 particles passes through. This is simply in a league of its own.
Normal fuel filtration mediums, even synthetic, would have been compromised even at a third of these extremes. iCerMax ™ offers excellent initial filtration efficiency and will ensure sustainable cleanliness levels throughout its entire lifecycle. It offers insurance against third party fuels. As demonstrated above the ceramic medium offers total sustainable cleanliness level surety. With the advancement of equipment technology and the associated running costs thereof, intermittent filtration is very costly and directly affects various areas of your business.

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Filtration Media Integrity


TOO MANY LARGE PARTICLES CAUSE THE FILTERS TO PLUG.
This results in large numbers of particles being forced through.
This gets progressively worse as the differential pressure across the filter increases.
Vibration, medium flexing & surges accentuate the problem. –
iCerMax™ doesn’t have this problem as the ceramic medium simply can’t be compromised, even at the filter’s saturation point.

How long do you have effective 1 Micro filter Filtration taking into account all the multiple factors that impact on cellulose & synthetic filtration medium?
What is your filter’s official dirt holding capacity in ideal conditions?
How sure are you that your equipment’s filters are not compromised during time based service intervals? Simply install iCerMax™ filters next into your equipment and extend the economical lifecycle of your equipment.

iCerMax™ sets new market standards for:
Bulk tank filtration
Kerbside pumps
Filtration of 3rd party fuel - ensuring cleanliness levels on equipment
Sustainable filtration surety at bulk tanks, mobile bousers and on equipment.

Filtration impact
The cost of bulk filtration or additional pre-filter filtration, is a fraction of the down stream negative impact on equipment, if there is inadequate, non sustainable or even no bulk filtration. All filters today have excellent efficiency, but have capacity constraints / limitations that are exacerbated by surges and vibration. These capacity constraints in high quality filters are typically from 50g in trucks (440 hp) spin-on to 2kg in high quality bulk tank filters. This is concerning if it is taken into
consideration that every 50 liters of diesel is allowed 1g of dirt, on a 24mg / kg official fuel specification at oil company point of sale.
Filters are more compromised on capacity than we realize in normal day to day service intervals.
This is frequently discussed in the press (read articles on our website)
The actual cost is neither unknown nor quantifiable, but filtration companies estimate that for every R1spent on filtration, R10 is saved. The lack of adequate or sustainable filtration has a direct proven impact on:

• Economical life cycle of equipment (minimum 20%)
• Maintenance cycles
• Engine failure - 70 % of engine failure is due to the Fuel system or heat
• Breakdown direct and indirect costs - Utilisation of equipment
• Fuel usage/ efficiency, especially later on in lifecycles 5-15%
• Soot / carbon build up, fuel dilution in oils
• Emission carbon footprint

The above impact on operational and capital costs are material, but we don’t comprehend the full impact as it is budgeted on the way we are used to operating. The current development into more advanced technology is going to be more of a culture shock, than the first advancement from ADE engines.
Some of the large mining groups are starting to materially invest in filtration, as they have realised the direct impact on their operational costs through case studies. Our medium does not compromise, even at filter saturation point.

Our Competitive Advantage is that our Brand of Products are unique and utilise patented concepts that provide both cost and functional benefits. They also compliment one another to provide a total solution to contamination, both particle and water in fuels & oils, materially lowering operational costs and extending the economical lifecycle of equipment.

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Bulk Tank Filtration

Bulk filtration at main fuel and oil tanks
Bulk filtration is mainly overlooked in the market place, and either doesn’t exist or is inferior. Non sustainable filters are installed, that simply don’t have the dirt holding capacity nor handle the multiple surges or are inadequately maintained. This practice places vast pressure on the OEM filters of equipment and is directly responsible for warranty claims, the shorter economical lifecycles of equipment, higher maintenance costs and poor fuel consumption figures. Both water and particle contamination needs to be addressed on a sustainable and economically viable basis, with ease and clear maintenance intervals. There are multiple sites where the pressure gauges indicate positively that there is no flow restriction and that filtration is in progress .But yet the filtration medium is totally compromised .iCerMax medium’s integrity can’t be compromised . The gauges will indicate the true reflection of dirt contained without any filtration medium compromise.

iCerMax™ ensures that if liquids flow through the depth ceramic medium, the cleanliness levels are sustainability improved and unconditionally obtained. The iCerMax™ medium simply can’t fail and the pressure gauges provide an accurate reflection of the filter’s lifecycle.

All-in-one iCerMax™ “Plug and Go" Combo Skid System
This unit offers the complete solution for addressing bulk tank contamination (both particle and water). It does so cost effectively with long maintenance intervals & low running costs and with easy installation.

	Only Connect External Hoses	Mini Mesh Sample Units
	Gauges to Monitor	Auto Water Dump Unit

The iCerMax™ ceramic steel filter and coalesce water separator is fully assembled on a steel frame with all connections, internal hoses, gauges and sample units installed. Only connect the current dispense hose to the dispense connection and connect the hose provided to the inlet connection. Secure the unit to the floor and it is fully installed. Addresses water and particle contamination at main source, lowering the overall contamination count, lowering downstream filter compromise on capacity and sustainability improving overall cleanliness levels.

• All in one solution (particle & water)
• Own pump, option (electrical or diesel)
• Easy installation and mobile if required
• Minimal maintenance, long service intervals
• Enclosed steel cage (security &simplicity)
• Cost effective – low running costs
• Kidney filtration, fills or dispenses bulk tanks
• Fitment to 4/3”, 1” or 11/2 “dispense hoses
• Frame measures 970 x 815
• Flow rates to 150 liter p / minute

Fuel skids custom made
There are various combinations to accommodate your specific requirements, with our ceramic filtration medium; we can offer direct unique benefits.

• 500 to 75 liters per minute.
• To accommodate high contamination levels in Africa (Water and Particle).
• ACCURATE pressure indication of filter media integrity (see Gauges Filtration Monitoring below)
• TOTAL sustainable cleanliness levels
• HIGH pressures up to 8 bar
• Frequent stop /start surges no compromise to ceramic medium – (see impact of stop start and surges on media below)
• Mobile units
• Easy installations

iCerMax™ - Ceramic core steel filter for bulk tanks

	Heavy steel vessels With this filter, particle contamination is addressed on a 100% sustainable basis due to the utilisation of iCerMax™ depth ceramic filter elements. It offers sustainable depth filtration throughout the filter's entire lifecycle. The ceramic medium is never compromised during filtration, as it can't form channels, rip, and tear or simply break, as it is a non-flex medium. This is why we are able to fit mini mesh sample units as standard. "If fuel / oil flows through iCerMax™, the cleanliness levels are being achieved". This filter possesses vast dirt holding capacity and was "IFTS" tested in France, and consists of a 3 x 1m long iCerMax™ core with lower required maintenance intervals and is fitted standard with differential pressure gauges. The flow rates on main fuel tanks on delivery or dispensing can be maintained. Units are available in three 3m, seven 7m or nine 9m iCerMax™ ceramic core. Filters fuels, oils, acids, water, gasses and air. Custom built to accommodate any flow rate & vast pressures Mini mesh sample units (standard on inlet & outlet) - to monitor cleanliness levels Industrial flanges ,Viton seals Built to pressure vessel standards
	Light Steel vessels This is extremely important in an African environment due to the vast quantities of particle and water contamination that compromise normal surface filtration. iCerMax™ ceramics, due to their nature, provide depth filtration with vast dirt holding capacity and the medium can't form channels nor be compromised. Fuels, oils, water, air, gas Easy installation on 1” or 1½“ Long life cycle Easy maintenance High flow rate Mini mesh sample units (standard) 2.7m iCerMax™ ceramic filter core Unequivalent Bulk pre-filter or filter Cost effective both in terms of installation and maintenance intervals.
	iCerMax™ - Ceramic filters for kerbside pumps Historically these have been problematic to filter, due to low pressure flow, stop / start surges that rip / tear the filtration medium and insufficient dirt holding capacity. Market spin-on filters simply can’t obtain cost effective sustainability. Ceramics are ideal for this application. We have various product options to effectively address kerbside filtration on a sustainable basis.
Automated coalesce water separator, 150 liters per minute – no cartridge required, automated water dumping The “silent killer” – Water has inferior lubrication properties, pressure, corrosion, fuel oxidation, viscosity and bacterial & fungi .etc. Utilise the coalesce principle - a reliable, proven and effective method. Highly effective water separation without the cost of expensive cartridges that collapse with a high volume of water concentrate and whose efficiency is compromised by particle contamination. Automatically dumps water in 500ml intervals. Highly effective separation up to 150 liters per minute Ideal” policeman " to combat the practice of diluting fuel with water during delivery to main tanks and to indicate dilution on equipment - an African practice of note. Ideal for Africa as the separator can consistently handle up to 5% of water per volume. Most cartridge filters simply collapse or saturate at these water volumes No costly cartridge that has water absorption limitations Automatically “dumps” water with iCerMax™ technology into a separate flameproof container and no operator intervention is required Long life due to robust construction Possesses no water absorption media which is sensitive to flow rate and surges Particle contamination negatively effects the water retention ability of cartridges (wax & coalesce fibre media) Flow rate - 150 litres per minute Volume size – 600 X 600 X 1100 Weight – approx 65kg Allows effective upstream removal of water contamination before entering the equipment’s or vehicle’s fuel tank. Highly effective at any sample interval, during and throughout operation Not a water or wax based absorption or coalesce cartridge media whose efficiency deteriorates as it reaches saturation or is diversely affected by dirt contamination and then has a direct drop in efficiency Applications Main fuel tanks water separation /filtration - if the flow rate is higher than 150 liter –fit two units in parallel Ideal for kidney systems as utilised in– iCerMax’s fuel kidney recirculating filtration systems for fuel bowsers and genset ‘s There is a full range of smaller units for onboard vehicles /equipment available that caters for all flow rates and mobile fuel tanks.
Spin-on filters at bulk fuel and oil tanks iCerMax™ ceramic spin on filters can fit directly to your current filter housing, as they come in a full range of various head sizes. Ideal to filter fuels, oils, gasses and air. iCerMax™ can handle the multiple surges, pressures, high flow rates and vast dirt capacity with ease on a sustainable basis. ”if it flows through iCerMax™, the cleanliness levels are sustainably improved, with depth filtration cleanliness levels”. Ceramics medium simply can’t compromise; it provides surety on sustainable filtration. Normal filtration medium, even expensive synthetic filters, will compromise which leads to intermediate filtration. The lack of sustainable filtration on bulk tanks places enormous pressure on OEM equipment filters, as both the pre-filter s and filter have dirt holding capacity constraints. Struggling to “cope” on the mere capacity of contamination levels it has to accommodate, will compromise the filtration medium. If the OEM equipment filters utilise wax, silica or cartridge based filters for water separation, it is directly compromised by particle contamination to perform this function. This leads to direct water contamination. TOO MANY PARTICLES CAUSE THE FILTERS TO PLUG. This results in large numbers of particles being forced through. This gets progressively worse as the differential pressure across the filter increases. Vibration & surges accentuate the problem. iCerMax™ simply can’t compromise
All-in-one-mini iCerMax™ “Plug and Go" Combo system This unit accommodates smaller flow rates as the coalesce water separators capacity is limited to 75 litre per minute and utilises ceramic spin-on filters for particle filtration. Ideal for mobile tank applications iCerMax™ ceramic & desiccant air vent breathers for bulk tanks The atmospheric breather is an air, dirt and water filter/breather for use on the tank vent of diesel fuel storage tanks both above and below ground. The particle filter media is the iCerMax™ Depth micron filter along with a five litre of desiccant, which removes moisture from the air going in and out of your tank. By replacing your current tank vent (which keeps out only bricks and stones) on your diesel fuel storage tank with the iCerMax™ breather, you virtually eliminate a primary source of dirt and water contamination in your fuel. iCerMax™ utilises a unique three valve system to ensure longevity of the desiccant, even at high humidity levels – coastal regions or during rainy seasons. Why upstream filtration? The more contamination is excluded from entering the fuel and filtered upstream the more reliable and effective the downstream filters can “cope” with particle and water contamination levels.

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Equipment Filtration

On equipment filtration range
This filtration range does not replace OEM filters, as it will compromise your warranty.
They are additional pre-filters to ensure your OEM filters are not compromised on capacity and ensure the efficiency of OEM standard fitted filters. They allow OEM filters to function in ideal conditions.

The iCerMax™ ceramic filters extend your economical lifecycle of engines and equipment due to the inherent characteristics that ceramic filtration offers. The iCerMax™ is a “Bulldog “when it comes to Africa’s contamination levels.

It is widely accepted that the additional cost of implementing these filters, will be recovered via: the longer economical lifecycle of equipment, less equipment failure and your fuel bill variance alone will pay the associated costs, due to less internal engine wear and extended combustion efficiency

iCerMax™ Duo system
Particle and water contamination in fuels

An ideal pre-filter for particle and water contamination in various harsh environments. Complete contamination buster.

• Utilises iCerMax™ depth ceramic medium for particle contamination and a coalesce water separator.
• Guards against “third party” diesel, where no control on cleanliness levels from bulk fuel tanks exists
• Highly cost effective for superior filtration.
• Easy to fit
• Used on all types of equipment, trucks or gensec’s
• Three filters in the DUO range
• Flow rates from 1.2 L/min, 3.7 l/min, Up to 681 LPH = 11.35 L/ Minute

Used on all types of equipment, yellow goods, trucks, bakkies or gensec’s

iCerMax™ ceramic spin-on filter
Fuels, oils, liquids, gas and air

The cellulose or synthetic medium of today's filters have excellent efficiencies on micron ratings but have an "Achilles heel" in terms of capacity. The iCerMax™ ceramic spin-on offers the ideal protection from the limited dirt holding capacity of today's filters. The ceramic pre-filter has a vast dirt holding capacity, a multiple of that of normal surface filters. Up to three times that of synthetic surface filters. This ensures that your standard filters are not compromised on capacity.

"If this filter blocks during its lifecycle, we have saved your equipment from failure or expensive maintenance and down time. The ceramic filtration is 100% sustainable. The spin-on filters fuels, oils, gasses, air and water and is available in various head sizes, i.e. ¾ “ 1”, 1,¾“, M16 TPN 12, and with the option of a bypass valve. We can also supply our own heads in various sizes. This spin-on ceramic filter is highly recommended for the rental, construction and mining markets or anywhere where external fuelling sites are used or where third parties supply fuel.

The iCerMax™ ceramic core is 225x76x56 mm

iCerMax™ Reusable spin-on

This is available in the same spin-on sizes as a normal spin-on and simply fits on normal readily used spin-on heads.

Multi versatile filter for filtration of fuels, oils, gasses & air.

Works on the same principle as a normal spin-on, except the spin- on can be opened and one simply replaces the iCerMax™ ceramic core cartridge inside the filter.

Due to the fact that the iCerMax™ spin-on can easily be opened up it is ideal to monitor the amount of particle contamination in any specific area. One micron filters commonly surpass their dirt holding capacity and are compromised in field applications.

iCerMax™ Reusable spin-on is available in aluminium or synthetic housings.

Easily monitored via pressure gauges

FBO with iCerMax™ ceramic filter cartridge

• Filters diesel & hydraulic oils
• iCerMax™ ceramic medium can be used for various applications
• Counteracts contamination which happens in various combinations :
  • water (coalescing or absorption media)
  • particle: Micron rating (1, 5 & 25)
• Long life –cost efficient
• Pressure gauge & water glass
• Ideal for large equipment with high flow rates

Paper depth Filtration conversion to iCerMax™ ceramic filtration medium

Modification kit easily converts the current filter housing to accommodate iCerMax™ ceramic filtration medium.

• Easy adaptor kit for current filter housing
• Accommodates the following :
  • TK 1 150 mm yellow
  • TK 2 350 mm yellow
• Sustainable filtration
• No channel formation or medium separation
• Low resistance to flow
• iCerMax™ ceramic filtration

Universal iCerMax™ ceramic air filters and air breathers

The iCerMax™ Depth micron filter prevents particle contamination from the air going into your tank. By replacing your current tank vent (which keeps out only bricks and stones) on your tank with the iCerMax™ breather, you virtually eliminate a material source of dirt contamination into your oil/fuel tanks.

• 100% sustainable depth filtration
• Depth iCerMax™ ceramic core – 80x60x40
• Oil reservoirs, mobile tanks & fuel tank breathers
• Easy to fit –Goodyear hose & adaptors
• Long service life
• Easy maintenance- replaceable core

Dry air filters are used for air suction on bulk fuel tanks, mobile fuel tanks, truck fuel tanks, oil tanks, compressors, Breather tanks and close containers.

As the truck drives the fuel is sucked from the tank and this creates a suction power of air through the breather pipe and all the dirt and dust particles are then sucked into the tank through the breather pipe.

To exacerbate the situation these breather pipes are virtually always behind the wheels, which generates a dust cloud in conjunction with the truck’s motion.

“Under normal highway conditions the air consumed in a 16 litre engine contains almost 20 kilograms of dirt/contaminants per 100 000 kms.” - Fleetguard

They are designed to prevent contaminants from entering fluid reservoirs as differential pressures occur through thermal expansion, contraction of the fluid and mostly during driving or operating.
They directly reduce particle contamination, help provide longer filter life, and reduce equipment wear.

Atmospheric iCerMax™ depth micron breather -air ventilation on oils (particle and water)

They are designed to prevent water and contaminants from entering fluid reservoirs as differential pressures occur through thermal expansion, contraction of the fluid and mostly during driving. They directly reduce particle and water-contamination, help provide longer filter integrity /life, and reduce equipment wear. Directly lowering particle and water contamination.
To achieve this utilise the iCerMax™ ceramic filtration medium.

Mobile tanks

There are various case studies on equipment failure directly contributed to contamination from mobile tanks.

To enable adequate filtration one requires pressure pumps and sustainable micron filters .To fit hand pumps with ” mesh” filters is simply inadequate to obtain any cleanliness levels.

Contamination blue print
It is imperative to address the entire contamination blue print for optimal results.
From bulk tanks, mobile tanks and physically on the equipment. If one ignores any of the major steps, it places critical pressure on the other areas. This is why there is excessive wear and failure of equipment, as the OEM filters simply can’t cope with the pure capacity of contamination, irrespective of their micron rating or filtration medium. BUT the smaller the micron rating the worse the capacity constraint, being a paper or synthetic filtration medium , as the shear particle volume increases exponentially .This is where iCerMax™ is setting new standards in sustainable micron filtration.

The rule is simply: prevent contamination (water & particle) from entering and lower contamination levels throughout the handling process.

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Kidney Filtration

Fuel & Oil Kidney Systems
Flow rates from 40 – 150 ltr per minute in oils and fuels

Fuel/Oil Portable Kidney filtration trolley @ 40 litres per minute
Used in oil transfer and cleaning of tanks. Advisable to utilise even with”new” oils, as the oil is below required cleanliness levels, especially in hydraulics.

• Used for both diesel and hydraulic oils
• Transfers fluids and cleans the fluids in the same operation; 40 litre p/minute
  • iCerMax™ supplies prefilter cartridges with vast life cycles and ensured sustainable cleanliness levels for optimal performance of the delivery filter to remove water.
• Removes water effectively by coalesce, adsorption or separation medium, full flexible range of cartridges for delivery filter
• Only removes harmful contaminates and will not disarm the additive pack on new oils
• Cleans until it is in “spec” with iCount indicator
• Strong powerful motor & industrial construction
• Cost effective – lasts multiple lives of the spin-on
• Customised with pressure gauges and mini mesh sample units
• Large range of cartridges with various microns ratings

This system is of industrial quality with high efficiency and is cost effective. It is mobile and most importantly user friendly.

Fuel/Oil Portable Kidney: filtration trolley@ customized litre per minute
Transfers fluids and cleans them in the same operation, example from delivery drum to equipment.
Custom built for various applications or as per client’s own specifications

• Ideal for “breaker oils “ , highly contaminant liquids or large volumes at high flow rates.
• iCerMax™ supplies pre-filter with vast dirt holding capacity and ensuring sustainable cleanliness levels during the entire filtration process. With 2,7m iCerMax™ ceramic core. Fitted with pressure gauges and mini mesh sample units.
• Removes water by coalesce, absorption or separation medium, full flexible range of cartridges for own custom delivery filter. FBO ,spin-on, etc.
• Removes harmful contaminates only, will not disarm additive pack on new oils.
• Robust, solid industrial construction.
• Sustainable cleanliness levels on particle contamination assured.

Combo unit
Bulk tank kidney filtration for fuels at 150 litres per minute

• Water and particle contamination
• Kidney filtration for bulk tanks
• Timer function on pump
• Long maintenance intervals
• Sustainable iCerMax™ filtration
• Ideal for gensec’s and large bulk tank applications

See Combo unit in bulk filtration section for more detailed information

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Industrial Filtration

The industrial application for the iCerMax™ ceramic is astounding.
iCerMax™ is made from a wear lining ceramic composition with a multitude of inherent product characteristics. We are able to utilise this ceramic even were other ceramics failed, due to its excellent even porosity, heat shock endurance and physical structural strength compatibilities.

Manufactured to ISO 12000 ISO 12001 and ISO 1400 -size tolerances being within microns.

• iCerMax™ filters almost any liquids, gasses & air.
• Sustainable filtration, with no medium compromise
• Single pass cleanliness levels
• Even porosity throughout the medium
• High flow rates
• Handles extreme pressure Surges
• Operates in extreme high pressures, but only requires low pressure to filtrate due to low differential medium resistance
• Heat shock resistant - applications up to 1600c - doesn’t alter porosity
• Acid filtration applications
• FTA approved for food application filtration

iCerMax™ as a filtration medium offers multiple advantages over conventional industrial filtration media. Flexible housings and sizes - custom made to client’s requirements.

Heat shock test – Heat iCerMax™ to 1000c in an oven and then drop it straight into cold water.
During this test the iCerMax™ ceramic experiences no negative effect , with its porosity and medium remaining totally in tact.

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Benefits of Filtration

Lack of sustainable filtration and its direct negative impact on revenue.

Filtration is all about the reduction of wear in Fuel systems and the optimisation of their economical lifecycles. Sustainable filtration in fuels and oils at correct cleanliness levels, easily extends the economical lifecycles of machinery by 20% and lowers their direct operational costs.

Combustion efficiency and lowering component wear is the prime objectives .We don’t understand or realize the material impact contamination has on our equipment, as the focus or budget has historically been lacking. The advancement in equipment technology requires improved cleanliness levels. Actual case studies have proven that sustainable cleanliness levels are becoming a necessity and that filtration pays with multiple returns in various direct and indirect benefits .The lack thereof impacts on various budgeted costs or has dire consequences.

To demonstrate this, consider the negative impact of current inadequate filtration systems on the fuel systems and economical lifecycles of your equipment.

Direct impact in fuel system on all of the following crucial elements:
Note: Contamination wear affects the entire fuel system and all internal combustion parts directly. Replacing the injectors doesn’t reverse the impact of contamination damage. The sleeves, piston, piston rings, bearings are all affected directly by contamination abrasion, heat disbursement and increased soot ,as the contamination passes through to the exhaust system.

Injector life > There is a direct correlation in wear and the sustainable cleanliness levels of fuels .Injectors are vital for optimal performance ,as they are directly responsible for the continuous optimal diesel spray pattens and the maximum possible oxidation of the fuel. Both are directly negatively impacted on by wear on the injectors.

Spray pattens > injectors today have up to 12 spray holes in one nozzle and inject up to 6 to 9 times per single piston burn cycle-CAT .i.a.w very advanced. If this is directly adversely affected this leads to poor fuel oxidisation.

Fuel oxidisation> It is vital to optimise and maintain fuel oxidisation as it impacts on all of the following:
Temperature disbursement Delayed or heat build up due to droplets, or worse, streams of diesel, leads to combustion chamber failure. The combustion heat does not timely disburse, resulting in the piston and sleave deforming, due to excessive heat.
Fuel consumption The wear of injectors and the internal combustion chamber directly impacts on fuel efficiency. In actual case studies this were conservatively 5 -12% over a timeline. This cost alone justifies attention and an active focus on filtration. Fuel saving alone pays for filtration costs, if not budgeted. Unburnt fuel simply increases heat, dilutes oil and exits thought the exhaust system.
Soot formation Soot is a highly abrasive substance and naturally occurs during diesel combustion, however improperly burnt fuel drastically increases soot. Soot also affects the spray pattens directly, as it deposits on the spray nozzle and increases internal abrasion wear, everywhere.
Oil dilutions Fuel and soot dilution, through poor combustion, negatively affects the functional service intervals and effectiveness of oils. This increases internal wear and leads to premature failures.
Toxic emissions Direct result of bad combustion. The excessive soot exiting and depositing on the exhaust is a clear indication of poor combustion.
Engine Lifecycles are directly economically extendable by a minimum of 20%, if fuels and oil are sustainably filtered to the required cleanliness levels. Fuels should be a minimum of
10-8 mg/kg at bulk tank levels, this is the current European specification.
Engine failures have a direct correlation to both particle and water contamination. Contamination failures are totally preventable by the implementation of a contamination blueprint. Even small improvements assist with filter capacity constraints.
Running costs are materially affected but are mostly budgeted for. We are used to treating the symptoms, not the cause, due to lack of sustainable cleanliness levels.
Running, maintenance, fuel, down-time and financial replacement costs are all directly materially impacted.

What is normal wear and how do we bench mark it? Firstly benchmarking is complicated due to a multiple of variances. However through case studies and multiple fuel sampling it is clear that contamination levels are simply above adequate. Most mining sites run between 50 -75 mg/kg. This is simply not sustainable in the future.

Minimum 20% increase in economical lifecycle on all equipment is achievable, especially on the current contamination blueprint low base levels, which are totally achievable.

Test on filtration:

1. What are your current cleanliness levels on fuel and oils?
2. Were correct test procedures followed for representative sample extraction?
3. What does the OEM suggest in terms of cleanliness levels?
4. Who actively monitors the cleanliness levels?
5. Whose responsibility is it to maintain tank farms?
6. Who is monitoring the changing of filtration filters and air breathers?
7. Were these filters in bypass or filtration medium compromised?
8. What is your contamination blueprint?

Currently most bulk filtration is totally inadequate or non-existent, placing severe capacity constraints on downstream filters. The filters simply can’t handle the sheer volume of particles, particle size and water contamination it has to contain. Downstream filters have capacity and filtration efficiency constraints. When compromised on capacity, they simply go to bypass mode or medium compromise occurs. iCerMax™ ceramic filter medium is 100% sustainable, as the medium offers depth filtration without channel formation or medium compromise - it can’t even flex. That is why dirt restrained by ceramics, stay in ceramic filters. Vast dirt holding capacity, flow rates, service intervals, surges and sustainable cleanliness levels are all benefits of iCerMax™ .

The sole intent of this is to bring awareness to contamination and the impact on equipment.
We’ve read about contamination for years, in various publications, but seldom take correcting action .This is one of the easiest projects to implement - a contamination blueprint, with a high return, as the current market base is substandard or neglected. It is the market’s view that it is the responsibility of third parties to combat contamination. The bad news is they won’t, if they are not reimbursed for implementing and maintaining these cleanliness levels.

Facts on filtration

It is interesting to note according to OEM’s that over 75% of all engine failures is directly contributed to the fuel system or heat.

Mining houses are starting to understand the value of sustainable filtration, taking ownership of their bulk tanks and investing into cleanliness levels on oils and fuels.
This is due to a learning curve based on actual case studies and the realization of the technical advancement of equipment. Kumba –Sishen site is a model example.

Lack of sustainable filtration and inadequate design on main bulk tanks and mobile tanks leads to capacity constraints and compromises on the equipment’s water and particle filters. Contamination levels must decline, not increase during handling. A few spin-on filters or single bulk filters are inadequate to sustain the required cleanliness levels.

Filters today have efficiency – micron rating, if matched correctly BUT capacity is the “Achilles heel”, mainly due to capacity constraints and surges.

“The fuel systems of most diesel engines are equipped with water separators and two-stage fuel filters. Machine manufacturers add these or other fuel filtering systems to their equipment. Such devices will handle small amounts of contamination, but continued or excessive contamination of the fuel system will result in accelerated wear of the engine and the fuel system components “ - Source: DEEP: intense multi million dollar study on: Diesel Emissions evaluation Program - www.deep.org

A 420 hp truck is fitted with a world leading brand filter with a maximum dirt holding capacity of 50g (premium to market standard). The SABS contamination specification is 24mg /kg, which translates (0.835) to 21mg/ltr. This means that every 50 ltr of fuel ads 1 gram of dirt to the fuel system.
Which translated means that in every 2500 ltr of diesel there is 50g of dirt, as is allowed per the contamination specification, thus the filter can possibly be compromised on capacity. This directly indicates that the filtration systems on trucks are periodically compromised, which leads to internal wear and which is responsible for premature failure. Especially if service intervals are taken into consideration based on distance and not volume of dirt retained in the medium. There are case studies where one BAD forecourt refueling has lead to engine failure.

Clean new oil dispensed from “new” drums are not within the required cleanliness specification of OEM‘s, especially in hydraulic oils.

The cost benefit ratio 1:10, which is fractional as to what contamination is costing in parts, fuel consumption, down-time, the logistics around breakdown, production losses, failures, back-up equipment and the lifecycles of equipment. The worst is that we delegate this
important function to third parties without accountability or reimbursement for implementation and maintaining proper sustainable cleanliness levels in our fuels and oils. Take ownership of your contamination, the rewards are more than merely financial.

We know from history that older trucks use more fuel than when they were new. One major contributor to this is the internal wear inside the engine. The contamination that has over time impacted negatively on the components, the injectors, sleeves, piston rings etc,
By introducing sustainable filtration, the wear patterns are materially reduced, therefore the fuel saving of 4-6% pays for the filtration costs over and over again.

Contamination is liquid sandpaper – water & particle - which directly affects efficiencies, warranties and lifecycles

Material balance equation of contamination
Ctn = Cto + Ca-Cs
Total contamination = Start contamination + added contamination – removed contamination
The more you remove contamination at bulk tanks, mobile tanks and on equipment, the lower your total contamination at any specific point.

“Knowing the cleanliness level of a fluid is the basis for contamination control measures” Manufacturers specify optimum cleanliness levels for fuels, oils (engine, hydraulic & gear etc.)

Useful in warranty claims if one adheres to and implements these cleanliness levels on a sustainable level.

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Guage Filtration Monitoring - How Accurate Is it?

This is not an uncommon site, filtration both water and particle severely compromised. The filtration system filters installed, working indefinite.This can not happen with iCerMax™ ceramics as the medium do not compromise, and the seals are designed not to compromise. Therefore the pressure gauges are a TRUE indication and sustainable filtration not compromised at any time.

Filtration cost in budget & working - the Gauges indicates "filters working with in working pressure"
is this necessarily a true indication?

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What is the impact of stop start and surges on media?

An operating system is at risk whenever the critical contamination level is exceeded

Contamination levels determine the individual component’s wear rate (useful life) and ability to perform as intended (functionality).

System design, filter performance and maintenance practices largely determine the contamination level in a system.

Filters are expected to maintain contamination below critical tolerance levels. Filter performance in a dynamic operating system is variable based upon flow rate and flow density, changes in flow rate (duty cycle), viscosity, fluid and structure borne vibration (Hz), contamination levels, ingression rate and several other conditions. All filters are subjected to some form of system dynamics.

Filters encounter frequent and rapid changes in flow rate accompanied by frequency changes. Bulk tank filters typically experience dynamic conditions during start up and shut down.

Two key characteristics of filter performance are capture efficiency and retention efficiency.

Capture efficiency can be thought of simply as how effectively a filter captures particles while Retention efficiency is a measure of how effectively that filter retains the particles it has captured. A filter is not a black hole, and its performance must not be based solely on how efficiently it captures particles. If not properly designed and applied, a filter can become one of the most damaging sources of contamination in a system.

• The phenomenon of releasing captured contaminant is called unloading, and can result in temporary contamination levels, that are well above the critical contamination tolerance level of a system.
• This phenomenon can best be described as "contaminant unloading". As the Filter element captures more dirt, greater amounts may be released back into the system that it is installed to protect when the element is subjected to a dynamic flow condition and change in differential pressure across the element. Unloading may also occur when the flow rate changes from high flow to low flow, represented by the alternating smaller peaks . The filter element typically recovers shortly after the dynamic condition, but highly contaminated clouds of fluid from contaminant unloading can cause severe component damage and unreliable system performance.
• Excessive unloading in the early stage of element life may be symptomatic of an element that will eventually fail and lose it’s efficiency all together (media breakdown).

• During the restart-Cold start test there is no contaminant being injected so any particles measured were already in the system or were released by the element (unloading). The result is a temporary state of highly contaminated fluid that has resulted because the filter element did not properly retain the dirt.

Filter element performance is at it’s worst during flow changes isolating those sequences can help predict performance in dynamic flow systems

The advantages of using ceramic filters:

• Multi- functional wear resistant (Pyrites) ceramic filtration medium – ideal for air, gas & liquids or any combination of these and for industrial applications.
• There is surety of sustainable cleanliness levels, compared to other market filtration mediums, as iCerMax™ ceramic’s don’t form channels, don’t have medium migration and there is no severe unloading or element collapse. iCerMax™ ceramics possess a non-flexi depth medium.
• Structural integrity, iCerMax™ eliminates filtration medium breakdowns or compromise caused by multiple surges , hammering effects, operating pressures ( high or low ), severe pressure variances, extreme heat -800 degrees plus , chemicals, surfactants ,water ,acids, biocides or expiry dates, etc.
• Excellent sustainable Capture efficiency –unsurpassed Micron ratings even under severe pressures and surges.
• Holding capacity and dirt retention (the main “Achillis heel” of various filtration mediums) are exceeded, as dirt remains in the filter due to the unsurpassed structural integrity of the filter medium i.a.w there is no costly dirt surges or any seepage that negatively affect or compromise the cleanliness levels.
• Reliable filtration monitoring sensors/ pressure gauges. As the medium does not compromise the filtration monitoring sensors reflect the actual real time status of the filtration process thus eliminating estimated change intervals based on shifts, volume, or on hourly or distance monitoring.
• Process applications efficiencies: the inherent characteristics of iCerMax™ allow for a functional optimisation design of processes, which requiring a superior multi functional filtration solution.
• With higher pressures/ flow rates and their vast dirt holding capacity iCerMax™ ceramics set new standards in bulk filtration sustainable cleanliness levels and totally in a league of their own.
  

Fleetwatch May 2009 - Diesel fuel and why engines fail - Patrick Swan
Fleetwatch - A few microns can punch massive holes At von Wiellig

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