Steel Pipe Forming
Company Name: EXL Tube (Steel Ventures)
Location: Kansas City, USA
Eclipse Product Installed: Steel Processing
Industry: Pipe Forming Mill
Process Type: Triple AM12 AutoMag Skid
EXL tube is a leading manufacturer of mechanical and structural steel tubing. The tubes, ranging from 1” (25mm) to 24” (600mm) diameter, are progressively rolled from flat steel plate. They are then seam welded to form tubes. During the rolling process the steel is flooded with 6% strength aqueous cutting coolant. The fluid is circulated via a 6000 gallon (22000 litre) holding tank, passing through in-line paper filters in an attempt to clean out any ferrous particles.
During the rolling process scale on the face of the steel peels off creating “Mill Mud”. Previous paper filters became blocked very quickly. High flow rates then caused the fluid to overflow, by-passing the filter and depositing ferrous contamination in the holding tank. In an attempt to find a solution, EXL engineers tried a more porous paper filter, this resulted in a similar end result. Smaller ferrous particles simply passed through the filter pores and settled in the tank.
Inadequate filtration presented many problems. The holding tank became clogged with solid “Mill Mud” and had to be dug out regularly, resulting in down time. In addition, particles re-circulated in the coolant damaging the product surface. Dirty coolant had to be replaced regularly and pumps/seals were subject to high wear, again due to being bombarded by ferrous particles.
As different types of paper filter proved inadequate the engineers looked for an alternative solution. However they were quoted $110,000 for an upgrade system based on barrier filtration media. Eclipse came up with a less expensive but more effective solution – a triple AM12 AutoMag Skid was installed. The AutoMag Unit is located above the coolant tank - It runs on rails above the tank with 2 drop pipes into the tank. The skid unit is moved up and down the length of the tank sucking up the collected ferrous particles. This is then cleaned by the Automag. The unit cleans 700 gallons per minute (2650 litres per minute) through 2 pumps and removes a remarkable 1000lbs (450 kgs) of ferrous solids every week.
Fitting the AutoMag Skid has dramatically increased the fluid life, improved surface finish on the tubes and enabled them to completely remove the paper filtration system. In addition is the ferrous waste is now sold as part of EXLs scrap reclaim programme.
EXLs Maintenance Manager commented “I cannot begin to tell you how much it has helped our operation, the magnetic filtration unit has been a real problem solver it has surpassed all our expectations. Its cured a 30 year plague!”
"We were delighted with the service provided by Eclipse Magnetics; from the initial site survey through to delivery."
"I cannot begin to tell you how much it has helped our operation, the magnetic filtration unit has been a real problem solver it has surpassed all our expectations. Its cured a 30 year plague!"
"This technology is economical, reliable and efficient. I believe that magnetic filtration technology is the future."
"Magnetic filtration has dramatically cleaned up our fluids and improved the surface finish we can offer. It extracts around 50Kg per day of ferrous waste."
"We chose Eclipse Magnetics to supply our housed grid because they are a respected and well-established brand. They offered us a very competitive price, and the process of ordering and installation was straightforward and reliable."
“We are delighted with the Automag installation; it’s solved all the problems we were having previously with downtime and maintenance costs. The filter means that we are able to use recycled water, which is saving us £1000 per week!”
"Here at Qualflow, we base our business on a philosophy of make the product simple to use, reliable and cost-effective. Eclipse Magnetics’ neodymium magnets offer the strongest magnetic performance, and are nickel plated, making them a cost effective.."
"The Ultralift Plus magnetic lifter from Eclipse Magnetics is the perfect solution for the pick-up and transportation of the ultrasonic calibration blocks in our facility"
"The result is an aesthetically pleasing system, which is effective in trapping metal contaminants and is easy to clean..."