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icerMax™: ff
iCerMax™ Ceramic Medium
Why Ceramic in Fuels
Bulk Tank Filtration
Equipment Filtration
Kidney Filtration
Lifecycle of Ceramic Filters
Fuel Cleanliness Levels SA
Diesel Theft Protection
Independant Tests
Benefits of Filtration
Gauge Filtration Monitoring
Contaminant Unloading
Industrial Filtration
Hot Gas Candle Filtration
 
Latest News:

New Distributors

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as official product distributors with their extended network
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New modular skid approach to bulk diesel tank filtration?
Totally flexible, easy to install and cost effective to address any possible bulk tank filtration site plan. Modular flexibility allows for upgrades and relocation of the filter combo skids to the actual contamination site or to new sites. Easy maintenance
read more >>
 
New iCerMax™ Duo onboard equipment
The “BullDog” of onboard filtration to protect against third party fuelling sites/diesel .A Blocked ceramic filter is cheaper and less hassle than a lost engine. Ideal to protect rental equipment .read more
read more >>
 
Protect against Fuel theft and dilution
IP & free Water test kits effectively address fuel theft through double unaligned physical barriers without affecting diesel flow rates.- iCustodian™
read more >>
 
New Kidney Filtration?
Fully automated cleaning system to ensure the diesel remains in an optimal condition. Early warning system on filter to warn operator that filter needs replacing and water needs draining.
read more >>
 
Electra mining Show

We thank the visitors to our stand
 
 
 
 

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

Ceramic Water Filter, Ceramic Filters, Ceramic Steel Filter, High Volume Ceramic Water Filter

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.

The importance of diesel fuel quality in modern engines performance by Patrick Swan and the benefits of ceramic filters in bulk filtration

How clean is your ”filtered” fuel, even after the bulk tank filters?

Summary on iCerMax™ Ceramic Depth Medium Filtration

Bulk Diesel Tank/Farm Filtration

Bulk Diesel Tank Filtration with a Modular Skid combinations Approach

Diesel bulk installation site in DRC addressing water and particle diesel contamination on a sustainable basis with a Ceramic filtration medium. Client installed this Ceramic filtration medium on all his African sites, including South Africa.

Diesel Tank farm filtration throughout Africa and other parts of the world where the cost impact of the lack of sustainable filtration is being realised.

We proprietary designed Six skid combinations, that are used in a modular basis in various easy to install combinations to address any African fuel contamination scenario. Various combinations address: vast daily volumes, high dirt levels and free water levels up to 5%, see attached modular installation combinations. These skids were designed in Africa for African conditions and maintenance standards.

ICerMax have 12 standard skid Combinations, to accommodate any flowrate, contamination levels (particle & free water) and service intervals scenarios with total sustainable cleanliness levels – see details in Product listing

3 “ flow rates and Wiggins installation are easily addressed with no system design costs and minimal installation costs. The systems are fully installable by clients, as installation simply requires the connecting of various fully pre-assembled skid combinations. Modifying the installations or reallocating skids is easy with low costs. Individual skids or custom combinations are available in secure containers

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.

Diesel Ceramic Filter iCerMax Ceramic Filter
Only Connect External Hoses
iCerMax Diesel Ceramic Filter
Mini Mesh Sample Units
Ceramic Steel Filter
Gauges to Monitor
Diesel Ceramic Filters
Auto Water Dump Unit

The iCerMax™ ceramic steel filter and coalescer 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 Water Filter Ceramic, Ceramic Core Steel Filtercontamination 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”, 11/2" or 3" dispense hoses
  • Frame measures 970 x 815
  • Flow rates 40 to 1300 liters per /m

Water Filter Ceramic, Ceramic Core Steel FilterFuel skids to sustainably address any diesel fuel bulk tank farm
Filter combinations fitted onto a skid to address any bulk diesel tank farm scenario, in various modular combinations, easy to install, relocate or upgrade tank farms.

  • 3M steel ceramic filter, Bag filter & Auto water coalesce separator
  • 7M steel ceramic filter, Bag filter & Auto water coalesce separator
  • One bag filter and one Auto water coalesce separator
  • Two bag filters & Two Auto water coalesce separator
  • One 7M Steel ceramic filters & Two Auto water coalesce separator
  • Two 7M Steel ceramic filters & Two Auto water coalesce separator
  • Four Bag filters

The filters are fully assembled with ceramic filter & bag elements. Only connect the inlet pipe and outlet pipe to the pump and dispense nozzle. A total plug and play system with other skids in modular combinations, if required, to sustainably address any diesel tank farm scenario.

For more information, click here to View Diagrams

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
  • Mobile units
  • Easy installations - modulae bases

It is advisable to fit an iCerMax™ bulk combo unit to the bulk fuel tanks and the iCerMax DUO on to equipment - The end result is lower operational costs all-round, and a multi stage filtration approach, which leads to effective and sustainable filtration. It is expensive to create bottle neck filtration and then to rely on filters with black hole characteristics which allow unlimited superfluous use, due to compromise of their fiber/synthetic mediums, without obtaining the required cleanliness levels.

iCerMax™ - Ceramic core steel filter for bulk tanks

Ceramic Core Steel Filter

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
Seven Steel Filter -S7F

7M Seven Steel Filter -S7F
Made for Africa providing vast capacity and longer maintance intervals - simply put - the "African Filter Tank" catering for the vast dirt levels found in africa.

  • 7M iCerMax ceramic filter core
  • Two mini mesh sample units - inlet and outlet - real time efficency testing
  • Easy installation
  • EXTRA Long lifecycle
  • High flow rate
  • Unequivalent bulk pre -filter or filter
  • Cost effective both in terms of installation and maintenance intervals
Triple Steel Filter - STF

3M Triple Steel Filter - STF
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)
  • 3M 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 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.
Bag filter

Bag filter
Pre-filter to accommodate the extreme dirt levels of Africa and the shear volumes of particle contamination

• Micro‘s 1, 5, 10, 25, 50
• Cost effective filtration
• Improve cleanliness levels
• Extend main filter lifecycle
• Easy monitoring with pressure gauges

Mesh filter
Steel mesh to remove large bulk materials from BAD fuel, mainly used before bag filters.

Magnetic filter
Magnetic filter
Removal of ferrous particulate, small and sharp metal particulates are entrapped before they can result in metal on metal wear. The magnitude of metal contamination in diesel is high. Sources are all tanks and piping in the supply chain.

The magnet filters are used to cut and stun the bacteria prior to them reaching the secondary filters

No back pressure, no fuel loss, no consumables required.

1M Ceramic single core steel - SSF

Ceramic Diesel Filter

Custom built for mobile applications and low monthly volumes.

Diesel Cart Filter
Farmer Tank Filter
Diesel Fuel Filter
Diesel carts /mobile
Farmer’s tanks
deal for small monthly volumes

 

Ceramic Steel Filter Seals are designed not to compromise – double seals and spring loaded at top, This ensures sustainable filtration, with the characteristics of the iCerMax™ medium. The fuel flow will stop before the cleanliness levels are compromised.

Unequivalent water separator- for Africa's water levels, which commonly exceeds 5%

Automated coalescer Water Separator – Proprietary iCerMax™ Design

Automated coalesce water separator, 300 liters per minute – no cartridge required, automated water dumping
The “silent killer” – Water has inferior lubrication properties, pressure, corrosion, fuel oxidation, viscosity and bacterial & fung etc.

Ceramic Water Filter, Ceramic Filters, Ceramic Steel FilterUtilise 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 300 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. Flow volume limited to 150 litres per minute
  • No costly cartridge that has water absorption limitations
  • Automatically “dumps” water with iCerMax™ technology into a separate 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 - 300 litres per minute
  • Volume size – 600 X 600 X 1100
  • Weight – approx 65kg

Read more Automated coalesce Water Separator – Proprietary iCerMax™ Design

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

Steel Water Filter
Steel Water Filters
Officially this site has not water problem? But water is dumped automatically at regular intervals. As the free water is removed from the diesel during dispensing.

Applications

  • Main fuel tanks water separation /filtration - 300 liter. With three water levels higher than 5% volume, flow rate limited to 150 litres per minute - fit two units in parallel.
  • Inbound filtration into bulk tanks, cleans fuel during tanker delivery up to 1050 lpm ( see inbound filtration )
  • 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 - iCerMax DUO of smaller units for onboard vehicles /equipment available that caters for all flow rates and mobile fuel tanks.

Inbound filtration
Filtration of fuel (particle and water) during the offloading process, from a tanker into bulk storage tanks, up to 1050 l/p/m. This was developed as a result of a request from our clients in Africa. The unit allows three stage filtration. Providing unsurpassed cleanliness levels in bulk tanks and monitoring the dirt and water levels during each fuel delivery in real time.

Water Filter Ceramic, Ceramic Core Steel Filter

The system is modular based and easy to install without high installation costs.
It offers low maintenance as the only consumable is the filter bags.
Flow rates from 300 l/m to 1050 l/m are easily accommodated.

Read more iCerMax™ - Inbound Filtration Combo Unit into bulk tanks (STD)

Amber diesel -Orange juice – silent failure- “Water added to diesel during deliveries ‘’

Diesel Filters
  • Not detected by water finding paste
  • Not removed by absorption medium nor “normal market “filters
  • However our Water separator efficiency does show its presence
  • This amber diesel that would directly go to the combustion chamber with damaging consequences
  • A large percentage of failure is not particle contamination but actually water related failures
  • Usually detected during OEM warranty claims investigations

Free water in diesel dispensed fully automatically
System remains optimal – no efficiency loss- due to no capacity problems as it operates on a coalesce pressure system and therefore does not suffer from the same capacity constraints associated with normal filters, Normal filters have capacity constraints and get blocked by sheer water volumes or particles effecting their water separation abilities.

Biodiesel filtration
Filtration of biodiesel - The iCerMax™ ceramic filtration medium is neither heat nor water sensitive and wax build up can be removed from the ceramic .These properties are ideal for the filtration of biodiesel. It is cost effective to use the iCerMax™ ceramic filtration medium in conjunction with the iCerMax™ proprietary auto water coalesor

Filtration of Paraffin or Acids
The iCerMax™ ceramic filtration medium and filtration range is ideal to filter IP (Paraffin). Our medium’s integrity can even filter 100% sulphuric acid. It can handle severe instant thermal shocks. It has remarkable wear resistant properties with total sustainable medium integrity and no medium flexing, channel formations or unloading.

Spin-on filters at bulk fuel and oil tanks

Spin-on filters at bulk fuel and oil tank

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 breathersiCerMax™ 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, 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.

iCerMax™ ceramic & desiccant air vent breathers

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/m, 3.7 l/m, Up to 681 l/h = 11.35 l/m

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

iCerMax™ DUO -Coalesce Duel Water Separator “The Bulldog” and Why visible inspection of diesel fuel is important.


Click here to view Case Study explanation on the above

Deutz DieselPower DUO 1000 Test Results on Differential Pressure - suction and pressure

Efficiency to remove free water, currently the number one cause of engine failure SABS TEST on efficiency on coalescing to remove water on a single pass

The coalesce principle is utilised - a reliable, proven and effective method. Highly effective water separation is achieved without the cost of expensive cartridges that collapse with a high volume of water concentrate and whose efficiency is compromised by particle contamination, OR where the water absorption simply exceeds the water holding capacity.

“New market concept“ Filter to be utilised in virtually any diesel application – flow rate up to 3.8 litre per minute for diesel engines up to a 4 litre capacity.

The filter is totally revolutionary as it offers a complete contamination free solution to address fuel contamination, both particles (Ceramics) and water it is a highly effective mythology in a single pass and offers unequivocal benefits in comparison with current market offerings.

The main focus will be on “bakkies”, forklifts, and refrigeration engines, marine and other diesel engines up to four litre capacity with a fuel flow rate of up to 3.8 litres per minute.

This filter concept has been around for several years, but because of the problem of how to truly address water contamination in a very limited space it was not brought to fruition. ICerMax™ did not want to launch just a normal filter, but wanted to launch something truly special both in its functionality and its application in multiple areas and a filter that the end users would gladly convert to.

Key points of the design that offers market distinction (unique to this iCerMax™ filter) :

- Particle contamination addressed by ceramic depth media
- Water contamination addressed by iCerMax™ coalescing

Functionality of design:

- Unit virtually totally constructed from plastics – marine and underground applications
- See through clear plastic bowl to allow inspection of visible water detection
- Large water bowl reservoir with drain plug and nut plug for water sensor
- Unit size compact and multi-functional
- Ease of cartridge change
- Visual inspection of all contamination levels ( key to functionality perception )
- Visual inspection of fuel quality

Water Separation Technology on our new onboard Filtration range

Any Diesel engine smaller than 4.0, four cubic or the “Bakkie diesel filter”

Launch in April 2014

iCerMax™ - DUO - ACTIVE - Engine Protection
Save Fuel protection in Real time - before the damage occurs
The iCerMax™ DUO actively indicates the condition of the fuel by monitoring the total particle dirt levels and indicates crucial water levels in the fuel filter. This ensures that OEM filters are not compromised due to excessive contamination which exceeds their dirt holding capacity. Engine failures and excessive engine wear are a direct result of OEM filtering compromises, due to high levels of particulate and water contamination in fuels. This phenomenon can occur with one BAD fuel tank filling and is a major warranty void even on full maintenance leased vehicles.

  • Monitors the filter condition in REALTIME
  • Indicates if service is required - audible 80 decibel buzzer
    and RED LED light, green LED light indicates normal operation
  • Prevents costly engine failures due to fuel contamination
  • The perfect "BULL DOG" for on-board filtration, the last
    defence before costly injectors need replacing or before
    engine failure.
  • Utilises iCerMax™ ceramic filtration media for particle
    filtration and the coalesce double cone for water filtration -
    the best of both worlds.
  • Easy to install and lowers maintenance costs

Sustainable filtration directly extends the economical lifecycles of engines, lowers maintenance costs and directly leads to lower fuel consumption as the efficiency in internal combustion is maintained, due to less internal wear on components, for example on the fuel injectors.

It is advised to fit an iCerMax™ bulk combo unit to the bulk fuel tanks and the iCerMax DUO on the equipment – The end result is lower operational costs all-round, and a multi stage filtration approach, which leads to effective, sustainable filtration. It is expensive to create bottle neck filtration and then to rely on filters with black hole characteristics.

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

iCerMax™ ceramic spin-on filterThe 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-oniCerMax™ 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 cartridgeFBO 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

iCerMax™ ceramic filtration mediumModification 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

ceramic air filtersThe 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.

The mobile trailer is custom designed to enhance the fluid's cleanliness levels. Due to the characteristics of ceramic filtration a sustainable cleanliness level is ensured at all times.

The trailer is functional and does not require constant maintenance as it has no cartridges or small strainers that block constantly needing to be changed. Nor does it allow unlimited superfluous use like other filters do due to the compromise of their fiber/synthetic mediums, without obtaining the required cleanliness levels.

Fuel theft is dealt with a superior anti-siphon device that is fitted above the tank.

It is advised to fit an iCerMax™ bulk combo unit to the bulk fuel tanks and the iCerMax™ DUO on the equipment - The end result is lower operational costs all-round, and a multi stage filtration approach, which leads to effective, sustainable filtration. It is expensive to create bottle neck filtration and then to rely on filters with black hole characteristics.

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

iCerMax™ - Kidney Systems

iCerMax™ - Gensets / Fixed storage tanks

Fully automated cleaning system to ensure the diesel remains in an optimal condition.
The answer to preventing the catastrophic non start-up of crucial equipment.

Fuel & Oil Kidney Systems
  • Circulates diesel to avoid diesel separation
  • Removes water and particle contamination
  • Automatically dumps free water, as water
    retained in the system causes algae and fungal
    growth to start by providing the habitat and
    food for such growth
  • Thus prevents algae and fungal growth
  • Totally programmable operational intervals,
    similar to a swimming pool
  • Two pressure gauges to accurately monitor
    the condition of the iCerMax™ ceramic filter
    life
  • Warning systems to ensure functionality
  • Easy to install with low maintenance
  • Ensures diesel remains optimal
  • Customised to each site's requirements

System is fully automated and easy to maintain. It utilises the iCerMax™ DUO filters, which utilise ceramic medium for particle and coalesce for water contamination, the best of both worlds. The system also addresses the Achilles heel of kidney filtration by our proprietary auto dumping of free water, removed from the diesel, therefore not allowing a foothold for algae or bacteria in any retained free water .The market standard in other kidney units is to retain all free water until the next service interval allowing a breeding hatch for infestation .

Fuel & Oil Kidney Systems
Flow rates from 40 – 300 ltr per minute in oils and fuels

iCerMax™ - Two stage Portable Filter Trolley

iCerMax™ - Two stage Portable Filter Trolley iCerMax™ - Two stage Portable Filter Trolley iCerMax™ - Two stage Portable Filter Trolley


The trailer is functional and does not require constant maintenance as it has no cartridges or small strainers that block constantly needing to be changed. Nor does it allow unlimited superfluous use like other filters do due to the compromise of their fiber/synthetic mediums, without obtaining the required cleanliness levels.

  • Suitable for both diesel fuels and hydraulic oils
  • Transfers and cleans fluids in the same operation
  • High flow rate - constant flow 72 ltr/pm until 4 bar
  • iCerMax™ Ceramic medium ensures sustainable cleanliness levels and accurate monitoring
  • Cleans and transfers a 210 ltr oil drum in under 3 minutes

Read more iCerMax™ - Two stage Portable Filter Trolley

Read more iCerMax™ - Two Stage Portable Filter Gear Pump


Fuel/Oil Portable Kidney filtration trolley @ 40 litres per minute
Fuel/Oil Portable Kidney filtration trolleyUsed 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 FiltrationFuel/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 units
Bulk tank kidney filtration for fuels at 75- 300 l/m

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

See Combo unit in bulk filtration section for more detailed information

Customisation and shipping
We custom build our bulk units, filtration trollies, mobile trailers to clients’ specific needs , requirements or specifications and ship all over the world - land, sea and air.


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Why Ceramic filtration in Fuels?

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

Lifecycles of iCerMax™ ceramic fuel filters
The lifecycle is directly comparable to normal market filtration mediums that deliver the same sustainable cleanliness levels. It even holds more dirt if the particle distribution allows caking on the filtration medium. The ceramics have been tested at International Filter Testing Services (IFTS) in France delivering sustainable cleanliness levels, even at 8 bar differential pressure. We also use bag filters extensively, to lower the filtration cost per litre, as they are extremely cost effective. The system is totally modular and flexible; it is easy to increase capacity if site conditions change, or move to another location /site. The associated costs are minimal. The fact is that ceramic will always ensure sustainable cleanliness levels in the fuel, where normal mediums will compromise. Please read attached PDF on page two.

The importance of diesel fuel quality in modern engines performance by Patrick Swan and the benefits of ceramic filters in bulk filtration

Depth filtration is closer to the perfect filter as it conforms closer to filter performance criteria.
The effective repeatedly 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.

How clean is my fuel – test samples from two year old 83 m2 tanks – replenished every 48 hours

This is a sample from new tanks with a high turnover volume – with the assumption that the diesel must be clean.
Bottom sample - sedimint at bottom – large amount of metal particles, - Free water clearly visible with traces of fungal presence.

Middle sample – Clean and clear to the eye BUT it is over four times the SABS cleanliness spec, at over 80 mg /kg.
The particles you can’t see cause the most damage to your equipment and the smaller the particles sizes, the more the shear volume of dirt particles exponentially.

Result of contamination

Levels of contamination

Sample of a patch magnified to 100X showing a fluid at a cleanliness of approximately ISO 22/20/18, fairly typical of fuel at the filling pump
Sample of a patch magnified 100X showing a fluid cleanliness of approximately ISO 14/13/11, the target level for clean diesel fuel.

Current cleanliness recommendations by some manufacturers of high pressure fuel injection systems have already indicated they need significantly cleaner fuels. They already require fuel in an ISO 4406 cleanliness range of 12/9/6 or better for on-vehicle filtration.

Several studies have been conducted on fuel cleanliness coming out of the pump, and it’s not uncommon to find a newly-delivered batch of diesel fuel with an ISO cleanliness level of 22/21/18. So who is signing up to cleaning diesel fuels to cleanliness levels of 12/9/6 or better?

Cleaning fuel from an ISO 4406 cleanliness level of 22/21/18 to approximately 12/9/6 or better requires approximately a one thousand times reduction in the particulate contamination.

For more information please read: Fuel filtration reality check – paper no. IFC09-018 9Th international filtration conference, paper by Donaldson Filtration

Contamination levels ISO 4406 explained

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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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Fuel cleanliness levels in SA – WearCheck Tests

65% of 6985 WearCheck fuel samples failed. Free water and particle contamination contributed to the majority of the test sample failures - over 70% or 5000+ samples. This is a clear indication that diesel is being contaminated in the supply chain and at bulk tanks. It is a costly myth that diesel fuel in South Africa is clean when it reaches the combustion chamber of a modern engine. The shear volume of contamination is leading to failures, as OEM filtration systems are under severe pressure or failure. iCermax ™ offer various filtration solutions to address free water and partial contamination.

Protect Diesel from theft - iP, adding water and physical diesel theft. (Protect diesel from theft)

(iP) illuminating Paraffin in Diesel – STIP lab presence Test -Accurate
Reliable test kit to verify if illuminating Paraffin (IP) was added to the diesel, exceeding the refinery percentage. Easy and extremely reliable, similar to Pregnancy stick test. Available form iCerMax™

Water finding paste
The above levels of free water is alarming. As over a third of samples failed on free water and moisture. Fact - Water is being added to diesel to increase volume. Water finding paste detects free water and is available from iCerMax™. A proven real time solution is to install the iCerMax™ auto dumping coalescing filter, iCerMax ™ DUO on equipment, or inbound / outbound filtration on the bulk tanks.

Solution 1 -Proprietary iCerMax™ Automated Coalescer Water Separator Design
Solution 2 - iCerMax™ Duo System
Solution 3 - All-in-one iCerMax™ “Plug and Go" Combo Skid System

Diesel theft – iCustodian™ – anti- siphon device – prevents diesel theft – this is simply the most effective device in the market place. Diesel theft – iCustodian™

The iCustodian anti -theft diesel device, being physically abused, repeatedly with a slamming Crowbar

Invention in anti-siphon technology: Patent ZA2011-6647 & ZA2010/1363-PCT 2008/4142

With the iCustodian™ it is totally impossible to access the fuel without physically attacking the robust device itself, thanks to our patented baffle plate and 2-6 mm hole sizes. Stainless steel wire mesh inserts prevent all access to the fuel and traps large contamination particles preventing them from entering the fuel tank. Excellent Flow rates.

Easy to inspect for ANY tampering

OUR devices prevent fuel theft from all makes of trucks -large or small, bakkies, yellow goods, construction equipment, tractors, generators & fuel main bulk tanks - in short, anything that uses fuel. We custom manufacture to your and your equipment's requirements, based on material use, unit length, grooves or holes and fitment method. We have years of experience and do fitment to large national fleets.

Eliminate normal day-to-day diesel theft by fitting well designed, logical and field-tested equipment, with the sole mission to truly reduce fuel theft.

We have developed a range of products that have no equivalent in the market. By effectively addressing the problem with patented innovations we stop daily fuel theft.

No wonder we are the national standard for various large fleets, mining and construction companies.

Invention in anti-siphon technology: Patent ZA2011-6647 & ZA2010/1363-PCT 2008/4142 - Baffle plate, Internal Mesh, 2-6 mm holes/groves and 20 Rockwell Plus hardness (Domex),

Patented internal Stainless Steel Mesh for improved Flow rate and Secure Prevention to fuel access.Short or long units – Short units limit access to Top tank fuel

Invention in anti-siphon technology: Patent ZA2011-6647 & ZA2010/1363-PCT 2008/4142

Stainless steel wire mesh inserts to prevent all access to fuel and trap large contamination particles from entering the fuel tank. Excellent Flow rates above 150 ltr/pm

Limit access to FUEL in top of tanks with the New SHORT custodian, still with excellent flow rates. Our patented internal stainless steel mesh insert enhances protection of access to the fuel with our patented double unaligned baffle plates. Not as per the unit on the right, where diesel is easily stolen due to deep tank access and multi entry points

Large corporate client base – Most Effective devices over a large range of equipment

The physical protection of fuel is vital as fuel is an escalating material operational cost, therefore the installation of anti-siphon devices that “work” is crucial.

Buying inferior devices or simply buying on price is the most costly, as the fuel is not protected from theft.

Our device is the ultimate in fuel protection .

We eliminate normal day-to-day diesel theft by fitting well designed, logical and field tested equipment, with the sole mission to truly reduce fuel theft.

We have developed a range of products that have no equivalent in the market.

Our devices protect even against the smallest tubes or pipes, whilst still maintaining excellent Flow rates and offer five different secure fitment options.

5 mm hole is all that is required for fuel theft - Prevents access whilst maintaining excellent fuel flow rates

Caution: buying an anti -siphon device purely based on price is a costly mistake. The difference between effective design, quality materials and construction and a “cheap device “is only a few litres of fuel easily lost in one month. The device has to protect access to the fuel and ensure longevity. Fuel is an ever rising commodity and therefore requires effective protection.

We are the most effective and that is what saves money.




iCerMax™ supplies a wide range of physical fuel
theft protection devices. The iCerMax™ DUO filter
fuel theft protection device physically protects the
filter and allows full visible monitoring of the
presence of free water levels in the water capturing
bowl, especially with our red floating indicator.

Diesel Theft Protection

View detailed product list on Anti Siphoning Devices (Diesel Proppe)

The total fuel quantity dispensed at the pump is the same fuel quantity pumped into the fuel tank

Problem
The biggest problem with the fuel tag system is that there is no guarantee / control that the quantity of fuel pumped actually went into fuel tank, as per the attached photos and video, the card reader and nozzle just have to be in the proximity of one another. The “New “ updated current systems still have the same problem, just the distance of proximity in smaller.

   
   

All the Fuel Tag systems, both new and old, are not controlling diesel flow direction. Fuel nozzles are simply placed near the “ring” and fuel is dispensed.
Major fuel volumes are misappropriated, as end users are relaying on only the liter volume pumped not realising that a considerable quantity of fuel did not even enter the fuel tank.

Just calculate the monthly fleet fuel theft cost of five liters per fill.

Efuel, BP Fuel Master and Easy Fuel Theft Protection Devices to prevent side fueling

Solutions
Our system ensures that the amount of fuel dispensed, is the exact amount of fuel pumped into the fuel tank, as the proximity activation can only be triggered with the dosng nozzle securely placed into the system. This forces the fuel down the pipe at full flow rate with no deviations possibility.

Remains in the fuel tank
There is a whole lot that can be said around this, as there are various possible ways to steal diesel from a truck, nearly the same amount of devices as to prevent theft.

The easiest way to prevent theft is to think fuel theft. Most anti –siphoning devices:

  • Have no effective control for fuel tags during filling
  • Have huge holes or are easily accessible for small pipes (motorised or not)
  • Have structures that can be easily altered by drilling, bending, forcing, etc.- access is only needed at one place/point
  • Are temporarily removable
  • Leak between tank and device

This sounds simple but it isn’t, fuel theft is a major problem and an estimated 15-20% of fuel is stolen yearly (oil companies estimate), and is a growing material income source for drivers, who have ample time on their hands and years of fuel siphoning experience.

ARMOUR -Anti- theft/siphoning device
This solves the two biggest fraud elements of filling, i.e., did the fuel ever enter my fuel tank and equally important did it stay there?

   

If you have a fleet and think that you have no diesel theft, you just aren’t aware of it!

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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 Micron 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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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.

How clean is your ”filtered” fuel, even after the bulk tank filters?

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

iCerMax™ invites any scientific based test on sustainable cleanliness levels on contamination (water and particle) –one on one testing

 

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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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Particle contamination is “liquid sandpaper” and dirt larger than 0.7 micron and smaller than 5 micron is “crusher stones” in a modern engine.

Lower contamination levels upstream at bouser and downstream on the fiscal vehicle, improve physical wear patterns and directly extend economical lifecycles and improve fuel consumption due to longer optimal fuel spray patens inside combustion chamber, due to less internal wear of injectors and critical engine parts.

Direct correlation between ISO cleanliness levels and economic lifecycles of equipment – E.C. Fitch

Test done by E.C. Fitch on oil contamination levels. This illustrates the direct correlation between cleanliness levels and efficiency lifecycles. By changing ISO level standards, we increased pump life from 2 > 14 years.

Education on filtration and contamination control fundamentals is just as important as the type of component or system to buy. This leaves us to ask the main question: What does the end user want his filtration systems to accomplish at the end of the day? Cost vs. benefits?

Why is filtering so critical? Why are fuel systems the number one contributor to engine failures? Contamination in diesel is nothing more than “liquid sandpaper “. It has a direct negative impact on lubricity and increases wear patterns exponentially or directly cause component failure. Some of the clearances in engines can be as tight as 2 Micron in injectors at pressures of 1800 – 3500 bar; in the combustion chambers there is a ring gap clearance of 0.09-0.12 mm or 90-120 micron at pressures up to 230-280 bars. Contamination in the fuel can adversely affect the performance and reliability of the combustion components and this will affect the overall efficiencies (carbon generation, heat, oil, emissions and fuel), lifecycles and failures.

If should also be noted that filtration systems must offer total sustainable filtration , Paper or synthetic filtration medium are prone to periodic cleanliness levels or particle unloading leading to component wear or failure . iCerMax™ ceramic filtration medium is a total sustainable cleanliness level achievable , due to the superior inherent characteristics of ceramic filtration , as illustrated ……

The importance of diesel fuel quality in modern engines performance by Patrick Swan and the benefits of ceramic filters in bulk filtration

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The Role of the Filter

To appreciate the importance of the filter in the management of the system, consider the primary function of the filter: It has to protect the components from the damaging, critical clearance-sized particles (particles that can penetrate and interfere with the working clearances of components). The filter should control the fluid cleanliness to a level that is equal to the performance, life and reliability of the system required by the user. It should allow fluid to pass through at the given flow with the minimum pressure drop (DP) to minimize stress and energy losses.

A filter must control the levels of all contaminant particles at and above the size critical to its operating system. If the filter fails to provide the necessary control of damaging-sized particles, then their presence in the system will lead to a substantial increase in the number of particles generated within the system through a chain reaction of wear. Particles entering component working clearances will become work hardened and produce more wear particles. This makes the capture of these particles, by the filter, essential to sustain the good health of the system.

Filter performance Criteria

Reliable Performance: Absolute removal of solids from fluid streams to any micron size specified.

High Integrity: Fixed Pore Construction prevents seized particles from being released back into the liquid stream during flow or pressure surges.

Resistance to flow or differential pressures: shows how pressure drops across the filter or how much resistance to flow the filter imparts to the system. This resistance has a direct bearing on filter life

Collapse Strength: is the minimum acceptable differential pressure at which structural failure of the filter element. This is serious because unfiltered fluid can be routed back into the system.

Structural integrity: This ensure that the filter media does not leak due to holes or channelling (where the media simply form channels or collapse) This is serious because unfiltered fluid can simple flow thru the media.

Capacity /Efficiency: How much contaminant the filter will retain and the efficiency of the filter is removing the contaminant.

Longer Life and Lower Costs: High surface area results in high dirt holding capacity and long element life for lower net operating costs

Chemical Capability: This iCerMax™ depth ceramic media is compatible with Hydrocarbons and is a media that water has no negative effect of any nature what so ever on. It can even filter 100% water. Most depth filter media are highly sensitive and block with water retention even more so than with particles and shed particles or fibers.

Conclusion
The perfect filter would have no pressure drop, hold an unlimited amount of dirt, be small enough to fit anywhere in a system, give great ISO cleanliness codes, have high capture efficiency and cost nothing. Obviously this combination cannot exist, and the pursuit of the perfect compromise has always been the challenge for filter manufacturers.
For many years, filtration companies have been trying to educate end users on why filtration is important and how it helps the end user protect his equipment, save him money in the long run, or both. Many end users understand that there are often trade-offs to lower micron rating and higher capture efficiencies of filters.
iCerMax™ ceramic depth filtration medium excels is the above filter performance criteria.

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