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Tag Archive: metal hydraulic tank

  1. Shockingly Effective Anti-Static Filter Elements

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    Struggles With Static

    Over the last decade, users of hydraulic systems noticed a sharp increase in unusual failures and contamination within their equipment, including:

    • Burned and discolored filter elements
    • Rapid oil degradation
    • Prematurely worn, damaged components
    • Electrical arcing outside of the system

    The culprit? Electrostatic discharge, also known as ESD, was becoming more frequent within hydraulic equipment. Static buildup is already a known issue, but why was it suddenly happening more often, and to greater extremes?

    Behind the ‘Electrifying’ Increase in ESD

    Fundamentally, static discharge in a hydraulic system is caused by friction—just like how shuffling across carpet in thick socks allows you to lightly zap someone else with static electricity. Oil may be a lubricant, but there is still some friction between hydraulic fluid and the filter media it passes through, and thus, static buildup can occur.

    GIF animation showing visible electrostatic discharge in a filter element during hydraulic operations

    In a system with highly conductive hydraulic fluid or oil, this static buildup is more easily absorbed and evenly distributed. This prevents the worst effects of electrostatic discharge. However, environmental standards driving changes in oil composition meant that low conductivity oil was becoming more widespread.

    Diagram showing Group I versus Group II and Group III oils. Under Group 1 oils, bullets read: High conductivity, more toxic, less static/ESD, Under Group II and Group III oils, bullets read: Low conductivity, more eco-friendly, more static/ESD.

    Group I ‘Lightly Refined’ Oils were once the most common class of hydraulic fluid.

    • These oils contained aromatics and heavy metals. Due to the presence of heavy metals, Group I oils have high electrical conductivity.
    • However, the heavy metals within Group 1 oils are mostly toxic. Due to this toxicity and the potential threat to the environment, Group 1 oils do not comply with newer, international environmental standards.

    Group II & III ‘Hydrocracked’ or ‘Synthetic’ oils are replacing Group I oils as a more eco-friendly alternative.

    • Group II and III oils contain no toxins or carcinogens, as the toxic heavy metals have been removed.
    • Due to the lack of heavy metals, these oils have much lower electrical conductivity than Group 1 oils.
    Learn More About Oil Conductivity

    Between 2012 and 2020, the global market share of Group 1 oils fell by half, from 51% to roughly 26% of hydraulic oils in use. This trend is expected to continue. While moving away from Group I oils is much better for the environment, the proliferation of low conductivity oils led to more electrostatic discharge in hydraulic systems.

    Chart comparing Global API Group Oil Market Share between 2012 and 2020. Group I oils decreased from 51% of market share to 26%.

    Effects of Electrostatic Discharge on Hydraulic Systems

    Electrostatic discharge and static cause a variety of serious issues in hydraulic systems, including:

    Image of filter element scorched by ESD/electrostatic discharge
    • Damaged elements. Scorched, degraded filter elements are a hallmark of static buildup in a hydraulic system.
    • Increased contamination. When damaged, filter elements become unable to filter out contamination as intended, and the filter element itself may become a source of contamination as it degrades.
    • Reduced oil and component life. The increase in contamination and compromised filtration drastically reduces oil life and increases component wear.
    • Formation of sludge and varnish. As oil rapidly degrades, varnish is deposited in the system, affecting system function.
    • Fire risk. High amounts of ESD can potentially cause deflagration, or combustion of gas within the hydraulic reservoir.
    • Arcing and discharge outside of the system. In extreme cases, the electrostatic discharge can become so intense that it becomes an electrocution hazard to workers, as well as damaging to surrounding equipment.

    Anti-Static Solutions from Schroeder Industries

    Anti-Stat Premium and Anti-Stat Media from Schroeder industries are engineered to combat static buildup while providing robust filtration. Because levels of ESD can vary based on factors like fluid type and temperature, two levels of protection are available.

    Both offer virtually the same efficiency as Schroeder’s standard, exceptionally powerful microglass media. For superior protection from both typical particulate contamination and the effects of electrostatic discharge, look no further!

    NEW: Anti-Stat Premium

    Anti-Stat Premium: Supercharged Static-Busting Capabilities For Extreme ESD

    • Specially formulated media dissipates electric charges before they can begin damaging your system
    • Eliminates all static buildup at the source
    • Effective for even the most critical cases of ESD, tackling conductivity values lower than 100 pS/m
    Request a Quote

    Anti-Stat Media

    Anti-Stat Media: Reliable, High-Performance Solution For Low to Moderate ESD

    • Specially formulated media dissipates electric charges before they can begin damaging your system
    • Cost-effective option for mid-range ESD scenarios
    • Effective for conductivity values higher than 100 pS/m
    Request a Quote

    Schroeder Anti-Stat: Proven Performance

    See how these customers benefited from the static-suppressing characteristics of Anti-Stat Media!

    When a paper mill was experiencing a shortened filter element life of just 30 days, Schroeder Industries stepped in to extend the filter life, reduce oil waste, and reduce unscheduled downtime.

    A Schroeder expert immediately identified the signs of static discharge in the hydraulic system. As the elements were burned and degraded by the electrostatic buildup, they failed prematurely, forcing the customer to swap out elements much sooner than usual.

    Switching to Anti-Stat Media took the shock out of their system, extending their filter life and leading to substantial savings!

    Oil Service Life Increased +3 Years

    Annual Oil Usage Decreased -951 Gallons

    $24.8K Annual Filter & Oil Cost Savings

    Read Full Case Study

    An automotive plant contacted Schroeder Industries when, after switching to a new hydraulic oil, their oil lifespan dropped by as much as 80%.

    The customer’s new oil blend was zinc and ash-free, meaning its conductivity was lower than their previous hydraulic oil. As we’ve discussed, the lower a hydraulic fluid’s conductivity, the more likely static buildup is to occur!

    Burn marks and varnish on the customer’s used elements confirmed that electrostatic discharge was building up in the customer’s system. By switching to Anti-Stat Media, the customer was able to get the most out of their oil and more!

    Oil Service Life Increased +4 Years

    +2.6K Gallons of Oil Saved Per Press, Per Year

    +31.7K Gallons of Oil Saved Annually

    Read Full Case Study

    In Need of Anti-Stat? Ask the Experts!

    Contact-Blog-Anti-Stat Premium Introduction

    • Max. file size: 256 MB.

  2. Unlock Peace of Mind: Prevent Water Contamination Fast

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    Most hydraulic reservoirs in major industries including pulp & paper, primary metals, and more feature a pocket of open space between the fluid level and the top of the reservoir. This open space, known as head space, fills with moisture as humid air ingresses via faulty seals, vents, and other entry points.

    As the moisture builds in the head space, water condenses at the top of the reservoir, eventually coalescing and falling into the oil.

    This water contamination can cause a range of serious problems which can impact your equipment’s efficiency and may require repairs, including:

    • Rust
    • Cavitation
    • Sensor failures
    • Reduced oil lubricity

    How Schroeder’s Head Space Dehydrator Helps:

    Dewatering units such as the Triton Dehydration Stations are excellent for targeting water contamination when oil has already become saturated, but preventing contamination before it reaches critical levels is ideal.

    The new Head Space Dehydrator is designed to combat moisture in the head space of a hydraulic reservoir before it contaminates the oil. This unit is permanently installed on a hydraulic reservoir so that humidity inside the reservoir can be managed continuously.

    Here’s how it works:

    1. The Head Space Dehydrator assembly pulls ambient air into the chamber through a series of particulate breathers.
    2. The clean, dry air is then blown through the head space above the fluid level, displacing and venting the moist internal air though existing ventilation points.
    3. As the moist air is displaced, the opportunity for water contamination via condensation is reduced.

    Specifications:

    Flow Rating:Max flow rate 282 cfm (7985 lpm)
    Blower:1/2HP blower with 220-275/380-480V-60Hz-3 phase motor
    Breathers:Uses 4 breathers which include -0.5 psi (-0.035 bar) differential pressure indicators

    Features & Benefits

    • Cost effective, reliable solution for water ingression
    • Improved oil cleanliness
    • Increased lifespan of oil and components

    Markets & Applications

    Ideal for industrial applications where water contamination may be introduced to the reservoir head space, particularly:

    • Steel & Primary Metals
    • Pulp & Paper Production
    • Bulk Storage
    • and more!

    Ask the experts at Schroeder what the HSD can do for your application!

    Contact-Blog-HSD Introduction

    • Max. file size: 256 MB.

  3. Supercharge Your Hydraulic Systems with Expert Tank Optimization

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    How can tank optimization benefit you? Ask the experts.

    Rising oil and fuel costs, trends towards electrification, and overall concerns about sustainability across virtually every industry are driving an increased push for improved efficiency in the designs of hydraulic equipment.

    Schroeder Industries family of hydraulic tanks, TNK Series

    One area where great opportunities for improvement lie is with the hydraulic tank. Due to inefficient designs, many machines operate with oversized hydraulic tanks containing more oil than needed.

    Many benefits can be realized through tank optimization, including:

    • Increased energy efficiency
    • Overall machine weight savings
    • Steel and oil savings per machine
    • CO2 emission reduction
    • Tank downsizing
    • Additional machine space for other features

    Read on to learn more about the benefits of optimizing your hydraulic reservoir, and how Schroeder Industries can help:

    What Is Tank Optimization?

    The goal of hydraulic tank optimization is to reduce the reservoir size and thus reduce its fluid volume. Two main factors determine how much a tank can be optimized:

    • Volume Utilization. In a suboptimal reservoir design, ‘dead zones’ can appear, where fluid stagnates and is not effectively utilized by the system. In a properly designed tank, every cubic inch of the hydraulic fluid should circulate within the reservoir. Dead zones can be detected by digital simulations, and are a strong indicator that tank optimization is needed.
    • Fluid Velocity. Fluid velocity impacts how well a tank can de-aerate, or release trapped air from within the fluid, and prevent new air from entering the fluid due to splashing. Increased air contamination causes a variety of issues within hydraulic systems, decreasing operating efficiency and component lifespan. Fluid velocity can be reduced through improved in-tank filtration and adjusting the structure of the hydraulic tank itself.

    The Benefits of Hydraulic Tank Optimization

    Here’s some of the ways optimizing a hydraulic tank design can benefit both OEMs and end users:

    • Cost Savings. Downsizing a reservoir with tank optimization means less steel and oil are needed upon initial construction, reducing up front manufacturing expenses for OEMs. Additional savings are passed on to end users, who will need less hydraulic oil to run the equipment over its lifetime.
    • Improved Energy Efficiency. A smaller reservoir with reduced fluid volume reduces the overall weight of the equipment, translating to improved energy efficiency. Lower fluid volume also reduces warmup time in cold start conditions. Any improvements in energy efficiency are especially important for electric-powered equipment, which relies on more limited battery power.
    • Increased Machine Space. A smaller hydraulic reservoir can allow overall downsizing of the equipment or make way for additional improvements to the design. Larger batteries or fuel tanks, cooling units and other beneficial modifications can be made when space is freed up within the machine.
    • Sustainability Benefits. Tank optimization reduces the carbon footprint of an operation in several ways:

      1. By downsizing a reservoir, less hydraulic oil must be produced and then disposed of, reducing the emissions from both the initial manufacturing of the oil and lowering the amount of waste oil per machine.

      2. The carbon footprint of initial construction is also mitigated by the reduction in materials needed to create the reservoir itself.

      3. Improvements in fuel efficiency for diesel and other fossil fuel-powered equipment reduces CO2 and other harmful emissions overall.

      4. Finally, the increase in energy efficiency and available machine space can open up avenues for electrifying equipment, or improving the performance of electric-powered machines, which are at the forefront of sustainable equipment.

    The benefits of optimizing your tanks are clear, and the filtration experts at Schroeder Industries can help you get the most out of your reservoir.

    Let Schroeder’s Experts Help Optimize Your Tank!

    Tank Optimization Services from Schroeder Industries

    Rendering of flow simulation using a TNK.

    Schroeder Industries is leveraging our extensive experience in hydraulic system filtration components towards tank optimization. Through cutting-edge flow simulations, our experts can identify dead zones and inefficiencies in hydraulic tank designs and work with your company to develop a solution that suits your specific application.

    The benefits of optimizing your hydraulic tank are more than just theory. In the following case study, learn how one OEM saw substantial savings with Schroeder’s tank optimization services:

    Closeup image of stump grinding machine with TNK12 in the foreground

    An OEM customer producing stump grinding machines for the forestry industry came to Schroeder Industries searching for updated filtration solutions.

    An engineering analysis of their fabricated tanks found that not only were they heavy and prone to weld cracks: The volume utilization was subpar.

    Further testing concluded that the existing Schroeder TNK12 would provide equivalent deaeration performance to the customer’s current tanks with a 40% reduction in tank volume.

    This resulted in substantial savings on both oil and tank production cost in their stump grinder manufacturing:

    Oil reduced per unit: 8 gallons Oil Reduced annually: 4,000 gallons Cost savings: $28,000 USD
    Labor cost per TNK: $30 USD TNKs used annually: 500 Labor cost savings: $15,000 USD
    Read the Full Case Study

    TNK Series and Air Fusion Technology

    Schroeder’s tank optimization services are backed by expertly crafted reservoirs and filters. Learn more about these premium products:

    Schroeder Industries TNK7 with Air Fusion Technology AFT filter.

    Lightweight tanks, heavyweight performance! The Schroeder Industries series of rotomolded HDPE tanks are lighter than traditional steel tanks, but built to take a beating in the field with no risk of corrosion. Available in five performance optimized sizes, with custom options available, there’s almost certainly a TNK for your application.

    Engineered with baffling that improves deaeration and cools returning oil by creating settling zones, these tanks are designed to assist in the ever-important degassing of hydraulic fluid.

    Specifications:

    Tank Materials:High Density Polyethylene (HDPE)
    Tank Volumes:4 gal (15L)
    7 gal (26L)
    12 gal (45L)
    18 gal (70L)
    25 gal (100L)
    Operating Temperature:High Density Polyethylene (HDPE) 20°F to 180°F (-29°C to 82°C)

    Nylon (PA)
    32°F to 240°F (0°C to 116°C)
    Max. Return Flow:TNK4: 25 gpm
    TNK7: 35 gpm (135 L/min)
    TNK12: 40 gpm (150 L/min)
    TNK18: 40 gpm (150 L/min)
    TNK25: 75 gpm (284 L/min)
    TNK Weight:TNK4 (AFT4): 11.5 lbs (5.2 kg)
    TNK4 (AFT8): 11.5 lbs (5.2 kg)
    TNK7: 16 lbs (7.3 kg)
    TNK12: 21 lbs (9.7 kg)
    TNK18: 33 lbs (15 kg)
    TNK25: 45 lbs (20 kg)
    Schroeder Industries Air Fusion Technology AFT filter

    Schroeder’s secret weapon in the quest for tank downsizing is the AFT. This next-gen in-tank filter offers superior deaeration, engineered to reduce fluid turbidity and enhance degassing, reducing the amount of air entering the hydraulic system.

    With this powerful filter, see up to 60% reduction in reservoir size! With the AFT, our goal is to create a smaller, more efficient hydraulic system to help our customers get the most out of their fuel source.

    Specifications:

    Flow Rating:40 gpm (151 L/min)
    Max. Operating Pressure:100 psi (7 bar)
    Min. Yield Pressure:350 psi (24 bar)
    Rated Fatigue Pressure:100 psi (7 bar)
    Temp Range:-20°F to 225°F
    (-29°C to 107°C)

    Ask The Experts How Your Tank Can Be Optimized!

    If you could be getting more out of your reservoir and in-tank filtration, Schroeder Industries can help.

    Tank Optimization Request Form-Tank Optimization Blog

    • Max. file size: 256 MB.