Rio Tinto Confirms Magnetic Filtration Reduces Contamination, Cuts Costs, and Extends Asset Life

From 2007 to 2009, Rio Tinto’s U.S., Canadian and Australian operations conducted extensive field trials on HME draglines, fixed‑plant equipment, and mobile units. All tests used One Eye Industries magnetic filtration and separation systems.

Across every trial, the magnetic filters reduced both ferrous and non‑ferrous debris. The equipment met higher ISO oil cleanliness standards and saw a dramatic drop in the PQ Index – a key indicator of particles larger than 8 µm.

These results support Rio Tinto’s Heavy‑Duty Clean Machine (HCM) strategy, which prioritises oil and fuel cleanliness to maximise asset life.

Key Benefits of One Eye Magnetic Filtration

• Reusable Design – Cleanable with a 10‑plus‑year service life; no replacement parts required.
• Minimal Flow Restriction – Works on gravity return lines, can be combined with other filters without adding flow loss, and consumes negligible energy.
• Easy Visual Inspection – Captured debris can be analysed, providing early warning of potential failures.
• Extended Fluid Life – Removes ferrous particles that accelerate oil oxidation, keeping fuels and lubricants cleaner for longer.
• Positive ROI – Lower total life‑cycle costs compared with conventional filters that need frequent replacement or heavy cleaning.
• Environmentally Friendly & HSE‑Compliant – Fewer conventional filters are purchased, reducing disposal costs; the product comes with clear safety and handling instructions.
• Component Life Extension – Field data shows life extensions from 1.5× to 3×, consistent with ISO cleanliness predictions.

One representative field test highlighted a 25 % reduction in maintenance spend per unit and a corresponding increase in machine uptime and production output. The oil cleanliness level improved from 21/17 to 18/15 and continues to trend downward.

Based on these findings, One Eye magnetic separators are recommended for all fixed and mobile Rio Tinto assets that generate high ferrous wear – such as gearboxes, hydraulic systems, and fuel lines – where debris can degrade performance.

The trials demonstrate immediate value: cleaner fuels and lubricants, longer component life, and a key deliverable for the group’s asset‑management and HCM strategy.

For additional details or to discuss the trials, contact Steve Baxter, Principal Adviser for Hydrocarbons at Rio Tinto Technology and Innovation, or Owen Uebel, Manager at One Eye Industries.