The Magnatech System IN AN INDUSTRIAL OPERATION

Improve fuel efficiency, reduce operating costs and cut emissions — typically without operational change or process disruption.

The Magnatech System is a non-invasive combustion-performance technology for suitable industrial boilers, furnaces and fired heaters operating on natural gas, LPG or fuel oil. Installed externally to the fuel supply line close to the burner, it can reduce specific fuel consumption without modifying the appliance or control system and is typically installed with minimal process disruption.

How the Magnatech System Works

Installed immediately upstream of the burner, the Magnatech System applies a proprietary engineered, non-homogeneous magnetic field designed to influence combustion conditions at the point of burning. For industrial applications, the key measure is the fuel required to deliver the same useful production output. Depending on the process, savings can be assessed against production throughput, operating hours, load and other relevant operating variables. When less fuel is required for the same useful output, specific fuel consumption, operating cost and associated CO2 emissions all fall.

Step 1 Installation

The Magnatech System is fitted externally to the fuel supply pipe, as close as practicable to the burner inlet. There are no modifications to the appliance, controls or fuel pipework. In most cases installation is completed in a single visit by a trained engineer and can be carried out with minimal operational disruption.

Step 2 Fuel conditioning

Fuel passes through the proprietary engineered, non-homogeneous magnetic field created by the Magnatech System immediately before entering the burner. Published experimental research has shown that appropriately configured magnetic fields can measurably influence combustion phenomena, including methane-air combustion. The Magnatech System applies this principle continuously, with no external power, no moving parts and no routine maintenance requirement.

Step 3 Improved combustion

The Magnatech System improves combustion performance at the burner. The operational result is straightforward: where less fuel is required to deliver the same useful output, the saving is measured against the agreed baseline after the bedding-in period.

Step 4 Reduced emissions

When less fuel is required to deliver the same useful output, total fuel-related CO2 emissions are reduced accordingly. Other combustion emissions, including NOx and CO, vary with burner design, air–fuel ratio, load and operating conditions and can be measured during combustion analysis.

Step 5 The savings

Fuel savings are measured against a pre-agreed baseline using a documented M&V methodology. For industrial processes, relevant variables such as production throughput, operating hours, load and line speed can be incorporated so performance is compared on a like-for-like basis. Where appropriate, a specific-energy KPI — such as fuel consumed per tonne or kilogram of product — is used to express the change in fuel required for the same useful output.

The Magnatech System Savings Pathway

Every Magnatech System project follows a structured six-stage pathway from site survey to a site-specific savings report. For industrial processes, the baseline is built around the variables that materially affect fuel use and useful output, so the post-installation comparison reflects process performance rather than a simple before-and-after meter reading.

Stage 1 Site survey

One of our engineers visits your site to assess suitability, identify the correct installation point on your fuel supply pipework and confirm the Magnatech System configuration required. We’ll also discuss your fuel type, appliance configuration and operational schedule to ensure the Magnatech System is correctly matched to your installation.

Stage 2 Baseline data collection

Before installation, we establish an agreed performance baseline using the variables that matter to your process. This may include fuel consumption, production throughput, operating hours, load, line speed and other relevant process variables, together with combustion analysis where appropriate. Where useful output can be quantified, a specific-energy KPI — such as fuel consumed per tonne or kilogram of product — can be agreed so post-installation performance is compared on a like-for-like basis.

Stage 3 Magnatech System installation

The Magnatech System is fitted externally to the fuel supply pipe, as close as practicable to the burner inlet. There are no modifications to the appliance, controls or safety systems. The Magnatech System incorporates directional shielding intended to minimise stray magnetic-field exposure to nearby instrumentation and components. In most cases the work can be completed in a single visit with minimal operational disruption.

Stage 4 Bedding-in period

Following installation, an initial bedding-in period is allowed before final performance assessment. The period depends on the application and pipework material; Magnatech’s field protocol allows longer on steel pipework than on copper or non-ferrous pipework. No customer intervention is required during this period.

Stage 5 Analysis & calibration

Once the bedding-in period is complete, post-installation performance is assessed under comparable operating conditions. Results are compared with the agreed baseline and, where necessary, the Magnatech System installation configuration can be reviewed or adjusted. Where sufficient operational data is available, statistical analysis can also be used to assess the robustness of the measured saving.

Stage 6 Savings report

From baseline to result, every Magnatech project follows a clear measurement pathway: site survey, baseline data, installation, bedding-in, analysis and savings reporting. The Measurement & Verification approach is agreed before analysis, and the recorded operating and consumption data are interpreted by the customer and/or an independent M&V provider. Where appropriate, fuel consumption is normalised against production output, operating hours, load or other relevant variables to provide a like-for-like comparison. The result is not simply a before-and-after meter reading — it is a documented assessment of the fuel required to deliver the same useful production output.