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Modern centrifuges are used in technical processes for the mechanical separation of mixtures of solids and liquids. Sedimentation, centrifugation, and filtration are mechanical separation processes, in contrast to distillation, incineration and thermal drying, which are
thermal separation processes. In many processes, mechanical separation is primarily responsible for product quality, production efficiency and environmental control. Mechanical separation processes are found in practically all industrial sectors, including food, chemi-
Applications
The following basic process operations are possible with solid bowl decanter centrifuges: Clarification of liquids Dewatering of sludges and suspensions Thickening of slurries Separation of three-phase mixtures, i.e. two immiscible liquid phases and a solid phase
Classification of solids in a suspension according to particle size (wet classification) Sorting of solids by density.
FLOTTWEG CENTRIFUGES can more effectively help one reach their processing goals by offering a variety of basic designs, such as the DECANTER,
To obtain optimum results, solid bowl decanter centrifuges must be custom designed to suit specific separation processes.
TRICANTER, SEDICANTER and SORTICANTER. Solid bowl centrifuges are used in most areas of mechanical liquid-solid separation.
Typical processes
Foodstuffs Animal fat Blood Brewers yeast and trub Casein Clarified butter Coffee essence Corn stillage Drinking water treatment Fish meal Fish water Fruit juices Gelatin Lactose Meat extracts Molasses Mycelia Potato protein Potato scrapings Proteins Sorbose Soybean flour Starches Vegetable extracts Vegetable juices Vegetable oils Wine and beer
Chemical products Aluminum hydroxide Barium sulfate Bauxite Bentonite Calcium carbonate Calcium fluoride Calcium sulfate Carbide sludges Caustic soda Cellulose derivatives Clay sludge Color pigments Cryolite DMT Epoxy resin Fluorescents Graphite Gypsum HDPE Iron hydroxide Iron oxide Kaolin Latex Lead oxide Lead sulfate Lignine sulfate Magnesium hydroxide Mica Mineral oil Nickel hydroxide Pharmaceutical intermediates Coal tar cleaning Drilling mud Hide scrapings Industrial wastewater treatment Manure Municipal wastewater treatment Oil sludges Paint sludges Plastics sorting/recycling Steelworks sludges Miscellaneous Phosphate compounds Phosphoric acid Plastics derivatives/additives PMMA Polypropylene Polystyrene PVC Silica Silicate Sodium chloride Titanium dioxide Tricalcium phosphate Various salts Vitamins Zinc carbonate Zinc oxide Zinc sulfate
The basic principle of the solid bowl centrifuge has been known since the end of the 19th century. Over the course of time, technology improvements along with the availability of high strength and corrosion resistant raw materials have allowed solid bowl de-
canters to be applicable to many processes. The utilization of electronic and electromechanical measuring and control components has improved the performance and availability of the machines. The basic design of a solid bowl centrifuge is relatively
simple and can be customized by Flottweg for different requirements. Of all modern industrial centrifuges, solid bowl centrifuges have the broadest range of application.
Feed
The slurry is fed through a stationary pipe into the feed zone located in the center of the scroll. The product is then accelerated circumferentially and delivered through distribution ports into the bowl.
with the bowl at the operating speed and forms a concentric layer at the bowl wall. The solids contained in the slurry are deposited against the bowl wall by centrifugal force. The length of the cylindrical bowl section and the cone angle are selected to meet the specific
and conveys the deposited solids toward the conical end of the bowl. This differential speed determines the residence time of the solids in the bowl. Residence time is an important variable for the dry solids content. It can be adjusted by changing the differential speed of the scroll thus providing optimal separation.
Bowl
The bowl has a cylindrical/ conical shape and rotates at a pre-set speed optimal for the application. The slurry rotates
requirements of an application.
Scroll
The scroll rotates at a slightly different speed than the bowl
If the physical properties of the slurry change, FLOTTWEG DECANTERS can be supplied
feed inlet
solids discharge
FLOTTWEG DECANTER for the liquid-solid separation with gravity overflow of the liquid phase (centrate)
with a different scroll design or by modifying an existing scroll. Scroll pitch and single or multiple flight configurations are important design variables.
Solids discharge
Settled solids are ejected through ports at the conical end of the bowl into the solids housing and fall through to the discharge chute.
Rotor bearing
A special selection and arrangement of bearings provides long life and exceptional reliability. A central lubrication system supplies either grease or oil to bearings.
precise adjustment of the pond depth in the bowl. Overflow is then collected in a centrate chamber and discharged by gravity.
neering refinement that permits quick and precise adjustment of the pond depth during operation to accommodate changing conditions.
Impeller (skimmer)
The clarified liquid can also be decanted with an impeller and discharged from the bowl under pressure. This eliminates the need for a separate centrate pump. The FLOTTWEG adjustable impeller is an engiliquid discharge under pressure
Materials of construction
FLOTTWEG uses high-quality stainless steel for all wetted areas. Bowl and scroll castings are made from centrifugal cast high strength and corrosion resistant stainless steel.
Overflow weirs
The clarified liquids flow to the cylindrical end of the bowl where they exit over weir plates. Easily adjustable precision weir plates allow for the
feed inlet
solids discharge
FLOTTWEG DECANTER with pressurized centrate discharge
Adjustable impeller
The FLOTTWEG TRICANTER enables three-phase separation, i.e. the simultaneous separation of two immiscible liquids with different densities and one solid phase, provided that the solid phase is the heaviest phase. The most important difference from a decanter is the separate discharge of the two liquid phases. The FLOTTWEG TRICANTER
discharges the heavy liquid through an adjustable impeller under pressure and the light phase by gravity. The adjustable impeller allows adjusting the separation zone and degree of separation within the machine during operation. This optimizes purity of the liquids and may possibly eliminate downstream equipment.
feed inlet
solids discharge
FLOTTWEG TRICANTER (THREE PHASE DECANTER) Discharge of the centrate: heavy liquid phase under pressure, light phase by gravity
liquid discharge
Adjustable impeller
FLOTTWEG SORTICANTER
The innovative FLOTTWEG SORTICANTER is designed for the separation of solids by density. The process is aided by a carrier liquid with a specific gravity that is between the densities of the two solid streams to be separated.
bowl wall. The scroll conveys the deposited layer of heavy solids toward the conical bowl sec-
The bowl and lagging scroll rotate at a high speed in the same direction. The solid-liquid mixture is conveyed through the centrifuge feed pipe and inlet ports in the scroll body into
tion, over the drying zone and ejects them through ports into the stationary solids housing and down the discharge chute. The solids which are lighter than the carrier liquid float and are conveyed with the liquid toward the cylindrical end of the bowl. When the floating particles have reached the second inner cone, scroll
the bowl and accelerated to the bowl speed. Centrifugal force causes the solids which are heavier than the carrier liquid to settle against the
cylindrical conical bowl with a second inner cone at the cylindrical end and a double acting
feed inlet
flights wound in the opposite direction to those conveying sedimentated solids transfer the lighter solids across a drying zone to the exit ports. The liquid is skimmed off and discharged under pressure by an
After an intermediate cleaning step, liquid may be recycled as carrier liquid. Carrier liquids with different densities enable
FLOTTWEG SEDICANTER
The FLOTTWEG SEDICANTER is used for the separation of solids from liquids when the solids form a soft but flowable sediment.
liquid and solids move in the same direction without having to pass through a turbulent inlet zone. The centrate is discharged through an adjustable impeller within the scroll. The
products such as biomasses, yeast suspensions, protein suspensions and fermentation broths.
Technical features:
Up to 10,000 x g centrifugal force possible to facilitate the separation of very fine, slowsettling solids Uniquely designed feed distributor and bowl seal to pre-
The
SEDICANTER
is used in
cases where the solids are too fine-grained to be processed in a normal decanter and the sediment cannot be easily discharged from the decanter due to its soft consistency. During the separation process, the
phase, is accumulated and pressed out of the bowl under an immersion disc.
feed inlet
solids discharge
FLOTTWEG SEDICANTER
Gastight machine design Clean-in-place provisions available to meet pharmaceutical industry standards
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Centrifuge cleaning
Centrifuges must always be cal and food processing appliflushed clean before shutdown. Depending on the application, different cleaning systems may be incorporated into the centrifuge design.
FLOTTWEG CENTRIFUGES are designed for continuous operation and do not need to be opened for cleaning. FLOTTWEG CENTRIFUGES for pharmaceutical, biotechnologications are designed with Clean-in-Place (CiP) systems.
product-dependent. In most cases, the use of a solids-free centrate will be adequate. Additional rinsing nozzles for
biotechnological and food processing industries to meet the highest demands for cleanliness. Requirements and specifications for design, manufacturing and testing are according to specific company standards.
cleaning the housing, the bowl exterior and the scroll interior can be installed if required.
Characteristic features of centrifuges to meet hygienic requirements are: All welds are ground to meet specific sanitary finish standards. All product-contact parts are provided with a surface finish in accordance with specified roughness values.
Rinsing nozzles are provided for the centrifuge housing and for the interior of the scroll body. The centrate impeller is adjustable to facilitate flushing of the bowl. Frequency-controlled drives for CIP-cleaning at low speed. Electropolished scroll, housing and bowl surfaces. Special hygienic housing seals Electrically reversible scroll rotation for enhancing cleaning during CIP cleaning.
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Drives
General
Decanter centrifuges are subject to two conflicting basic drive requirements. On one hand, the entire rotor has to run at high speed, and on the other hand, the scroll inside the bowl has to rotate at a very low differential speed and simultaneously at a high torque relative to the bowl wall.
FLOTTWEG frequency controlled electric motors or speed-adjustable hydraulic motors offer infinitely variable speed. Long start-up times help overcome a high inertia moment and avoid peak loads during the initial current phase. FLOTTWEG offers hydraulic motors or gear drives to drive the scroll depending on the
application. The majority of the drive configurations offer variable differential speeds. This ensures optimum adjustment to meet individual customer requirements.
Hybrid drive
mits the use of variably adjustable control, monitoring and analog control. The drives design enables independent rotation of the scroll even when the bowl is shut down.
because only one oil circuit is required. Control and adjustment are the same as with the hydraulic drive. Hydraulic drives offer particular advantages for applications in mobile processing systems. Their
Hybrid drive
In this version, a frequencycontrolled electric motor drives the bowl instead of a hydraulic motor. The hydraulic aggregate for the scroll is compact
compact design (controls, aggregate) provides for optimal utilization of floor space. Another advantage is applicability in explosion proof areas.
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The FLOTTWEG gear drive is the most basic drive solution and is particularly suited for separation processes which do not require operating adjustment of the differential speed.
separately adjusted with a preset range and controlled and monitored independently of torque. Both drive motors are powered by a FLOTTWEG frequency inverter, which is power-linked via a regenerative cir-
Bowl drive Scroll drive Backdrive with Dual-VFD SIMP-DRIVE = registered trademark in various countries
SIMP-DRIVE
The SIMP-DRIVE constitutes the new generation of the FLOTTWEGs dual frequency inverter back drive concept. This new electric drive arrangement includes the advantages of the hydraulic and electromechanical drives. The main feature of this new concept is a multi-stage planetary gear which allows for entirely independent operation and drive of
Constant torque, high solids Simple integration into process control systems
Benefits include: High efficiency and low energy demand A simple drive system not requiring linkage Independent frequency inverters (VFDs) which are standard designs, simple to operate and simple to maintain
Smallest possible inverter size High flexibility in the selection of the operating speed Discharge of the bowl even at full stop Applicable for small to medium differential speeds Low power draw.
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Centrifuge controls
Fluctuations of the solid throughput and concentration in the centrifuge may cause a decrease in separation results, blockage or an overload of the centrifuge. To avoid problems and to fully utilize the capacity of the centrifuge, the differential speed needs to be continuously adjusted for operating conditions.
which are based on the following principle. Scroll torque is a measure of bowl solids load. Load and torque should be kept at an optimum value.
creases. This automatic control process ensures optimum separation during normal operation. An integrated two-stage overload protection offers excellent control of the machine
If the torque exceeds the optimum value, the FLOTTWEG control system increases the differential speed to convey the solid faster out of the bowl until the torque decreases. Con-
If the increase in differential speed is not sufficient to compensate for a solids overload, the feed supply is stopped until the torque falls back below set
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point. In the majority of situations, this is sufficient to remedy the overload without having to shutdown the system. If this measure is insufficient to keep the scroll torque from rising, the bowl drive is shut down when the torque reaches the second set point.
for manually removing the solids. Machines with hydraulic drive or SIMP-DRIVE enable
with a hydraulic-mechanical analog control via an electronic industrial control system to programmable logic controllers (PLC) and integration into distributive control systems (DCS).
solids discharge at full-torque scroll operation during the bowl shut down.
FLOTTWEG provides all machines with adjustable differential speeds (hydraulic drives,
All electronic systems allow for remote control and monitoring. Programmable controls support a variety of complex links and monitoring for plant systems (e.g. CIP and automated process steps).
As the bowl speed decreases, the torque is reduced and the machine will usually empty itself. Typically there is no need
SIMP-DRIVE
drives) with this control system. The range of control systems covers a basic version
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Sealing systems
Most sizes and models of FLOTTWEG CENTRIFUGES are available in a variety of rotor and housing seal designs for the following operating conditions: atmospheric vapor-tight gas-tight
Atmospheric centrifuges are the standard version. They are used for applications where there is no harm from products or vapors released to the environment and where it is not necessary to isolate the centrifuge bowl from the surrounding atmosphere.
process could pollute the environment or if contact of the product with ambient air is undesirable. Additional seals on rotor shafts and housing provide the necessary seal. Emissions can be eliminated when purge gas/air is applied to seals or the centrifuge housing is vented.
Vapor-tight versions of FLOTTWEG centrifuges are the right choice in cases where substances emitted from the
Atmospheric
Vapor-tight
Gas-tight
Gas-tight centrifuges allow the safe operation with toxic, corrosive or flammable media by applying inert purge gas to rotor seals and by inertizing the process chamber and centrifuge housing. Slight positive
or negative pressures can be maintained in the process area by regulating the purge gas supply. Special sealing elements minimize the seal gas consumption.
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and pharmaceutical industry, processes with flammable organic solvents or oil sludge treatment processes. These centrifuges comply with ATEX 95 in Zone 1, up to temperature class T4.
oxygen is reduced below critical level with the inert gas. Purging is complete if a multiple of the system volume has passed through the machine or if an oxygen probe at the centrifuge housing shows a safe oxygen concentration.
small overpressure. This prevents atmospheric air from penetrating into the system.
Purging
Before starting, the entire system including the centrifuge is purged. For this purpose, large volumes of inert gas are flushed through the system until the
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Lubrication
FLOTTWEG CENTRIFUGES can be provided with different lubrication systems. The lubrication system depends on the type of operation, for example, batch or continuous operation and the degree of automation of the entire system.
pensed proportionally through a special piston distributor. The scroll bearings are permanently sealed and lubricated, but can also be re-greased manually.
be automatically activated. This ensures the uniform and reliable lubrication of the centrifuge. It prevents bearings from being under- or over-lubricated and rules out short-term spikes in bearing temperatures and excessive grease consumption. The grease pump is automatically controlled. For many applications, an airoperated oil droplet lubrication system is supplied.
available for utilization in explosion-proof areas. They are suited for Zone 1 up to temperature class T4 according to ATEX 95. This system does not require oil recirculation or treatment.
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Wear protection
FLOTTWEG offers a wide range of wear protection to meet the requirements of the many different applications in which centrifuges are installed:
[1] Welded hard facing or spray coating [2] Ceramic [3] Tungsten carbide tiles, brazed or bolted [4] Chill castings [5] Plastic liners
In order to minimize maintenance costs for applications involving highly abrasive products, all wear protection elements, except welded hard facings or spray coatings, are field-replaceable.
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Centrifuge monitoring
temperature limits, the centrifuge alarms or shuts down. This preventive measure safeguards against bearing failure or machine damage.
Pressure waves (stock impulses) emitted by damaged or worn bearings are picked up by the sensor and converted into an electrical signal An alarm is triggered if the signals from the sensor exceed a set limit more than once every 10 seconds.
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Customer service
preventive maintenance.
ISO certification
FLOTTWEG is ISO 9001 certified and manufactures its products in compliance with all current technical standards.
The Flottweg mobile test units. Service on call 365 days a year.
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Centrifugal force x g*
DECANTER
Z4E-3 Z4E-4
4150 4150
Z5E-4
3620
Z73-4
3170
Z92-3 Z92-4
2600 2600
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Centrifugal force x g*
TRICANTER
Z4E-3 Z4E-4
4150 4150
Z5E-4
3620
Z6E-3 Z6E-4
3550 3550
SORTICANTER
K4D-4 2880
K6E-4 K6EF-4
1680 2160
SEDICANTER PRODECANTER
S3E
10000
S4E
6500
S6E
5000
* dependent on temperature and density of the slurry
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Australia
Flottweg Australian Representative Office 90 A Pacific Highway Roseville, NSW 2069 Sydney AUSTRALIA Telephone +61/2-94102255 Telefax +61/2-94101466 flottwegsydney@ozemail.com.au
Germany
Flottweg AG Vertriebs- und Service-Center Bro Nord-Ost Handelsplatz 2 04319 Leipzig GERMANY Telephone +49/341 86898-0 Telefax +49/341 86898-40 leipzig@flottweg.com Flottweg AG Vertriebs- und Service-Center Bro Nord-West Rsrather Strae 265 51107 Kln GERMANY Telephone +49/221 299917-20 Telefax +49/221 299917-30 koeln@flottweg.com
Poland
Flottweg Polska ul. Pelplinska 8b 01-683 Warszawa POLAND Telephone +48/22-732 2230 Telefax +48/22-751 4791 FlottwegPoland@flottweg.com
USA/Kanada
Flottweg Separation Technology, Inc. 10700 Toebben Drive Independence, KY41051 USA Telephone +1/859 448-2300 Telefax +1/859 448-2333 sales@flottweg.net
China
Flottweg Separation Technology (Shanghai) Co. Ltd. No. 516, Chunzhong Road Xinzhuang Industrial Zone Shanghai 201108 P. R. CHINA Telephone +86/21-544 20775 Telefax +86/21-544 21653 flottweg@online.sh.cn
CIS/Russia
Flottweg AG Kutusowskij Prospekt 7/4 korpus 1, Office 192-193 121248 Moskau CIS/RUSSIA Telephone +7/095 9748 128 Telefax +7/095 9748 129 flottweg.moskau@flottweg.com
Italy
Veronesi Separatori SPA Via Don Minzoni, 1 40050 Villanova di Castenaso Bologna ITALY Telephone +39/051 6054511 Telefax +39/051 6053183 info@veronesi.separatori.com
For more than 50 FLOTTWEG representatives worldwide see our homepage: http://www.flottweg.com/ contact/service/addresses
France
Flottweg France SAS Technoparc-Espace Media 3 rue Gustave Eiffel 78306 Poissy Cedex FRANCE Telephone +33/1-3922-4044 Telefax +33/1-3922-6453 france@flottweg.fr
Mexico
Flottweg Mexico S.A. de C.V. German Centre Office N 6-4-14, Av. Santa Fe 170 Col. Lomas de Santa Fe 01210 Mexico, D.F. MEXICO Telephone +52/55-9172 9310 Telefax +52/55-9172 9311 juan.gaviria@flottweg.com
Representative:
PR 0004 I 10 5 05 / 09