PC D 00002EN 0909

Alfa Laval decanter centrifuge technology

S e p a ra tin g so lid s fro m liq u id s
A lfa L a va l in b rie f
Alfa Laval is a leading global provider
of specialized products and engineered
solutions.
O ur equipm ent, system s and services
are dedicated to helping custom ers
to optim ize the perform ance of their
processes. Tim e and tim e again.
W e help our custom ers to heat, cool,
separate and transport products such
as oil, w ater, chem icals, beverages,
foodstuff, starch and pharm aceuticals.
O ur w orldw ide organization w orks closely
w ith custom ers in alm ost 100 countries
to help them stay ahead.
H o w to c o n ta c t A lfa L a va l
U p-to-date Alfa Laval contact details
for all countries are alw ays available
on our w ebsite at w w w .alfalaval.com
Separating solids from liquids plays a key role in
countless industrial processes.
D ecanter centrifuges from Alfa Laval perform this
crucial function exceptionally w ell.
A c c e le ra tin g th e p ro c e ss
H ow ever, such clarification is an
extrem ely slow process and w as not
able to m eet industrys needs for m ore
rapid, controllable results.
The idea behind the developm ent of
the decanter centrifuge w as therefore
to provide the continuous m echanical
separation of liquids from solids, to
keep pace w ith m odern industrial
dem ands.
In essence, a centrifuge is a clarifier
w hose base is w rapped around a
4 Alfa Laval decanter centrifuge technology
W orking principles
C o n tin u o u s se p a ra tio n
Virtually all branches of industry need
to separate solids from liquids at som e
point in their m anufacturing processes.
Alfa Laval has m ore than fifty years of
experience in m eeting this requirem ent
using decanter centrifuge technology.
The decanter centrifuge is based on
the sim ple idea of a clarifier or settling
tank, in w hich particles, sedim ent and
solids gradually fall to the bottom due
to the force of gravity.
centre line. R otating this unit rapidly
m eans that the effect of gravity is
replaced by a centrifugal force the
effect of w hich can be up to 4000
tim es greater.
This force is then used to separate
solids from liquids efficiently in a
m anner that is easy to control.
D epending on the particular
configuration and surrounding
equipm ent, a decanter centrifuge can
be used to separate a w ide range of
different solids from one or tw o liquid
phases, on a continuous basis.
Pond of clarified liquid
O utlet for clarified liquid Screw conveyor
VFD -controlled m otor
for screw conveyor
The sedim ent form ed by the solid
particles is continuously rem oved by
the screw conveyor, w hich rotates at a
different speed than the bow l. As a
result, the solids are gradually
ploughedout of the pond and up the
conical beach.
The centrifugal force com pacts the
solids and expels the surplus liquid.
The dried solids then discharge from
the bow l. The clarified liquid phase or
phases overflow the dam plates
situated at the opposite end of the
bow l. B affles w ithin the centrifuge
casing direct the separated phases into
the correct flow path and prevent any
risk of cross-contam ination.
Alfa Laval decanter centrifuge technology 5
Solids deposited on
bow l w all
C onical beach section
Erosion-protected
solids discharge ports
Inlet tube
H o w a d e c a n te r c e n trifu g e wo rk s
A decanter centrifuge separates solids
from one or tw o liquid phases in one
single continuous process. This is done
using centrifugal forces that can be
w ell beyond 3000 tim es greater than
gravity.
W hen subject to such forces, the
denser solid particles are pressed
outw ards against the rotating bow l
w all, w hile the less dense liquid phase
form s a concentric inner layer. D ifferent
dam plates are used to vary the depth
of the liquid the so-called pond as
required.
W eirs Side w all
depth
C ake
com paction
Surface area Feed system C ake rem oval
C larifier becom es a decanter centrifuge
The speed of the screw conveyor m ay
be autom atically adjusted by use of the
variable frequency drive (VFD ) in order
to adjust to variation in the solids load.
M ain m otor
The key
to exceptional perform ance
In specifying a decanter centrifuge for a
particular application, a series of other
specific design considerations has to
be taken into account:
the pitch of the conveyor
feed zone design
beach angle
bow l surface
abrasion resistance
m aterials used in construction.
T h e fo u r m a in se c tio n s
Alfa Laval decanter centrifuges feature
four m ain sections, each optim ized for
m axim um perform ance.
I n le t zo n e
The inlet zone accelerates the feed
slurry up to the speed of the bow l. A
properly designed inlet zone keeps any
degradation of the feed solids to a
m inim um as w ell as avoiding disturb-
ance of the sedim ent in the bow l.
6 Alfa Laval decanter centrifuge technology
Wid e -ra n g in g p e rfo rm a n c e
Alfa Laval decanter centrifuges provide
exceptional perform ance w hen
separating solids from liquids, and
m ake it possible to do so continuously,
efficiently and controllably.
D ecanters are invariably the first choice
to m eet such separation needs by
virtue of their high reliability, continuous
operation, low capital cost/capacity
ratio and low m aintenance costs.
Alfa Laval decanter centrifuges are
designed to handle a w ide range of
solid particles w ith diam eters from 5
m m to a few m icrons.
D ecanter units can also handle slurries
w ith a solid content from as low as
0.1% w /w to m ore than 65% w /w .
D ecanter centrifuges can accept
variations in the feed m ore effectively
than other types of centrifuge or
separation equipm ent.
P e rfo rm a n c e c rite ria
Five crucial factors determ ine the
perform ance of decanter centrifuges:
the centrifugal force required for
sedim entation of the solids
the clarification area necessary to
capturethe solids
the differential speed required to
transport the solids out of the
decanter
the hydrodynam ic design, w hich
determ ines the exact param eters for
the turbulence
the design of the conveyor and
beach sections, w hich are im portant
for efficient solids transportation.
Alfa Laval decanter centrifuge technology 7
A num ber of feed zone specifications
are available for Alfa Laval decanter
centrifuges, each designed to ensure
m axim um perform ance in conjunction
w ith a specific process.
S c re w c o n ve yo r
The key to good decanter perform ance
lies in the efficient, effective scrolling of
the sedim ented solids. The design of
the screw conveyor is therefore crucial.
Alfa Laval has the expertise needed to
m atch the dem ands involved in specific
industrial processes w ith specific
configurations of flight pitch, lead angle
and differential speed, in order to
secure the best possible results.
S o lid s d isc h a rg e se c tio n
D epending on the application, the
consistency of the separated solids
can vary from a dry pow der to a paste.
The configuration of the discharge
zone is therefore chosen to enable
such cakesto exit as effectively as
possible.
Innovative Alfa Laval design enables
erosion-prone com ponents used in the
solids discharge zone to be replaced
on site at low cost and w ith a m inim um
of disturbance to production.
L iq u id d isc h a rg e se c tio n
In a tw o-phase decanter, the liquid
level is regulated by dam plates.
W hen operating in a three-phase
m ode, each phase discharges over a
set of dam plates into separate baffled
com partm ents in the casing.
In certain applications, a centripetal
pum p discharge that utilizes the
pressure head developed by the
rotating liquid phase is used to pum p
the liquid from the decanter.
L iq u id p h a se o u tle t
Three-phase design Paring disc design
Light liquid phase outlet
H eavy liquid phase outlet
Liquid outlet
8 Alfa Laval decanter centrifuge technology
B enefits and features
T h e A lfa L a va l d iffe re n c e
The ability to separate the liquid and
solid com ponents of often highly
com plex, high-value processing
stream s and to do so w ith m eticulous
control, low cost and high reliability
requires decanter centrifuge technology
that is second to none.
W hen the profitability of an entire
process is at stake, it is im portant that
the custom er has a partner that can be
relied on to m eet the highly com plex
dem ands associated w ith m odern
industrial separation.
E x p e rie n c e c o u n ts
Alfa Laval has m ore than fifty years of
practical experience w ith the design
and m anufacture of high perform ance
decanter centrifuges.
This puts us in a unique position to
translate custom er requirem ents into
efficient, reliable m achine design and
solutions.
And w ith facilities all over the w orld,
Alfa Laval is in a position to provide
custom ers w ith superior products,
superior service and superior results at
any location.
R e se a rc h a n d d e ve lo p m e n t
Alfa Laval conducts extensive ongoing
R &D into all the technologies involved
in the design and operation of decanter
centrifuges.
O ur know -how and specialist process
experience put us in a unique position
to m atch the exact needs of each
custom er and each particular
application and installation.
M a te ria ls te c h n o lo g y
Alfa Laval uses high-grade stainless
steel for all parts that com e into
contact w ith the process, in order to
avoid any risk of the corrosion
associated w ith the use of carbon
steel. C orrosion leads to product
contam ination, lack of balance, high
m aintenance and lengthy dow n tim e.
Alfa Laval decanter centrifuge technology 9
Ease of m aintenance and m inim um
dow n tim e are im portant for users of
decanter centrifuges. R otating
com ponents of Alfa Laval decanter
centrifuges exposed to high stress are
therefore m achined from high-strength
centrifugally cast stainless steel. This
ensures castings w ith a uniform grain
structure free from flaw s and defects
as w ell as a com pletely w eld-free
finished com ponent. The results are
m axim um strength, unparalleled
reliability and a long service life.
In decanter centrifuges, the optim al
choice of m aterials for each
com ponent is crucial for success.
A b ra sio n re sista n c e
W ear caused by the abrasive action of
solids affects both the perform ance
and service life of all centrifuges. Alfa
Laval m etallurgists identified this w ear
as the result of low stress scratching
abrasion and w ere therefore able to
develop w ays of elim inating its effects.
All w ear-prone areas of Alfa Laval
centrifuges the feed zone, solids
discharge output zone, bow l and scroll
are therefore protected by abrasion-
resistant m aterial, selected to m atch
the pattern of w ear in each particular
industrial process.
S e a l te c h n o lo g y
Special casing seals capable of dealing
w ith pressure differentials are required
w herever the processing involves
solvents or toxic m aterials. The types
of seals used, and the details of their
design, depend on the requirem ents
associated w ith each particular
process. C ontinual refinem ent of the
seal technology used in Alfa Laval
decanter centrifuges is ensured by our
technological resources. This is an area
w here Alfa Laval expertise and
experience m ake a key difference.
After fifty years of experience w ith decanter centrifuges, Alfa Laval has reference
installations that are second to none, across a w ide range of industries.
10 Alfa Laval decanter centrifuge technology
P ro c e ss in d u stry a p p lic a tio n s
M in e ra l p ro c e ssin g in d u stry
Kaolin clay and calcium carbonate processing, bentonite and titanium dioxide m anufacturers
O il/g a s e x p lo ra tio n a n d p e tro c h e m ic a l in d u stry
O il and gas exploration, oil refineries and related industries, lubricating oil additives and w aste oil stream recycling
O rg a n ic c h e m ic a l in d u stry
O rganic interm ediate and end products
P o lym e r in d u stry
Therm oplastics including PVC , polypropylene, polystyrene, synthetic rubber and fibres
I n o rg a n ic c h e m ic a l in d u stry
B leaching agents, acids, silica products and fertilizers
E th a n o l p ro d u c tio n
Processing of grain alcohol spent w ash and m olasses ferm enter residues
S ta rc h p ro c e ssin g
B ased on w heat, m aize, tapioca, cassava and potatoes
Wa ste re c yc lin g
R ecovery and recycling of w aste stream s from the sectors listed above
B enefits pay off
Applications
Alfa Laval decanter centrifuge technology 11
F o o d a p p lic a tio n s
A n im a l p ro te in
Fish and m eat by-product processing
Surim i processing
Edible protein recovery
B re we ry
R ecovery of extract, w ort and yeast
C o ffe e a n d te a
Extraction of instant coffee and tea
D a iry
R ecovery of casein, lactose, w hey fines and cheese fines
E d ib le o il
C larification of palm oil, olive oil and pressed seed oil
J u ic e
Extraction from fruit, berries and vegetables
P e c tin
R ecovery of extracted pectin
Ve g e ta b le p ro te in
Extraction from soybeans, oil seeds and legum inous crops
Win e
M ust and w ine clarification
12 Alfa Laval decanter centrifuge technology
In m odern industrial processes,
efficient, w ell-planned service plays an
im portant part in m aintaining profitable
operations.
F u ll c o n tro l
Alfa Laval operates w ith a highly
sophisticated N onstop Perform ance
concept m ade possible by our
w orldw ide netw ork of service and
spare parts distribution centres in m ore
than fifty countries throughout
the w orld.
N onstop Perform ance
Service counts
Alfa Laval decanter centrifuge technology 13
Alfa Laval has full control over the entire
supply chain, w hich m eans that w e can
provide custom ers w ith response tim es,
availability and lead tim es that are
second to none.
S e rvic e wh e n it fits in
The service requirem ents for Alfa Laval
decanter centrifuges are m inim al, and
planned preventive m aintenance is the
key to m aking sure this alw ays rem ains
the case.
Alfa Lavals w orldw ide service
capabilities and vast experience w ith
the contract m aintenance and service
of decanter centrifuges ensure that any
service w ork required involves the
absolute m inim um of disturbance to
operations.
14 Alfa Laval decanter centrifuge technology
Separating solids from liquids plays a key role in
countless industrial processes.
D ecanter centrifuges from Alfa Laval perform this
crucial function exceptionally w ell.
PC D 00002EN 0909
Alfa Laval decanter centrifuge technology
S e p a ra tin g so lid s fro m liq u id s
A lfa L a va l in b rie f
Alfa Laval is a leading global provider
of specialized products and engineered
solutions.
O ur equipm ent, system s and services
are dedicated to helping custom ers
to optim ize the perform ance of their
processes. Tim e and tim e again.
W e help our custom ers to heat, cool,
separate and transport products such
as oil, w ater, chem icals, beverages,
foodstuff, starch and pharm aceuticals.
O ur w orldw ide organization w orks closely
w ith custom ers in alm ost 100 countries
to help them stay ahead.
H o w to c o n ta c t A lfa L a va l
U p-to-date Alfa Laval contact details
for all countries are alw ays available
on our w ebsite at w w w .alfalaval.com