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INNOVATIVE SOLID BOWL CENTRIFUGE TECHNOLOGY

INNOVATIVE SOLID BOWL CENTRIFUGE TECHNOLOGY

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<strong>INNOVATIVE</strong> <strong>SOLID</strong> <strong>BOWL</strong><br />

<strong>CENTRIFUGE</strong> <strong>TECHNOLOGY</strong>


2<br />

Solid bowl centrifuge technology<br />

Modern centrifuges are used<br />

in technical processes for the<br />

mechanical separation of mixtures<br />

of solids and liquids.<br />

Sedimentation, centrifugation,<br />

and filtration are mechanical<br />

separation processes, in contrast<br />

to distillation, incineration<br />

and thermal drying, which are<br />

Modern centrifuges have many<br />

advantages in comparison to<br />

other separation processes<br />

such as filtration and sedimentation.<br />

Compact designs,<br />

thermal separation processes.<br />

In many processes, mechanical<br />

separation is primarily responsible<br />

for product quality,<br />

production efficiency and environmental<br />

control. Mechanical<br />

separation processes are<br />

found in practically all industrial<br />

sectors, including food, chemi-<br />

sealed construction to control<br />

odor emissions and avoid contamination<br />

of the product, ease<br />

of operation with continuous or<br />

automatic control systems,<br />

cal, pharmaceutical, biotech,<br />

mineral, and environmental.<br />

Advantages of modern centrifuges<br />

and limited replaceable operating<br />

parts such as filter media or<br />

filter aids make centrifuges advantageous<br />

to use.


Applications<br />

The following basic process<br />

operations are possible with<br />

solid bowl decanter centrifuges:<br />

• Clarification of liquids<br />

• Dewatering of sludges and<br />

suspensions<br />

• Thickening of slurries<br />

• Separation of three-phase<br />

mixtures, i.e. two immiscible<br />

liquid phases and a solid<br />

phase<br />

® = registered trademark in various countries<br />

• Classification of solids in a<br />

suspension according to particle<br />

size (wet classification)<br />

• Sorting of solids by density.<br />

To obtain optimum results, solid<br />

bowl decanter centrifuges<br />

must be custom designed to<br />

suit specific separation<br />

processes.<br />

FLOTTWEG <strong>CENTRIFUGE</strong>S<br />

can more effectively help one<br />

reach their processing goals by<br />

offering a variety of basic designs,<br />

such as the DECANTER,<br />

TRICANTER ® , SEDICANTER ®<br />

and SORTICANTER ® . Solid<br />

bowl centrifuges are used in<br />

most areas of mechanical<br />

liquid-solid separation.<br />

3


4<br />

Typical processes<br />

Foodstuffs<br />

Animal fat<br />

Blood<br />

Brewer’s yeast and trub<br />

Casein<br />

Clarified butter<br />

Coffee essence<br />

Corn stillage<br />

Drinking water treatment<br />

Fish meal<br />

Fish water<br />

Fruit juices<br />

Gelatin<br />

Lactose<br />

Meat extracts<br />

Molasses<br />

Mycelia<br />

Potato protein<br />

Potato scrapings<br />

Proteins<br />

Sorbose<br />

Soybean flour<br />

Starches<br />

Vegetable extracts<br />

Vegetable juices<br />

Vegetable oils<br />

Wine and beer<br />

Examples from more than 300 different applications<br />

Chemical products<br />

Aluminum hydroxide<br />

Barium sulfate<br />

Bauxite<br />

Bentonite<br />

Calcium carbonate<br />

Calcium fluoride<br />

Calcium sulfate<br />

Carbide sludges<br />

Caustic soda<br />

Cellulose derivatives<br />

Clay sludge<br />

Color pigments<br />

Cryolite<br />

DMT<br />

Epoxy resin<br />

Fluorescents<br />

Graphite<br />

Gypsum<br />

HDPE<br />

Iron hydroxide<br />

Iron oxide<br />

Kaolin<br />

Latex<br />

Lead oxide<br />

Lead sulfate<br />

Lignine sulfate<br />

Magnesium hydroxide<br />

Mica<br />

Mineral oil<br />

Nickel hydroxide<br />

Pharmaceutical intermediates<br />

Phosphate compounds<br />

Phosphoric acid<br />

Plastics derivatives/additives<br />

PMMA<br />

Polypropylene<br />

Polystyrene<br />

PVC<br />

Silica<br />

Silicate<br />

Sodium chloride<br />

Titanium dioxide<br />

Tricalcium phosphate<br />

Various salts<br />

Vitamins<br />

Zinc carbonate<br />

Zinc oxide<br />

Zinc sulfate<br />

Miscellaneous<br />

Coal tar cleaning<br />

Drilling mud<br />

Hide scrapings<br />

Industrial wastewater treatment<br />

Manure<br />

Municipal wastewater treatment<br />

Oil sludges<br />

Paint sludges<br />

Plastics sorting/recycling<br />

Steelworks sludges


Solid bowl centrifuges<br />

The basic principle of the solid<br />

bowl centrifuge has been<br />

known since the end of the<br />

19th century. Over the course<br />

of time, technology improvements<br />

along with the availability<br />

of high strength and corrosion<br />

resistant raw materials<br />

have allowed solid bowl de-<br />

canters to be applicable to<br />

many processes. The utilization<br />

of electronic and electromechanical<br />

measuring and<br />

control components has improved<br />

the performance and<br />

availability of the machines.<br />

The basic design of a solid<br />

bowl centrifuge is relatively<br />

simple and can be customized<br />

by Flottweg for different requirements.<br />

Of all modern industrial<br />

centrifuges, solid bowl<br />

centrifuges have the broadest<br />

range of application.<br />

5


6<br />

FLOTTWEG DECANTER <strong>CENTRIFUGE</strong>S<br />

Feed<br />

The slurry is fed through a stationary<br />

pipe into the feed zone<br />

located in the center of the<br />

scroll. The product is then accelerated<br />

circumferentially and<br />

delivered through distribution<br />

ports into the bowl.<br />

Bowl<br />

The bowl has a cylindrical/<br />

conical shape and rotates at<br />

a pre-set speed optimal for the<br />

application. The slurry rotates<br />

solids discharge<br />

FLOTTWEG DECANTER for the liquid-solid separation<br />

with gravity overflow of the liquid phase (centrate)<br />

with a different scroll design or<br />

by modifying an existing scroll.<br />

Scroll pitch and single or multiple<br />

flight configurations are important<br />

design variables.<br />

with the bowl at the operating<br />

speed and forms a concentric<br />

layer at the bowl wall. The<br />

solids contained in the slurry<br />

are deposited against the bowl<br />

wall by centrifugal force. The<br />

length of the cylindrical bowl<br />

section and the cone angle are<br />

selected to meet the specific<br />

requirements of an application.<br />

Scroll<br />

The scroll rotates at a slightly<br />

different speed than the bowl<br />

Eccentric – adjustable weir plates (patented)<br />

and conveys the deposited<br />

solids toward the conical end<br />

of the bowl. This differential<br />

speed determines the residence<br />

time of the solids in the<br />

bowl. Residence time is an important<br />

variable for the dry<br />

solids content. It can be adjusted<br />

by changing the differential<br />

speed of the scroll thus<br />

providing optimal separation.<br />

If the physical properties of the<br />

slurry change, FLOTTWEG<br />

DECANTERS can be supplied<br />

liquid discharge by gravity<br />

feed inlet


Solids discharge<br />

Settled solids are ejected<br />

through ports at the conical<br />

end of the bowl into the solids<br />

housing and fall through to the<br />

discharge chute.<br />

Materials of construction<br />

FLOTTWEG uses high-quality<br />

stainless steel for all wetted<br />

areas. Bowl and scroll castings<br />

are made from centrifugal cast<br />

high strength and corrosion<br />

resistant stainless steel.<br />

solids discharge<br />

Rotor bearing<br />

A special selection and<br />

arrangement of bearings provides<br />

long life and exceptional<br />

reliability. A central lubrication<br />

system supplies either grease<br />

or oil to bearings.<br />

Overflow weirs<br />

The clarified liquids flow to the<br />

cylindrical end of the bowl<br />

where they exit over weir<br />

plates. Easily adjustable precision<br />

weir plates allow for the<br />

FLOTTWEG DECANTER with pressurized centrate discharge<br />

precise adjustment of the pond<br />

depth in the bowl. Overflow is<br />

then collected in a centrate<br />

chamber and discharged by<br />

gravity.<br />

Impeller (skimmer)<br />

The clarified liquid can also be<br />

decanted with an impeller and<br />

discharged from the bowl under<br />

pressure. This eliminates<br />

the need for a separate centrate<br />

pump. The FLOTTWEG<br />

adjustable impeller is an engi-<br />

Adjustable impeller<br />

neering refinement that permits<br />

quick and precise adjustment<br />

of the pond depth during<br />

operation to accommodate<br />

changing conditions.<br />

liquid discharge<br />

under pressure<br />

feed inlet


8<br />

FLOTTWEG TRICANTER ®<br />

3-phase separation<br />

The FLOTTWEG TRICANTER ®<br />

enables three-phase separation,<br />

i.e. the simultaneous<br />

separation of two immiscible<br />

liquids with different densities<br />

and one solid phase, provided<br />

that the solid phase is the<br />

heaviest phase. The most important<br />

difference from a decanter<br />

is the separate discharge<br />

of the two liquid phases. The<br />

FLOTTWEG TRICANTER ®<br />

discharges the heavy liquid<br />

through an adjustable impeller<br />

under pressure and the light<br />

phase by gravity. The adjustable<br />

impeller allows adjusting<br />

the separation zone and degree<br />

of separation within the<br />

machine during operation. This<br />

optimizes purity of the liquids<br />

and may possibly eliminate<br />

downstream equipment.<br />

solids discharge liquid discharge<br />

FLOTTWEG TRICANTER ® (THREE PHASE DECANTER)<br />

Discharge of the centrate: heavy liquid phase under pressure, light phase by gravity<br />

Adjustable impeller<br />

discharge<br />

of heavy phase<br />

under pressure<br />

feed inlet


FLOTTWEG SORTICANTER ®<br />

The innovative FLOTTWEG<br />

SORTICANTER ® is designed<br />

for the separation of solids by<br />

density. The process is aided<br />

by a carrier liquid with a specific<br />

gravity that is between the<br />

densities of the two solid<br />

streams to be separated.<br />

The patented FLOTTWEG<br />

SORTICANTER ® consists of a<br />

cylindrical conical bowl with a<br />

second inner cone at the cylindrical<br />

end and a double acting<br />

FLOTTWEG SORTICANTER ® for plastic recycling<br />

flights wound in the opposite<br />

direction to those conveying<br />

sedimentated solids transfer<br />

the lighter solids across a drying<br />

zone to the exit ports. The<br />

liquid is skimmed off and discharged<br />

under pressure by an<br />

® = registered trademark in various countries<br />

scroll conforming to the inner<br />

contour of the bowl.<br />

The bowl and lagging scroll<br />

rotate at a high speed in the<br />

same direction. The solid-liquid<br />

mixture is conveyed through<br />

the centrifuge feed pipe and inlet<br />

ports in the scroll body into<br />

the bowl and accelerated to<br />

the bowl speed. Centrifugal<br />

force causes the solids which<br />

are heavier than the carrier<br />

liquid to settle against the<br />

impeller at the cylindrical end<br />

of the bowl.<br />

After an intermediate cleaning<br />

step, liquid may be recycled as<br />

carrier liquid. Carrier liquids<br />

with different densities enable<br />

bowl wall. The scroll conveys the<br />

deposited layer of heavy solids<br />

toward the conical bowl section,<br />

over the drying zone and<br />

ejects them through ports into<br />

the stationary solids housing<br />

and down the discharge chute.<br />

The solids which are lighter<br />

than the carrier liquid float and<br />

are conveyed with the liquid<br />

toward the cylindrical end of<br />

the bowl. When the floating<br />

particles have reached the<br />

second inner cone, scroll<br />

the user to shift the effective<br />

interface zone.<br />

liquid discharge<br />

under pressure<br />

solids discharge of heavy phase solids discharge of light phase<br />

feed inlet<br />

9


10<br />

FLOTTWEG SEDICANTER ®<br />

The FLOTTWEG SEDICANTER ®<br />

is used for the separation of<br />

solids from liquids when the<br />

solids form a soft but flowable<br />

sediment.<br />

The SEDICANTER ® is used in<br />

cases where the solids are too<br />

fine-grained to be processed<br />

in a normal decanter and the<br />

sediment cannot be easily discharged<br />

from the decanter due<br />

to its soft consistency. During<br />

the separation process, the<br />

FLOTTWEG SEDICANTER ®<br />

• Gastight machine design<br />

• Clean-in-place provisions<br />

available to meet pharmaceutical<br />

industry standards<br />

liquid and solids move in the<br />

same direction without having<br />

to pass through a turbulent<br />

inlet zone. The centrate is discharged<br />

through an adjustable<br />

impeller within the scroll. The<br />

sediment formed in the<br />

SEDICANTER ® , the heavy<br />

phase, is accumulated and<br />

pressed out of the bowl under<br />

an immersion disc.<br />

Applications for the<br />

SEDICANTER ® include “soft<br />

• Fluoropolymer rotor seals<br />

available for critical applications<br />

FLOTTWEG SEDICANTER ® S4E-3<br />

products” such as biomasses,<br />

yeast suspensions, protein<br />

suspensions and fermentation<br />

broths.<br />

Technical features:<br />

• Up to 10,000 x g centrifugal<br />

force possible to facilitate the<br />

separation of very fine, slowsettling<br />

solids<br />

• Uniquely designed feed distributor<br />

and bowl seal to prevent<br />

foaming in the product<br />

inlet zone<br />

solids discharge<br />

liquid discharge<br />

under pressure<br />

• Optional drives including the<br />

FLOTTWEG SIMP-DRIVE ® .<br />

feed inlet


Centrifuge cleaning<br />

Centrifuges must always be<br />

flushed clean before shutdown.<br />

Depending on the<br />

application, different cleaning<br />

systems may be incorporated<br />

into the centrifuge<br />

design.<br />

FLOTTWEG <strong>CENTRIFUGE</strong>S<br />

are designed for continuous<br />

operation and do not need to<br />

be opened for cleaning.<br />

FLOTTWEG <strong>CENTRIFUGE</strong>S for<br />

pharmaceutical, biotechnologi-<br />

Characteristic features of<br />

centrifuges to meet hygienic<br />

requirements are:<br />

• All welds are ground to meet<br />

specific sanitary finish standards.<br />

• All product-contact parts are<br />

provided with a surface finish<br />

in accordance with specified<br />

roughness values.<br />

® = registered trademark in various countries<br />

cal and food processing applications<br />

are designed with<br />

Clean-in-Place (CiP) systems.<br />

Cleaning of Centrifuges for<br />

Standard Applications<br />

For the majority of applications<br />

(e.g. sludges, separation of<br />

crystalline products), it is sufficient<br />

to flush the centrifuge<br />

before shutdown through the<br />

feed pipe to remove deposits<br />

of solids. The flushing time and<br />

the type of cleaning fluid are<br />

• Rinsing nozzles are provided<br />

for the centrifuge housing<br />

and for the interior of the<br />

scroll body.<br />

• The centrate impeller is adjustable<br />

to facilitate flushing<br />

of the bowl.<br />

• Frequency-controlled drives<br />

for CIP-cleaning at low speed.<br />

• Electropolished scroll, housing<br />

and bowl surfaces.<br />

product-dependent. In most<br />

cases, the use of a solids-free<br />

centrate will be adequate.<br />

Additional rinsing nozzles for<br />

cleaning the housing, the bowl<br />

exterior and the scroll interior<br />

can be installed if required.<br />

Cleaning of Centrifuges for<br />

Pharmaceutical, Biotechnical<br />

and Food Processing<br />

Applications<br />

FLOTTWEG designs its centrifuges<br />

for the pharmaceutical,<br />

• Special hygienic housing<br />

seals<br />

• Electrically reversible scroll<br />

rotation for enhancing cleaning<br />

during CIP cleaning.<br />

biotechnological and food<br />

processing industries to meet<br />

the highest demands for cleanliness.<br />

Requirements and<br />

specifications for design,<br />

manufacturing and testing are<br />

according to specific company<br />

standards.<br />

11


12<br />

Drives<br />

General<br />

Decanter centrifuges are subject<br />

to two conflicting basic<br />

drive requirements. On one<br />

hand, the entire rotor has to<br />

run at high speed, and on the<br />

other hand, the scroll inside the<br />

bowl has to rotate at a very low<br />

differential speed and simultaneously<br />

at a high torque relative<br />

to the bowl wall.<br />

FLOTTWEG frequency controlled<br />

electric motors or<br />

speed-adjustable hydraulic<br />

motors offer infinitely variable<br />

speed. Long start-up times<br />

help overcome a high inertia<br />

moment and avoid peak loads<br />

during the initial current phase.<br />

FLOTTWEG offers hydraulic<br />

motors or gear drives to drive<br />

the scroll depending on the<br />

application. The majority of the<br />

drive configurations offer variable<br />

differential speeds. This<br />

ensures optimum adjustment<br />

to meet individual customer<br />

requirements.<br />

Fully hydraulic drive Hybrid drive Frequency inverter drive (VFD)<br />

Fully hydraulic drive<br />

The bowl and the scroll are<br />

driven by separate hydraulic<br />

motors. A compact hydraulic<br />

aggregate with two variable<br />

pumps feeds two separate oil<br />

circuits. The volume flow of the<br />

oil determines the bowl speed<br />

and the differential speed of<br />

the scroll, whereas the oil supply<br />

pressure is directly proportional<br />

to the torque output and<br />

thus to the load. This drive per-<br />

mits the use of variably adjustable<br />

control, monitoring<br />

and analog control. The drive’s<br />

design enables independent<br />

rotation of the scroll even when<br />

the bowl is shut down.<br />

Hybrid drive<br />

In this version, a frequencycontrolled<br />

electric motor drives<br />

the bowl instead of a hydraulic<br />

motor. The hydraulic aggregate<br />

for the scroll is compact<br />

because only one oil circuit is<br />

required. Control and adjustment<br />

are the same as with the<br />

hydraulic drive. Hydraulic<br />

drives offer particular advantages<br />

for applications in mobile<br />

processing systems. Their<br />

compact design (controls, aggregate)<br />

provides for optimal<br />

utilization of floor space. Another<br />

advantage is applicability<br />

in explosion proof areas.


Gear drive with frequency<br />

inverter<br />

A frequency-controlled electric<br />

motor drives the bowl via a<br />

V-belt drive. A second parallel<br />

V-belt drive with a slightly different<br />

transmission ratio powers<br />

a cycloid planetary gear<br />

and generates the differential<br />

speed of the scroll. The differential<br />

speed can be changed<br />

and adjusted by changing<br />

V-belt pulleys.<br />

Backdrive with Dual-VFD SIMP-DRIVE ®<br />

SIMP-DRIVE ®<br />

The SIMP-DRIVE ® constitutes<br />

the new generation of the<br />

FLOTTWEG’s dual frequency<br />

inverter back drive concept.<br />

This new electric drive arrangement<br />

includes the advantages<br />

of the hydraulic and electromechanical<br />

drives. The main<br />

feature of this new concept is<br />

a multi-stage planetary gear<br />

which allows for entirely independent<br />

operation and drive of<br />

The FLOTTWEG gear drive is<br />

the most basic drive solution<br />

and is particularly suited for<br />

separation processes which do<br />

not require operating adjustment<br />

of the differential speed.<br />

Backdrive with Dual-VFD<br />

This solution is derived from<br />

the FLOTTWEG gear drive with<br />

the scroll drive having its own<br />

frequency-controlled motor.<br />

The differential speed can be<br />

the bowl and scroll (similar to<br />

a hydraulic drive)<br />

Benefits include:<br />

• High efficiency and low<br />

energy demand<br />

• A simple drive system not<br />

requiring linkage<br />

• Independent frequency<br />

inverters (VFDs) which are<br />

standard designs, simple<br />

to operate and simple to<br />

maintain<br />

separately adjusted with a preset<br />

range and controlled and<br />

monitored independently of<br />

torque. Both drive motors are<br />

powered by a FLOTTWEG frequency<br />

inverter, which is power-linked<br />

via a regenerative circuit.<br />

This drive is best suited<br />

for high differential speeds.<br />

Bowl drive<br />

Scroll drive<br />

® = registered trademark in various countries<br />

• Constant torque, high solids<br />

• Simple integration into<br />

process control systems<br />

• Smallest possible inverter<br />

size<br />

• High flexibility in the selection<br />

of the operating speed<br />

• Discharge of the bowl even at<br />

full stop<br />

• Applicable for small to medium<br />

differential speeds<br />

• Low power draw.<br />

13


14<br />

Process control system<br />

Centrifuge controls<br />

Fluctuations of the solid<br />

throughput and concentration<br />

in the centrifuge may cause a<br />

decrease in separation results,<br />

blockage or an overload of the<br />

centrifuge. To avoid problems<br />

and to fully utilize the capacity<br />

of the centrifuge, the differential<br />

speed needs to be continuously<br />

adjusted for operating<br />

conditions.<br />

FLOTTWEG offers control systems<br />

for the differential speed<br />

which are based on the following<br />

principle. Scroll torque is a<br />

measure of bowl solids load.<br />

Load and torque should be<br />

kept at an optimum value.<br />

If the torque exceeds the optimum<br />

value, the FLOTTWEG<br />

control system increases the<br />

differential speed to convey the<br />

solid faster out of the bowl until<br />

the torque decreases. Conversely,<br />

the differential speed is<br />

reduced when the torque de-<br />

creases. This automatic control<br />

process ensures optimum separation<br />

during normal operation.<br />

An integrated two-stage<br />

overload protection offers excellent<br />

control of the machine<br />

resulting from process deviations.<br />

If the increase in differential<br />

speed is not sufficient to compensate<br />

for a solids overload,<br />

the feed supply is stopped until<br />

the torque falls back below set


point. In the majority of situations,<br />

this is sufficient to remedy<br />

the overload without having<br />

to shutdown the system. If this<br />

measure is insufficient to keep<br />

the scroll torque from rising,<br />

the bowl drive is shut down<br />

when the torque reaches the<br />

second set point.<br />

As the bowl speed decreases,<br />

the torque is reduced and the<br />

machine will usually empty<br />

itself. Typically there is no need<br />

PLC decanter controller<br />

for manually removing the<br />

solids. Machines with hydraulic<br />

drive or SIMP-DRIVE ® enable<br />

solids discharge at full-torque<br />

scroll operation during the<br />

bowl shut down.<br />

FLOTTWEG provides all machines<br />

with adjustable differential<br />

speeds (hydraulic drives,<br />

dual VFDs and SIMP-DRIVE ®<br />

drives) with this control system.<br />

The range of control systems<br />

covers a basic version<br />

with a hydraulic-mechanical<br />

analog control via an electronic<br />

industrial control system to<br />

programmable logic controllers<br />

(PLC) and integration into distributive<br />

control systems (DCS).<br />

All electronic systems allow for<br />

remote control and monitoring.<br />

Programmable controls support<br />

a variety of complex links<br />

and monitoring for plant<br />

systems (e.g. CIP and automated<br />

process steps).<br />

® = registered trademark<br />

in various countries<br />

15


16<br />

Sealing systems<br />

Most sizes and models of<br />

FLOTTWEG <strong>CENTRIFUGE</strong>S<br />

are available in a variety of<br />

rotor and housing seal designs<br />

for the following operating<br />

conditions:<br />

• atmospheric<br />

• vapor-tight<br />

• gas-tight<br />

FLOTTWEG <strong>CENTRIFUGE</strong>S<br />

can also be adapted for operating<br />

in closed-loop systems.<br />

Atmospheric centrifuges are<br />

the standard version. They are<br />

used for applications where<br />

there is no harm from products<br />

or vapors released to the environment<br />

and where it is not<br />

necessary to isolate the centrifuge<br />

bowl from the surrounding<br />

atmosphere.<br />

Vapor-tight versions of<br />

FLOTTWEG centrifuges are<br />

the right choice in cases where<br />

substances emitted from the<br />

Atmospheric Vapor-tight Gas-tight<br />

Gas-tight centrifuges allow<br />

the safe operation with toxic,<br />

corrosive or flammable media<br />

by applying inert purge gas to<br />

rotor seals and by inertizing the<br />

process chamber and centrifuge<br />

housing. Slight positive<br />

or negative pressures can be<br />

maintained in the process area<br />

by regulating the purge gas<br />

supply. Special sealing elements<br />

minimize the seal gas<br />

consumption.<br />

process could pollute the environment<br />

or if contact of the<br />

product with ambient air is undesirable.<br />

Additional seals on<br />

rotor shafts and housing provide<br />

the necessary seal. Emissions<br />

can be eliminated when<br />

purge gas/air is applied to<br />

seals or the centrifuge housing<br />

is vented.


Purging with inert gas<br />

Processing of hazardous<br />

materials<br />

Processes with any risk of<br />

explosion must be controlled<br />

by using inert gas. Generally,<br />

nitrogen is used. Centrifuges<br />

and system parts used for the<br />

processing of hazardous materials<br />

have to be gastight to prevent<br />

the exit of vapors into the<br />

atmosphere as well as to avoid<br />

the entry of air into the system.<br />

Typical examples are processes<br />

in the chemical, petroleum,<br />

Rotor<br />

Seal<br />

Housing<br />

Control of centrifuges<br />

purged with inert gas is<br />

based on differential pressure<br />

monitoring.<br />

Differential pressure monitoring<br />

maintains a fixed constant<br />

overpressure in the sealing<br />

system using control valves.<br />

This ensures a small overpressure<br />

within the sealing system<br />

and the inside of the centrifuge<br />

guaranteeing protection<br />

against air leakage into the<br />

and pharmaceutical industry,<br />

processes with flammable<br />

organic solvents or oil sludge<br />

treatment processes. These<br />

centrifuges comply with<br />

ATEX 95 in Zone 1, up to<br />

temperature class T4.<br />

Purging<br />

Before starting, the entire system<br />

including the centrifuge is<br />

purged. For this purpose, large<br />

volumes of inert gas are flushed<br />

through the system until the<br />

system and product emission<br />

into the atmosphere.<br />

Processing of materials<br />

susceptible to oxidation<br />

Often the processing of beverages<br />

and food requires that<br />

products be prevented from<br />

undergoing oxidation. For this<br />

purpose the leakage of air into<br />

the centrifuge is prevented by<br />

corresponding constructive<br />

measures and positive inert<br />

oxygen is reduced below critical<br />

level with the inert gas.<br />

Purging is complete if a multiple<br />

of the system volume has<br />

passed through the machine or<br />

if an oxygen probe at the centrifuge<br />

housing shows a safe<br />

oxygen concentration.<br />

Continuous inert gas supply<br />

After successful purging and<br />

during the operation with product,<br />

sufficient inert gas is fed<br />

into the system to ensure a<br />

FLOTTWEG purge gas control unit<br />

gas pressures are maintained<br />

at the centrifuge. In many<br />

cases, carbon dioxide is used<br />

as the inert gas. A system<br />

monitoring the flow of gas is<br />

typically used.<br />

small overpressure. This prevents<br />

atmospheric air from<br />

penetrating into the system.<br />

17


18<br />

Lubrication<br />

FLOTTWEG <strong>CENTRIFUGE</strong>S<br />

can be provided with different<br />

lubrication systems. The lubrication<br />

system depends on the<br />

type of operation, for example,<br />

batch or continuous operation<br />

and the degree of automation<br />

of the entire system.<br />

Central lubrication system<br />

All main lubrication points are<br />

permanently manifolded via<br />

tubing or hoses to a central<br />

pump. The lubricant is dis-<br />

Central lubrication system<br />

(manually operated)<br />

be automatically activated.<br />

This ensures the uniform and<br />

reliable lubrication of the centrifuge.<br />

It prevents bearings<br />

from being under- or over-lubricated<br />

and rules out short-term<br />

spikes in bearing temperatures<br />

and excessive grease consumption.<br />

The grease pump is<br />

automatically controlled.<br />

For many applications, an airoperated<br />

oil droplet lubrication<br />

system is supplied.<br />

pensed proportionally through<br />

a special piston distributor. The<br />

scroll bearings are permanently<br />

sealed and lubricated, but can<br />

also be re-greased manually.<br />

Automatic grease lubrication<br />

Automatic oil droplet<br />

lubrication system<br />

The fully automatic oil-air lubrication<br />

system ensures optimal<br />

lubrication with oil droplets<br />

transported via air to the bearings.<br />

Optimum lubrication is<br />

achieved at high speeds, with<br />

low oil consumption and no<br />

loss in performance. Monitoring<br />

of the oil and air pressure<br />

guarantees high operational<br />

safety. Pneumatic designs are<br />

Automatic grease<br />

lubrication<br />

In contrast to the manual<br />

central lubrication system,<br />

the greasing system can<br />

Oil droplet lubrication system<br />

available for utilization in<br />

explosion-proof areas.<br />

They are suited for Zone 1 up to<br />

temperature class T4 according<br />

to ATEX 95. This system does<br />

not require oil recirculation or<br />

treatment.


Wear protection<br />

FLOTTWEG offers a wide<br />

range of wear protection to<br />

meet the requirements of the<br />

many different applications in<br />

which centrifuges are installed:<br />

Illustration of replaceable wear protection elements<br />

[1] Welded hard facing or spray<br />

coating<br />

[2] Ceramic<br />

[3] Tungsten carbide tiles,<br />

brazed or bolted<br />

[4] Chill castings<br />

[5] Plastic liners<br />

In order to minimize maintenance<br />

costs for applications<br />

involving highly abrasive products,<br />

all wear protection elements,<br />

except welded hard<br />

facings or spray coatings, are<br />

field-replaceable.<br />

19


20<br />

Centrifuge monitoring<br />

Vibration monitoring<br />

(standard)<br />

Vibration sensors transmit acceleration<br />

signals to an analyzer<br />

that sounds an alarm or trips<br />

the centrifuge upon reaching<br />

the full limit value.<br />

Temperature Monitoring<br />

(optional)<br />

Bearing temperatures are constantly<br />

remote-monitored in<br />

Flottweg centrifuges by means<br />

of resistance thermometers.<br />

Upon exceeding pre-set<br />

Shock Pulse Measurement<br />

(SPM) (optional)<br />

The roller bearings in the centrifuge<br />

are monitored continuously<br />

using an SPM system.<br />

Shock-impulse sensors are<br />

installed at each bearing and<br />

connected to a central alarm.<br />

temperature limits, the centrifuge<br />

alarms or shuts down.<br />

This preventive measure safeguards<br />

against bearing failure<br />

or machine damage.<br />

Pressure waves (stock impulses)<br />

emitted by damaged or worn<br />

bearings are picked up by the<br />

sensor and converted into an<br />

electrical signal An alarm is<br />

triggered if the signals from the<br />

sensor exceed a set limit more<br />

than once every 10 seconds.


Customer service<br />

Customer service is our<br />

strength<br />

Application-based project<br />

planning, high-quality manufacturing<br />

and professional<br />

after-sales service are prerequisites<br />

for customer satisfaction.<br />

Experienced and reliable<br />

service engineers from our<br />

customer service department<br />

are ready to respond quickly<br />

to reduce down time. The<br />

FLOTTWEG service group is<br />

also available to perform<br />

The Flottweg mobile test units.<br />

Service on call 365 days a year.<br />

preventive maintenance.<br />

FLOTTWEG services<br />

include:<br />

• Competent advice on<br />

separation processes<br />

• Pilot tests on-site or at the<br />

Flottweg laboratory and test<br />

center<br />

• Selection and specification<br />

of equipment<br />

• Customer-tailored automation/control<br />

systems and<br />

process integration<br />

• Design and construction of<br />

complete process systems<br />

• Installation, commissioning,<br />

maintenance, repair and<br />

spare parts service worldwide.<br />

FLOTTWEG products are<br />

designed and manufactured<br />

in GERMANY!<br />

Service hotline<br />

ISO certification<br />

FLOTTWEG is ISO 9001<br />

certified and manufactures its<br />

products in compliance with<br />

all current technical standards.<br />

Telephone<br />

+49 / 8741 301-321<br />

+49 / 180 5035135<br />

Telefax<br />

+49 / 8741 301-404<br />

21


22<br />

DECANTER<br />

Solid bowl centrifuges<br />

Product lines and models<br />

Z23-3<br />

Z23-4<br />

Z32-3<br />

Z32-4<br />

Z4E-3<br />

Z4E-4<br />

Z5E-4<br />

Z6E-2<br />

Z6E-3<br />

Z6E-4<br />

Z73-4<br />

Z92-3<br />

Z92-4<br />

Centrifugal force x g*<br />

4630<br />

3890<br />

4470<br />

3620<br />

4150<br />

4150<br />

3620<br />

3550<br />

3550<br />

3550<br />

3170<br />

2600<br />

2600<br />

* dependent on temperature<br />

and density of the slurry


TRICANTER ®<br />

SORTICANTER ®<br />

SEDICANTER ®<br />

PRODECANTER ®<br />

® = registered trademark in various countries<br />

Z23-3<br />

Z23-4<br />

Z32-3<br />

Z4E-3<br />

Z4E-4<br />

Z6E-3<br />

Z6E-4<br />

K4D-4<br />

K6E-4<br />

1680<br />

K6EF-4 2160<br />

S3E<br />

S4E<br />

S6E<br />

Centrifugal force x g*<br />

4630<br />

3890<br />

4470<br />

Z32-4 3620<br />

Z5E-4<br />

4150<br />

4150<br />

3620<br />

3550<br />

3550<br />

2880<br />

10000<br />

6500<br />

5000<br />

* dependent on temperature<br />

and density of the slurry<br />

23


Representative:<br />

FLOTTWEG subsidiaries around the world<br />

Australia<br />

Flottweg Australian<br />

Representative Office<br />

90 A Pacific Highway<br />

Roseville, NSW 2069 Sydney<br />

AUSTRALIA<br />

Telephone +61/2-94102255<br />

Telefax +61/2-94101466<br />

flottwegsydney@ozemail.com.au<br />

China<br />

Flottweg Separation Technology<br />

(Shanghai) Co. Ltd.<br />

No. 516, Chunzhong Road<br />

Xinzhuang Industrial Zone<br />

Shanghai 201108<br />

P. R. CHINA<br />

Telephone +86/21-544 20775<br />

Telefax +86/21-544 21653<br />

flottweg@online.sh.cn<br />

CIS/Russia<br />

Flottweg AG<br />

Kutusowskij Prospekt<br />

7/4 korpus 1, Office 192-193<br />

121248 Moskau<br />

CIS/RUSSIA<br />

Telephone +7/095 9748 128<br />

Telefax +7/095 9748 129<br />

flottweg.moskau@flottweg.com<br />

France<br />

Flottweg France SAS<br />

Technoparc-Espace Media<br />

3 rue Gustave Eiffel<br />

78306 Poissy Cedex<br />

FRANCE<br />

Telephone +33/1-3922-4044<br />

Telefax +33/1-3922-6453<br />

france@flottweg.fr<br />

Germany<br />

Flottweg AG<br />

Vertriebs- und Service-Center<br />

Büro Nord-Ost<br />

Handelsplatz 2<br />

04319 Leipzig<br />

GERMANY<br />

Telephone +49/341 86898-0<br />

Telefax +49/341 86898-40<br />

leipzig@flottweg.com<br />

Flottweg AG<br />

Vertriebs- und Service-Center<br />

Büro Nord-West<br />

Rösrather Straße 265<br />

51107 Köln<br />

GERMANY<br />

Telephone +49/221 299917-20<br />

Telefax +49/221 299917-30<br />

koeln@flottweg.com<br />

Italy<br />

Veronesi Separatori SPA<br />

Via Don Minzoni, 1<br />

40050 Villanova di Castenaso<br />

Bologna<br />

ITALY<br />

Telephone +39/051 6054511<br />

Telefax +39/051 6053183<br />

info@veronesi.separatori.com<br />

Mexico<br />

Flottweg Mexico S.A. de C.V.<br />

German Centre Office N° 6-4-14,<br />

Av. Santa Fe 170<br />

Col. Lomas de Santa Fe<br />

01210 Mexico, D.F.<br />

MEXICO<br />

Telephone +52/55-9172 9310<br />

Telefax +52/55-9172 9311<br />

juan.gaviria@flottweg.com<br />

Poland<br />

Flottweg Polska<br />

ul. Pelplinska 8b<br />

01-683 Warszawa<br />

POLAND<br />

Telephone +48/22-732 2230<br />

Telefax +48/22-751 4791<br />

FlottwegPoland@flottweg.com<br />

USA/Kanada<br />

Flottweg Separation Technology, Inc.<br />

10700 Toebben Drive<br />

Independence, KY41051<br />

USA<br />

Telephone +1/859 448-2300<br />

Telefax +1/859 448-2333<br />

sales@flottweg.net<br />

For more than 50 FLOTTWEG<br />

representatives worldwide see<br />

our homepage:<br />

http://www.flottweg.com/<br />

contact/service/addresses<br />

PR – 0004 I – 10 5 05 / 09

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