Separator's Digest 2012/3

Separator’s Digest® 

The Magazine of GEA Westfalia Separator Group Edition 3 | 2012 

Insulin 

Expanding markets and production 

in the emerging nations 

Petrochemical Additives 

More stringent market requirements 

PECTIN PRODUCTION

GEA Westfalia Separator Group | Separator’s Digest ® 2012 ACHEMA Special 

Contents 

Preface 

3 Intelligent Solutions for Challenging Markets 

Separator‘s News 

4 Innovative Separator Concepts: 

GEA Westfalia Separator directdrive ∞ 

5 Robust and Very Reliable 

5 One Machine – Three Sizes 

GEA Westfalia Separator Group 

6 Production of Insulin 

10 Petrochemical Additives 

14 Boosting Yield and Efficiency 

18 The Sun Continues to Shine 

22 Valuable Protein from Stillage 

26 Drainage Systems for Drilling Platforms 

and Drilling Vessels 

Lifestyle 

30 Incredible Versatility 

Imprint 

Publisher: 

GEA Westfalia Separator Group GmbH 

Project management: Dr. Bertram Melzig-Thiel 

Editors: 

Dr. Bertram Melzig-Thiel (person responsible according 

to German press law), Manfred Kaiser, 

Lilian Schmalenstroer 

Photography: 

Michael Dannenmann, Tim Luhmann, 

GEA Westfalia Separator Group GmbH archive, 

iStock 

Conception and Layout: 

Kabutz Communication GmbH 

Feldstraße 5 · 59423 Unna (Germany) 

info@kabutz.de · www.kabutz.de 

The product information included in this magazine is 

solely for information purposes and is non-binding. 

Binding information, in particular regarding performance 

and suitability for specific applications, can only be 

provided in response to a specific enquiry. 

2


The number of proteins and enzymes which are 

used for therapeutic or immunising purposes is 

increasing at breakneck speed at the moment. 

Those so-called bio-pharmaceuticals include 

vaccines as well as insulin. These substances are 

taking an increasing share in pharmaceutical 

developments and markets. The trigger for the 

heavy demand for insulin is the change in the 

population structure, among other things. 

Separators from GEA Westfalia Separator Group 

take over the decisive function in the core process 

in the manufacture of recombinant insulin. 

Intelligent Solutions for 

CHALLENGING MARKETS 

In this issue of Separator’s Digest you will read more about the 

solutions for the production of insulin in the new plant of 

Gulf Pharmaceuticals Industries (Julphar) located in Ras al 

Khaimah. With this new insulin factory Julphar will render 

available this life-saving drug to many patients in the United 

Arab Emirates and the Near East. In its capacity as bidder for 

the complete solution, GEA was responsible for engineering, 

supply, start-up and qualification of the entire systems used 

to manufacture the extra-pure substances as well as several 

process systems and purification plants. 

Moreover, in this magazine we will present to you a new 

possibility of isolating proteins from the residues of alcohol 

distillation which being a valuable fodder protein attract new 

markets for animal fodder. Moreover, we will explain how 

further yield and profitability reserves can be used in the 

production of pectin, and in addition we will explain how centrifugal 

processing techniques provided by GEA Westfalia 

Separator Group ensure highly efficient recovery of recyclable 

materials in the wafer production for photovoltaic systems. 

And finally we will go on board of drilling platforms and 

drilling ships with you. For the treatment of drilling mud and 

water on the drilling decks, GEA Westfalia Separator Group 

has developed several graduated processes up to the recovery 

of the valuable heavy mineral of barite. 

Ever more complex tasks make one thing very clear: demanding 

markets require innovative and individual solutions on the 

highest level. For this reason, GEA Westfalia Separator Group 

is using Achema 2012 as an ideal platform for the launch of 

the new decanter generation ecoforce with summationdrive 

as well as the separator series directdrive ∞ for the fields of 

application in chemicals, pharmaceuticals, mineral processing 

and renewable resources. Another exhibit is the steam-sterilizable 

package unit with separator and the entire periphery on one 

single frame. The size presented is especially suitable for 

laboratory and pilot plants; the integrated separator is the only 

unit worldwide which reaches a centrifugal acceleration 

of 20,000 g. 

We think about things for you and find intelligent solutions in 

all fields of application. Please visit us at Achema 2012. 

We will show you. 

Markus Hüllmann 

Segment President GEA Mechanical Equipment 

3


Innovative 

Separator 

Concepts: 

GEA Westfalia 

Separator 

directdrive 

Robust separator with integrated 

direct drive for chemicals, 

pharmaceuticals and renewable 

resources 

The new series of separators with the integrated GEA Westfalia 

Separator directdrive ∞ can be used in multiple areas of 

application. This new drive concept offers advantages specifically 

with its much reduced level of maintenance requirement and 

the resultant higher level of availability. 

GEA Westfalia Separator Group is presenting the directdrive ∞ 

at ACHEMA, and is for the first time showing the whole 

spectrum of this series with integrated direct drive for 

applications in chemicals, pharmaceuticals, mineral processing 

and the field of renewable resources. Duties that are constantly 

gaining in complexity make one thing quite clear: to be able to 

serve these demanding markets successfully, customized 

high-end solutions had to be developed. This diversity is 

reflected in the wide range of design variants. By way of 

example, the directdrive ∞ is based on a gastight design with 

nitrogen blanketing, and is certified in compliance with the 

ATEX directive for use in explosion-hazarded zones. The 

models of the directdrive ∞ series have a fully automatic CIP 

system; aseptic and closed processing, optimum cleaning and 

reliable conformity with GMP requirements are also realized 

for specific process techniques. The GEA Westfalia Separator 

finetuner additionally enables optimum separation of the two 

product phases. The separating zone can be adjusted to the 

optimum working point while the machine is running. 

Integrated direct drive – 

efficient and service friendly 

The direct route is generally the most efficient. This is also 

applicable for the drive of a separator. If the energy used in 

such solutions is transferred by way of a direct connection 

from the motor to the bowl, energy losses are minimal. With 

the directdrive ∞ , the motor is housed completely in the frame 

of the separator. The bowl spindle serves simultaneously as 

the motor shaft. The integrated direct drive can therefore also 

be used in normal heights. There is consequently no separate 

motor shaft, no motor bearing, no coupling – and thus also no 

wear affecting these components. In addition, the component 

is used in conjunction with standard robust asynchronous 

motors which can be controlled with any normal frequency 

converter. With these frequency converters, infinitely variable 

speed regulation has been provided in a specified speed range 

with the integrated direct drive. 

The directdrive ∞ is thus very service-friendly. This is because 

the direct drive does not need numerous sensitive components 

such as bearings or belts: parts which do not exist do not have 

to be maintained. At the same time, it is extremely compact, 

which is the same as saying that it has a lower space requirement. 

The bowl can be removed easily as a single part from 

the frame, or the motor can be disassembled together with the 

drive as a single entity, thus considerably reducing the downtimes 

for maintenance work. 

4


Robust and Very Reliable 

New decanter family GEA Westfalia Separator ecoforce for maximum availability 

With the new decanter platform ecoforce, GEA Westfalia 

Separator Group has designed a series of multifunction 

machines which guarantee maximum availability, high 

throughput capacities and excellent separating efficiency. At 

the same time, it meets the user’s desire for maximum 

flexibility. The entire family of the new decanter generation 

ecoforce is extremely robust and provides a unique combination 

of excellent performance and low energy consumption. It can 

be adjusted in an individual and optimum manner to meet 

the needs of the specific application, and also enjoys the 

benefits of user-friendly service for optimum availability. 

Decanters from the ecoforce series are ideal for use in applications 

in chemicals, pharmaceuticals, mineral processing 

and the field of renewable resources. At ACHEMA 2012, 

GEA Westfalia Separator Group is presenting a machine from 

the new series in the mid-range performance segment – the 

decanter type: ecoforce CF 6000. 

High energy efficiency 

All models of the new ecoforce generation will feature the 

standardized GEA Westfalia Separator summationdrive. This 

high-torque drive ensures that the process is reliably provided 

with the optimum differential speed, thus guaranteeing 

maximum performance and high separating efficiency. This 

means that all shafts are provided only with the power which 

is actually required, which means that the drive operates in a 

particularly energy-efficient manner. 

Reliable operation 

Maximum availability of the systems is assured by the service 

of the original manufacturer, which has been integrated 

specifically for this decanter series: GEA Westfalia Separator 

directcare. The aim of this new concept is to ensure that all 

technical and financial advantages of the new ecoforce series 

can be used completely and throughout the entire life cycle 

and in a manner which is consistent with the customer’s needs 

by ensuring that total cost of ownership can be calculated. 

One machine – Three Sizes 

Package unit for laboratory and pilot installations in the 

pharmaceutical and biotechnology industry 

GEA Westfalia Separator Group is presenting the PU CSC 1/5/8 package unit 

for the pharmaceutical and biotechnology industry at ACHEMA. The package 

unit with a separator and the entire peripheral products on a single frame 

is particularly suitable for laboratory and pilot installations for the production, 

for instance, of vaccines, insulin and antibodies. In total, three bowl sizes 

for different throughput capacities are available. With the capacities 15 to 

30 litres per hour, 100 to 200 litres per hour and 150 to 300 litres per hour, the 

package unit can be adjusted in an optimum manner to the various fermenter 

sizes in biotechnology. This is also the first time that a package unit has 

been designed for micro fermenters. The entire package unit, including the 

pipework system and the special valve nodes, are steam-sterilizable and 

comply with GMP requirements. 

5


Production 

of Insulin 

EXPANDING MARKETS 

AND PRODUCTION IN THE 

EMERGING NATIONS 

Until a few years ago, the production of insulin was essentially in the hands of 

three pharmaceutical companies with international operations. Together, they 

covered up to 95 percent of the market. This situation has changed considerably 

recently, in line with globalisation and the simultaneous upswing of emerging 

countries. China, India, Brazil, the Middle East, Poland, Russia and the Ukraine are 

the new countries involved in the production of insulin. In these regions, the 

pharmaceutical industry is responding to rising demand for insulin and is producing 

the active agent for diabetes sufferers at more favourable conditions. 

Demand is strong particularly in these parts of the world: rising prosperity is being 

accompanied by an increase in the prevalence of diabetes. 

6


7


The WHO is expecting to see the 

number of diabetes sufferers increase 

from 220 million to 400 million 

by the year 2030 in the eight 

most affected countries. 

In India, for instance, the number 

of diabetes patients will rise to 

approximately 80 million by 2030, 

and the figure in China is 

expected to more than double. 

Diabetes 

is rising 

dramatically 

Being overweight and a lack of exercise mean that diabetes is 

becoming a global illness. Diabetes means that the human 

body does not produce sufficient insulin, is unresponsive or 

resistant to insulin. In its advanced stage, insulin is therefore 

administered in the correct dose to the patient as a life-saving 

measure. In general, the remaining life expectancy of patients 

is reduced by approximately one third after the point at which 

the illness is diagnosed. According to the fifth edition of the 

Diabetes Atlas, the International Diabetes Federation (IDF) 

expects to see a worldwide increase in the number of 

sufferers from 36 million in 2011 to approximately 552 million 

in 2030. IDF also estimates that approximately 183 million 

sufferers are not even aware of their illness. 80 percent of 

diabetes sufferers live in countries with low and medium 

incomes. According to the World Health Organization (WHO) 

3.2 million deaths annually are associated with diabetes. 

The diabetes market leader Novo Nordisk from Denmark 

accounts for an estimated more than 50 percent share of the 

worldwide market for insulin. Together with the French 

Sanofi-Aventis and the US manufacturer Eli Lilly, Novo 

Nordisk controls around 80 percent of the market. Other 

market players include newcomers and niche providers in the 

emerging countries, such as the Indian pharmaceutical 

manufacturer Biocon, the largest producer of insulin in Asia. 

Wanbang Biopharma for instance is the largest producer of 

insulin in its domestic market of China, accounting for almost 

half of the overall market. Mainly for exports to Europe and 

the USA, this Chinese producer now intends to build an 

insulin factory which, in its initial stage, will be able to 

produce around 130 million units annually. 

Julphar due to commission a new 

production facility in the Middle East 

In the United Arab Emirates, a new insulin factory is to be 

commissioned by Julphar (Gulf Pharmaceutical Industries) in 

mid-2012; in the same way as many other production facilities 

throughout the world, this facility will also be equipped 

with mechanical separating technology from GEA Westfalia 

Separator Group. As the largest producer of antibiotics delivered 

in oral form and in injectable form in the Middle East, 

Julphar produces its own brands and also operates as a subcontractor 

for worldwide demand under GMP conditions. 

The factories are also ISO-certified. 

Julphar pioneered the production of insulin in the Middle East 

and Africa. The company has been distributing insulin in 

cooperation with a French manufacturer since 1998; at that 

time, Julphar imported the insulin crystals. In 2006, Julphar 

decided to manufacture the raw material for insulin itself. 

This is a logical decision because, according to the International 

Diabetes Federation (IDF), there are already an estimated 32.6 

million diabetes sufferers in the region, and this figure is 

expected to double by the year 2030. The diabetes rates in the 

Middle East and North Africa are some of the highest in the 

world. 

8


a total of five separators in Ras Al Khaimah. A nozzle-type 

separator CFA 65with GEA Westfalia Separator viscon ® 

technology is used for separating the coli bacteria from the 

fermentation broth; in this solution, the solids are continuously 

discharged with a constant concentration. Following the 

homogenisation stage, two self-cleaning separators of the 

type CSE 80 separate the inclusion bodies from the cell 

fractions and wash them. Following the precipitation of the 

insulin crystals in the clean room, two chamber-type separators 

BKA 28 are then used to separate the crystals and thus produce 

concentrated insulin. Whereas the separators in the first 

two stages were supplied as compact package units, the 

chamber-type separators are stand-alone machines with the 

corresponding valve blocks and control unit. After GEA Westfalia 

Separator Group has provided intense training to the operating 

personnel, operations in Ras Al Khaimah will start providing 

product in mid-2012. 

Core processes from 

GEA Westfalia Separator Group 

Julphar‘s new production facility in Ras Al Khaimah north of 

Dubai is one of the most modern in the world for manufacturing 

insulin crystals for human cosumption. It covers floor area 

of 20,000 m 2 , including clean rooms of 5000 m 2 . Fifteen 

kilometres of pipework have been installed. GEA Diesel was 

responsible for the engineering, delivery, commissioning and 

qualification of the entire systems for the production of 

ultra-pure media as well as various process equipment and 

cleaning installations. In addition, the delivery comprised all 

necessary pipework and distribution systems for the production 

processes. In Ras Al Khaimah, Julphar uses the technology of 

recombinant DNA (r-DNA), by injecting the insulin gene into 

a suitable carrier substance, in this case Escherichia coli. Its 

genetic constitution is modified in such a way that it produces 

the human hormone insulin. In various stages, the bacteria 

then multiply in fermenters, and are subsequently recovered 

and purified in separators. Separators thus constitute the core 

processes in the production of insulin. Because GEA Westfalia 

Separator Group is known as the worldwide technology leader 

in the production of insulin, Julphar decided to use the knowhow 

of the company from Oelde with centrifugal technology 

in its new plant. GEA Westfalia Separator Group has installed 

GEA Westfalia Separator hycon 

as an alternative 

As an alternative to the production of insulin from Escherichia 

coli, other producers use yeast as the carrier substance. The 

process is similar, but the valuable substance in this case is 

not the solids, and instead is the clarified phase. In both 

methods, the hycon machines can be used as an alternative to 

the chamber-type separator after the crystallisation process. 

hycon is a completely closed system which enables the 

separating process to be carried out under clean room 

conditions without contamination by the drive or motor. 

Due to the principle of the suspended bowl, this twin-room 

concept has the bowl with the hood and solids holding tank in 

the clean room, whereas the drive units can be housed in a 

separate room with a lower classification. The machine is 

designed in such a way that the solids are automatically 

discharged from the suspended separator into closed containers 

installed below the separator. GEA Westfalia Separator Group 

achieves very gentle product treatment which is appropriate 

for the high value material by means of two features: the 

hermetic feed and the gentle discharge at operating speed or 

lower speed of the machine. Whereas chamber-type separators 

are not sterilised and can only be cleaned manually, hycon 

machines have fully automatic cleaning and, where necessary, 

sterilisation by means of CIP and SIP. Demand for the 

technologies of GEA Westfalia Separator Group for the 

production of insulin is very strong, particularly in the new 

markets of the emerging countries. 

Thomas Homann 

Senior Product Manager Biotechnology 

Business Line Chemical / Pharmaceutical Technology 

GEA Westfalia Separator Group, Oelde 

Phone +49 2522 77-1541 

thomas.homann@gea.com 

9


How to combat more 

stringent market requirements 

with centrifugal separating 

technology 

10


Petrochemical 

Additives 

11


Lube oils and fuels only provide their full impact in 

conjunction with specific additives which are designed 

precisely to meet the requirements of a particular 

application. Lube oil is for instance the engine oil 

which reduces friction which would otherwise prevent 

piston engines from functioning. 

Selected additives improve the properties of such oil. Additives also provide 

additional measurable benefit for fuels in combustion engines, for instance a 

reduction in the volume of particulate emissions in diesel engines. The 

petrochemical industry is therefore constantly carrying out research and 

development for even more efficient additives. 

Efficient separation of salts 

and excess basic substance 

Centrifugal separating technology is particularly suitable for industrial mass 

production of these additives for lube oils and fuels. Organic solvents are used 

as the carrier substance for the additives. In accordance with the fundamental 

rules of chemistry, the fundamental substance must first be added to the 

solvent in excess so that a desired reaction can take place. The excess reactant 

is then removed from the solvent. Depending on the application and the 

chemical formula involved, the added fundamental substance in the solvent is 

present either in dissolved form or in the form of finely suspended particles. 

These can be certain complexes which become attached to molecules, or they 

can also be nanoparticles which provide specific lubricating properties. 

The solvent also contains further undesired solids, in general salts precipitated 

from the previous chemical reaction. 

Decanters and separators from GEA Westfalia Separator Group are used for 

reliably separating these salts and the excess fundamental substance, the 

reactant, from the solvent with the valuable additive, irrespective of the specific 

application. And because the use of solvents frequently involves substances 

which form gas mixtures which tend to explode in the presence of oxygen, the 

centrifuges are virtually always explosion-protected and are usually provided 

with inert gas blanketing. The necessary solid-liquid separation, which is a 

traditional clarifying task, is performed either with decanters or with selfcleaning 

separators or, very frequently, in combination with both types of 

centrifuges in a two-phase process in which a high solid content in the decanter 

is first separated and the fine content is then clarified by a self-cleaning 

disc-type separator. 

A higher level of automation and 

more efficient clarification 

GEA Westfalia Separator Group is able to look back on decades of experience 

in the market for additives for fuel and lube oils. Numerous installations have, 

for instance, been operating for many years in the USA and the countries of 

the former Soviet Union. In many cases, a replacement investment is now 

necessary, involving a conversion to a new centrifuge generation. However, 

centrifugal separating technology is also ideal as a substitute for or an addition 

to existing facilities with static separators or filtration techniques. In the case of 

static separators, it may, for example, make sense to use a self-cleaning separator 

to subsequently clarify the upper clear discharge which contains residual 

amounts of suspended solids and thus to optimize the efficiency of the overall 

12


process. On the other hand, systems with filter installations 

have the disadvantage of high operating costs due to personnel 

and filter aid requirement. 

Increased requirements 

The requirements with regard to additives in lube oils and 

fuels have also become more stringent in recent years. This 

has much to do with more stringent environmental protection 

requirements. There is therefore a demand for additives which 

encourage better combustion of the fuel in order to generate 

fewer emissions. Or additives which promote the long service 

life of lube oil in order to use resources more efficiently as a 

result of having to change oil less frequently. The separators 

and decanters from GEA Westfalia Separator Group have 

adapted to these developments. Today, TSE separators are 

much more compact than was the case as recently as a few 

years ago. Due to a reduction in the number of components, 

they operate more efficiently while providing the same 

performance, and can be adjusted precisely to the required 

throughput volumes. Innovative drive concepts reduce the 

energy input. 

Precise adjustment 

to the processes 

GEA Westfalia Separator Group is also presenting the new generation of 

ecoforce decanters for chemical operations for the first time at ACHEMA 

2012. This new series enables operators to configure the machine to meet 

their individual needs: low or high torque, obtuse or acute conical angles, 

low or high differential speed as well as hot or normal operation. 

A previously unknown flexibility enables the machines to be precisely 

adjusted to the very different process conditions in the petrochemical 

industry for the wide range of lube oil and fuel additives. In parallel with 

this development, energy consumption in the new generation has also 

been considerably reduced. Certain processes are also affected by 

considerable wear. For this application, it is possible to use hard facing for 

the centrifuge materials. The machines are also much easier to maintain; 

this advantage is enhanced further by the integration of the service 

concept GEA Westfalia Separator directcare and the monitoring system 

wewatch ® . This increases availability, and maintenance tasks become 

easier to calculate. 

The challenges which are today facing manufacturers of additives for 

lube oils and fuels thus find a suitable solution in centrifugal separating 

technology incorporating the latest generation of separators and 

decanters. 

Sven Nitschke 

Product Manager 



Phone +49 2522 77-1983 

sven.nitschke@gea.com 

13


14


Boosting 

Yield and 

Efficiency 

Additional separating 

stages in the 

production of pectin 

15


Pectin is frequently an essential component, 

and acts as a jellying, thickening or stabilisation 

agent for marmalade, jam, fruit juices, dairy 

products and confectionery, and is also used in 

the pharmaceutical and cosmetic industries in 

order to boost the viscosity and stability of gels 

or creams. 

The producers of pectin are able to utilise even more reserves in terms of yield and 

efficiency. GEA Westfalia Separator Group has developed two side process stages 

which, combined with manageable levels of investment, promise to provide significant 

improvements in terms of efficiency. 

Firstly, additional washing of the pectin in hydrolysis ensures 

a higher yield. This process has already demonstrated its 

worth in practice at a manufacturer of pectin in Italy. Secondly, 

clarification of isopropanol in the precipitation of pectin 

enables the expensive solvent to be recovered more efficiently. 

A Czech producer has been using this solution for several 

years, and has good experience with this elegant type of 

making efficient use of resources. 

Pectin – an essential element 

in many foods 

The annual global market for pectin in 2009 was approximately 

42,000 tons, and is continuously expanding at a rate of 

approximately three percent per annum. Approximately ten 

manufacturers, mainly based in Europe, are involved with the 

production of pectin. The Danish market leader alone produces 

approximately 30 percent of the entire market. Although 

pectin is found in almost every terrestrial plant, the raw 

materials which are used are citrus peel from citrus juice 

production (approximately 70 percent), apple peel (approximately 

25 percent) and other fruit and vegetable residues (5 percent). 

This is due to the fact that citrus peel contains approximately 

30 percent pectin, apple pomace contains approximately 

15 percent and thus guarantees a much higher yield than other 

raw materials. 

The raw material therefore comes mainly from South America, 

and in particular Argentina, where the peel is dried and shipped. 

Pectin is made by the producers in numerous factories around 

the world. The polysaccharide pectin is generally approved for 

virtually all foods, where it is also very much in demand. It is 

frequently an essential component, and acts as a jellying, 

thickening or stabilisation agent for marmalade, jam, fruit 

juices, dairy products and confectionery, and is also used in 

the pharmaceutical and cosmetic industries in order to boost 

the viscosity and stability of gels or creams. In terms of 

nutritional physiology, pectins are roughage for humans. 

Additional washing stage in hydrolysis 

Pectin is mainly produced in two stages, namely hydrolysis 

and precipitation. In hydrolysis, all water-soluble substances 

are extracted from the raw materials with hot and very acidic 

water. This suspension is first clarified by a decanter, i.e. it is 

separated into solids with dry matter of approximately twelve 

percent and also into the liquid phase with the dissolved 

pectin and less than two percent solids. 

The liquid phase is further polished in a separator and a 

subsequent filtration process. The solids from the decanter are 

normally used as animal feed. But this is precisely where 

there are further benefits which have not yet been utilised: by 

means of an additional washing stage with hot water and a 

dewatering process by means of a decanter, it is possible for 

further valuable pectin to be recovered and thus the entire 

yield to be increased. 

16


Treating the isopropanol 

during precipitation 

In the second stage of pectin production, namely precipitation, 

the pectin concentrate which has previously been twice 

concentrated and membrane filtered is first precipitated with 

80 percent isopropanol, and the pectin fibres are then 

dewatered by a decanter. This process is repeated, but using 

99 percent isopropanol. In the second subsequent dewatering 

of the pectin fibres in a decanter the solids are discharged as 

end product: pectin with a dry substance content of up to 

37 percent, which is now dried further. 

The solvent isopropanol which is used in both stages is 

distilled in order to be recovered. However, the solvent still 

contains so many solids that the distillation process is affected 

and frequently has to be cleaned. It is protected by an 

intermediate decanter which treats the isopropanol and 

removes the solids which, depending on their quality, can 

also be used as pectin end product. However, a more important 

aspect in this case is the process of treating the expensive 

isopropanol so that it can be recovered easily and efficiently. 

Use hire decanters for testing the 

procedures in the user’s own operation 

In both cases, namely solids washing in hydrolysis and 

isopropanol recovery after precipitation, the users are able to 

employ the latest GEA Westfalia Separator ecoforce generation, 

of course in gas-tight explosion-protected design for isopropanol 

recovery. As the market leader among suppliers for pectin 

production, GEA Westfalia Separator Group provides producers 

with a unique opportunity of using hire decanters for testing 

the two procedures over several months in their own operation 

and thus to gain their own experience with the expected very 

good results. Significant increases in yield are assured. As 

is reliable after-sales service provided by GEA Westfalia 

Separator Group. 

Torsten Tusel 

Product Manager 



Phone +49 2522 77-1982 

torsten.tusel@gea.com 

42,000 t ANNUAL WORLD PECTIN MARKET IN 2009 

3 % GROWTH PER ANNUM 

70 % PECTIN FROM CITRUS PEEL 

25 % PECTIN FROM APPLE PEEL 

5 % PECTIN FROM OTHER FRUIT AND VEGETABLE RESIDUES 

30 % PROPORTION OF PECTIN IN CITRUS PEEL 

15 % PROPORTION OF PECTIN IN APPLE POMACE 

17


18


Recovery of 

RENEWABLE 

RESOURCES in 

wafer production 

The 

Sun 

Continues 

to Shine 

19


The basis of photovoltaic technology are so-called wafers 

which are produced by major companies in China, the USA 

and Europe. Large quantities of consumables can be recycled 

in the production of such wafers. Centrifugal process 

technologies of GEA Westfalia Separator Group ensure selective 

separation and highly efficient recovery of the recyclable 

materials. 

Wafers are square or round discs, with a thickness of 

approximately 50 µm to one millimetre and a diameter of 

between 150 and 450 cm; they are made from semiconductor 

ingots. These ingots are cylindrical or cuboid bars which are 

melted from silicon. Wafers are processed into solar cells in 

several stages, and are used for making solar modules. Or they 

are used as the base plate for electronic components in the 

semiconductor industry. 

Energy from 

photovoltaic 

installations – 

this market is 

booming 

worldwide 

Even if manufacturers of solar 

cells are currently having to 

contend with price erosion, 

which is severe in certain areas, 

demand will continue to rise. 

China alone, with its new 

five-year plan, will extend the 

photovoltaic capacity which 

had been installed by 2011 

from 1.7 gigawatt to 15 to 

20 gigawatt in 2015. 

Wafer cutting with wire saws 

The industry has developed various processes for cutting the 

wafers. Wire saws are used in some applications, and 

diamond saws have recently also been used. The process of 

cutting wafers with wire saws is supported by a carrier medium 

such as polyethylene glycol (PEG) or diethylene glycol (DEG) 

and a cutting agent based on silicon carbide (SiC). Both 

substances are relatively expensive. The process forms a 

slurry, which is a sludge consisting of silicon waste, the silicon 

carbide and the PEG. In order to ensure economic and 

environmentally-friendly wafer production methods, it is very 

important to ensure that the two materials SiC and PEG can 

be recycled efficently. 

Two-stage recycling of silicon carbide 

With its Central Process Engineering Research Centre (Zentrale 

Verfahrenstechnik – ZVT), GEA Westfalia Separator Group 

has carried out intensive trials to determine how the efficiency 

of this recycling process can be maximised. This has resulted 

in a two-stage classification process. Using the characteristics 

of different densities and particle sizes of the respective 

components, centrifugal methods permit highly-selective 

separation. In the first stage, a decanter centrifuge removes 

the coarse silicon carbide from the slurry at a relatively low 

g-force; this silicon carbide can then be mixed with new silicon 

carbide and can thus be recycled. The separating limit for the 

silicon carbide particles is approximately six µm. 

A second decanter, which is connected in series, operates with 

maximum available speed and removes the finer silicon 

carbide and the silicon fines as waste products from the 

polyethylene glycol carrier liquid. Approximately 80 percent of 

the silicon carbide recovered from the first stage is used as the 

starting point for new cutting agents; this means that, in reality, 

only one fifth new silicon carbide has to be added on each 

occasion. This is also applicable for the polyethylene glycol as the 

carrier medium. Again, four fifths are used from recovered 

PEG and one fifth fresh PEG is used for new carrier liquids. 

20


Advantages of the system 

compared with alternative methods 

The same decanter type can be used for both stages; the speed 

required in each case is set by means of a frequency converter. 

This process which has been developed by GEA Westfalia 

Separator Group has established an extremely good position 

on the market. This is understandable, because operating 

with decanters provides clear advantages compared with 

alternative methods used, such as hydrocyclones or filter presses. 

Due to the nature of the system involved, hydrocyclones are 

not able to match the quality of the classification stage of the 

second decanter stage; this means that it is not possible to 

separate the silicon particles smaller than six µm from the 

silicon fines and the PEG. The fact that this stage is less 

precise has a direct impact on the quality of the process. 

A further advantage of decanter technology is the lower total 

cost of ownership. It is true that hydrocyclones are less 

expensive in terms of the initial investment; however, they do 

not have the service life of decanters and have to be replaced if 

they are affected by wear. 

Inline slurry processing 

It does not matter which sawing method the wafer manufacturers 

use; the solutions of GEA Westfalia Separator Group 

are customised to meet the aim of attaining maximum 

process qualities and recycling ratios of the valuable slurry 

components. This is applicable for off-site concepts, when 

wafer producers outsource slurry processing to external 

providers, and also for inline processes in which the slurry 

is treated and separated in the wafer factory itself. As a result 

of the collapse in prices for wafers last year, more and more 

wafer producers are now preferring inline processing. The 

amortisation periods for such a changeover are generally less 

than two years. 

Tore Hartmann 

Senior Application Manager Mineral Processing 



Phone +49 2522 77-5684 

tore.hartmann@gea.com 

Compared with filter presses, compact decanters provide the 

advantage of a much smaller space requirement. Compared 

with the open operation of filter presses, centrifugal technology 

is a closed system. Filter presses require filter agents with all 

the associated disadvantages such as manual handling and 

waste management. A further aspect is that filter presses 

require start-up times of several hours for the classification 

process in order to provide constant results, whereas decanters 

are able to operate at full capacity within a few minutes. 

Single-stage recovery process for cutting 

with diamond saws 

In addition to the process of cutting the wafers with wire 

saws, which is currently used by industry in approximately 

80 percent of all applications, a new method is now becoming 

established, namely cutting with diamond saws. This method 

operates at much higher speeds and with greater precision 

and enables even thinner wafers to be cut, although it involves 

higher costs. It is not a question of whether this technology 

will be used more extensively; the question is how quickly 

will this process take place. 

Slurry is also encountered in this process; however, PEG is not 

used as the carrier liquid. Instead, water with surface-active 

substances is used. Accordingly, this slurry can be processed 

in a single stage with a self-cleaning separator. The advantage 

of this solution is to be seen in the use of maximum g-forces 

for very efficient separation into pure silicon as the solids and 

the carrier liquid as the liquid phase. Both materials can then 

be recycled. 

The sun will continue to shine on energy production by means 

of photovoltaic solutions and will thus also continue to shine 

on the wafer industry. Even if a slight shadow has been cast on 

the price situation as a result of political factors. Recycling of 

materials is beneficial for the photovoltaic industry and its 

suppliers in economic and also ecological terms. GEA Westfalia 

Separator Group is supporting them in this process. 

21


Valuable 

Protein from 

Stillage 

New procedure for 

recovering valuable 

substances from 

alcohol distillation 

residues 

22


23


The concept of perpetual motion unfortunately does 

not work. However, the new procedure of 

GEA Westfalia Separator Group for treating stillage 

from ethyl alcohol production does not fall far short 

of meeting this concept. However, this is really only 

an attractive additional effect. Of much greater 

importance is the possibility of treating the distillation 

residue in order to isolate proteins which, as valuable 

animal feed protein, serve new animal feed markets 

and which are suitable not only for ruminants, as is 

the case with conventional stillage. 

Alcohol can be made from raw materials which contain starch, e.g. corn, wheat 

and rye, by grinding the starch and converting it into sugar by enzymatic 

action; this is followed by a fermentation process, and the added yeast produces 

alcohol. This alcohol is distilled into ethyl alcohol. The distillate residue which 

is left over comprises all substances which cannot be fermented, such as fibres, 

pentosanes, proteins and salts, the so-called stillage. This residue is a popular 

and inexpensive feed for ruminants and cattle, goats or sheep. The fibre- and 

protein-rich stillage is used particularly frequently for fattening bulls. 

Conventional stillage under price pressure 

Smaller distilleries sell the stillage untreated to farmers in the region, most of 

whom collect the stillage themselves. However, for larger distilleries with a 

production of approximately 60,000 litres of ethanol per day, the logistics of 

the wet stillage becomes a critical problem because of the sheer volumes 

involved. This is because, in the distillation process, approximately ten litres of 

stillage are obtained for every litre of alcohol. In general, the stillage is then 

dewatered with decanters and processed into animal feed which can be stored 

and transported, using concentrators and driers (DDGS – Dried Distillers 

Grain with Solubles). This means that distilleries now have to consider stillage 

treatment as a separate branch of production in addition to the actual process 

of producing alcohol: stillage management has a considerable influence on the 

operating costs of a distillery. However, DDGS is having to face fierce competition, 

which has recently also been exacerbated by bioethanol producers, and the 

price of DDGS is not particularly attractive for the seller. 

The situation is somewhat different if we can move away from this fiercely 

competitive market of animal feed for ruminants. However, for this purpose, 

it is necessary to remove the fibres which other animals such as pigs, poultry 

or fish cannot digest. This means that distilleries are now able to approach an 

entirely new market for selling their stillage which occurs every day. 

Protein-enriched concentrate 

Initial whisky distilleries are already running trials with a separator which 

removes the proteins in the overflow of the decanter from the husks. 

GEA Westfalia Separator Group has gone one step further, and has developed 

a method which operates even more efficiently. This process does not use 

concentration, and instead uses a three-stage procedure chain with a decanter, 

24


membrane filtration and separator. This means that the stillage is broken down into three 

fractions. The end product is a protein-reduced wet distillers grain which contains fibres 

(WDG – Wet Distillers Grain), which is then dried to form DDG (Dried Distillers Grain) and is 

suitable for ruminants. A second entirely new and major fraction from the centrifugal separation 

process is a protein-enriched concentrate without fibres with a high nutritional value and a 

wide range of potential applications in pig breeding and poultry breeding as well as fattening 

fish. The prices of this protein concentrate are much better. 

However, this is not the whole story. As a third fraction, the process obtains a substrate from 

the membrane filtration installation with the clarified phase; this substrate can be used in 

biogas installations for generating electrical and heat energy. Calculations show that the energy 

obtained in this way is sufficient to power the entire protein recovery process described above. 

In other words: the system does not require any external energy input. And the membrane 

installation can also reduce the BOD and COD load in the effluent and might thus possibly also 

enable the effluent to be discharged directly into the sewerage system. 

No requirement for external energy input due to biogas 

A particularly elegant aspect of the stillage process developed by GEA Westfalia 

Separator Group is that existing conventional stillage treatments in the distilleries can easily be 

retrofitted with membrane filtration and a separator. Using a by-product in the low-price segment, 

distilleries in excess of a certain size are able to generate high-value protein products and 

considerably boost their efficiency. And the operators are also able to gain an ecological image 

with this process which does not require any input of external primary energy. 

New and substantial fraction from 

centrifugal separation is a proteinenriched 

concentrate without 

fibres, with high nutritional value 

and a broad range of potential 

applications in pig and poultry 

breeding, and in fish farming. 

This protein concentrate targets 

significantly better pricing. 

Burkhard Schiemann 

Project Manager 

Business Line Renewable Resources 


Phone +49 2522 77-1530 

burkhard.schiemann@gea.com 

25


26


Drainage 

Systems for 

Drilling 

Platforms and 

Drilling Vessels 

Additional 

recovery of 

barite possible 

27


GEA Westfalia Separator Group has developed several graduated methods for 

processing drilling mud and water on the drilling decks of drilling platforms and drilling 

vessels; these range from a simple combination of decanter and separator, the upstream 

installation of a skimmer tank right through to recovery of the valuable heavy mineral 

barite. All three methods have already demonstrated their worth in the rough working 

environment of drilling platforms. 

Drilling platforms and drilling vessels pose particular 

requirements with regard to the processing of bilgewater and 

drilling mud. The platforms and the vessels are in principle 

split in two. On the whole, it is necessary to treat water which 

is equivalent to the bilgewater on normal vessels and which 

can be treated by corresponding means. The tried-and-tested 

BilgeMaster ® systems from GEA Westfalia Separator Group 

are suitable for this purpose; they are currently being used in 

hundreds of applications on all types of vessels. 

Combination of decanter and 

GEA Westfalia Separator BilgeMaster ® 

The problem on the drilling deck is somewhat different. The 

process of changing drill pipes results in large quantities of 

drilling mud with a very high solids content on the deck. 

Drainage water poses major challenges in terms of processing. 

The composition of the drainage water varies considerably. 

The oil content can vary between zero and five percent (by 

volume), the water content can vary between 75 percent and 

95 percent (by volume), and the solids content can be up to 

20 percent (by volume). Erosive substances such as a high 

corrosive salt content can also be included. Drilling water and 

drilling muds on the drilling deck contain chemicals in 

suspension and in solution, mud containing water, salt water, 

rain water and formation water. The drilling muds also 

contain sand, floating solids, stones and large particles. 

Normal bilgewater processing systems are not suitable for this 

purpose. In this case, a good solution is to use a combination 

of an upstream decanter, which removes the coarse solids, 

and a downstream BilgeMaster ® separator. It is of course selfevident 

that this complete system has to be designed with 

ATEX explosion protection. The combination of a decanter 

and BilgeMaster ® has already demonstrated its worth. The 

required MARPOL figure of fewer than 15 ppm oil in water is 

attained reliably and consistently. Drilling companies have 

already used this technology of GEA Westfalia Separator Group 

on 17 occasions in the past two years for building new 

platforms and drilling vessels or retrofitting the equipment. 

28


Upstream skimmer tank 

The experience gained with the combination system decanter / 

BilgeMaster ® has been used by GEA Westfalia Separator Group 

in conjunction with the drilling companies and shipyards in 

order to further develop and improve the drainage system for 

the drill decks. The use of an upstream skimmer tank was a 

good solution for the preliminary separation of very large 

particles such as stones and beverage cans as well as floating 

solids. Four systems involving this combination of a skimmer 

tank / decanter / BilgeMaster ® are already being used in hard 

practical applications. 

The drainage systems from GEA Westfalia Separator Group 

were also part of a Samsung road show in the USA at which 

the new Samsung drilling vessel was presented to interested 

shipyards and drilling companies. 

Recovery of barite with 

classifying decanter 

Special treatment is required for the heavy mineral barite 

(barium sulphate), which has a minimum specific density of 

4.20 g/cm 3 . The comparatively expensive barite is added to the 

drilling mud on board in order to thicken the drilling mud. 

This rare and valuable mineral would have to be disposed of 

together with the dried drilling mud if it could not be 

separately precipitated. However, it is far too precious. In order 

to recover barite to be used again as an addition to the drilling 

mud, GEA Westfalia Separator Group has developed the 

possibility of installing a special classifying decanter upstream 

of the separating decanter. This special decanter removes only 

very heavy solids from the mud. A GEA Westfalia Separator 

rigMaster CF 4000 from the new ecoforce decanter generation 

is used for this application – with the inherent advantages 

such as high strength, maximum availability, high throughput 

capacities, excellent separating efficiency and low energy 

consumption. The separation of barite is currently also being 

used by two drilling companies. 

The price pressure on shipyards for new projects is high. 

All systems used on board drilling vessels and platforms are 

to be automated as far as possible; they should also feature 

user-friendly design in order to prevent the frequently 

changing crew from having to face problems. This is achieved 

by the drainage systems of GEA Westfalia Separator Group. 

GEA Westfalia Separator Group also ensures high sustainability 

by means of energy-saving measures. For instance, an 

economiser which uses clean hot water to heat the cold water 

in a heat exchanger counter flow arrangement is installed 

upstream of the separator. 

Thomas Perschke 

Director 

Business Line Oil & Gas 


Phone +49 2522 77-2645 

thomas.perschke@gea.com 

5 ppm in sight 

All of the three systems specified above 

guarantee a purity of the waste water of max. 

15 ppm oil content in water. In some regions of 

the world, e.g. the Arctic, the Antarctic and off the 

Norwegian, Danish and British coasts of the North Sea, 

a purity of 5 ppm oil in water is required. GEA Westfalia 

Separator Group is currently working on solutions for drilling 

vessels and platforms which are used in these regions. On normal 

vessels, it is already possible for bilgewater to be treated with only 5 ppm 

by the BilgeMaster ® cleandesign system. GEA Westfalia Separator Group is 

also working on configuring the complete systems to fit in containers so 

that they can easily be retrofitted on existing platforms and drilling vessels. 

29


How PET is 

made from PTA 

incredible 

versatility 

More than every third beverage in the world is consumed from PET 

bottles. Precisely 38 percent of all packaged beverages in 2010 

were filled in 422 billion PET packagings. According to Euromonitor, 

446 billion PET packagings have already been used in 2011. By the 

year 2015, market observers are predicting a further increase in the 

packaging market to 1.31 trillion beverage packagings, with a 

further increase in the share of PET to 42 percent. 

Demand for PET packagings is accordingly increasing by more than five percent per annum. 

Water and carbonated soft drinks alone account for approximately three quarters of the 

consumption of PET packagings. A tremendous victory march, considering that the PET bottle 

was first patented in 1973 by the chemist Nathaniel Wyeth. The main PET raw materials are 

pure terephthalic acid (PTA) and monoethylene glycol (MEG). A polycondensation process is 

used to trigger off a chemical reaction between the substances. This results in a polyester which 

is crystallised and polymerised in order to achieve the desired product quality. 

Mimicking nature 

Chemists have taken the idea of polymerisation from nature. Proteins, cotton, wool and cellulose 

are examples of polymers which occur naturally. These substances consist of very large 

molecules (macro molecules) with units, described as monomers, which join together to form a 

chain. Chemists have successfully copied the principle of combining small elements with 

hydrocarbons. This synthetic polymerisation process is used in the production of many plastics 

and other materials which are used in the production of everyday products such as bottles, 

foam cushions, non-stick pans, toys and computer housings. The development of chemical 

process engineering nowadays enables plastics to be produced cheaply and in large quantities. 

30


Plastics and polymers, such as polyethylene, PVC, polypropylene and polystyrene, 

are today estimated to account for 80 percent of the worldwide 

production output of the chemical industry. 

PTA (Purified Terephthalic Acid) which is necessary for PET production is a 

colourless crystalline solid with an acid smell. Approximately 90 percent of 

the annual production of terephtalic acid is used for the production of the 

plastic polyethylene terephthalate (PET). Normally, PTA is used in the form of 

a free-flowing powder in the production of saturated polyesters. Polyesters are 

polymers with ester functions, and include the widely used polycarbonates (PC) 

and particularly the technically important thermoplastic polyethylene (PET). 

In addition to PET bottles, saturated polyesters are used in the production of 

fibres for textiles and non-woven fabrics, transparencies, as a base material for 

flexible printed circuit boards, films, tennis strings and fibre-reinforced 

plastics. If every Chinese person were to buy one pair of new socks only once 

every year, a complete PTA plant would be necessary for this purpose alone. 

Up to 93 percent recycling of catalysts used 

Terephthalic acid is produced by means of oxidation with the aid of p-xylol 

catalysts. These catalysts are usually combinations of cobalt, manganese and 

bromine. Acetic acid is used as a reaction solvent. Cobalt and manganese in 

particular are valuable catalysts. This means that recycling is essential for 

efficient operations under economic aspects and also in line with the principle 

of making efficient use of resources. And this is precisely the point at which 

the technology of GEA Westfalia Separator Group comes into play. Up to 

93 percent of the catalysts cobalt and manganese which are used can be 

recycled back into the process by means of centrifugal separation technology. 

Depending on the process, either nozzle-type separators or decanters are 

suitable for the recycling process. The disc-type separators, for instance the 

type TDC 130 and TDC 160, are responsible for optimum clarification of the 

suspension and also for concentrating the solids from one to two percent 

(by weight) to four percent (by weight). Decanters on the other hand dewater 

the solids with a process-related content from between 0.5 and 22 percent (by 

weight) to 85 percent dry matter. Nozzle-type separators from GEA Westfalia 

Separator Group have so far been used at PTA manufacturers in India, China, 

Brazil, Portugal and Great Britain. An order for four nozzle-type separators has 

recently been placed for a manufacturer in Eastern Asia. Decanters have so far 

been used in China and Korea. So that the daily water or lemonade bottle can 

be produced efficiently. 

31

Rule the Liquids... 

...extreme forces must be safely under control. 

Our separators do a perfect job under the rough conditions 

of the chemical and petrochemical industry. 

GEA Westfalia Separator Group GmbH 

Werner-Habig-Straße 1, 59302 Oelde, Deutschland 

Phone: +49 2522 77-0, Fax: +49 2522 77-2488 

www.gea.com 

engineering for a better world 

B_WS-12-05-0032 EN · Printed in Germany · Printed on chlorine-free paper 

Westfalia ® , Westfalia Separator ® , Separator‘s Digest ® , BilgeMaster ® , viscon ® and wewatch ® are registered trademarks of GEA Mechanical Equipment GmbH. 

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Separator's Digest 2012/3 - GEA Westfalia Separator Group

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