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Chemical Industry pdf, 3.7 MB - GEA Westfalia Separator

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Liquids to Value<strong>Chemical</strong> <strong>Industry</strong>Components, systems and installationsfrom <strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong><strong>GEA</strong> Mechanical Equipment / <strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong>


Efficiency and Safetyin the Strongest Possible BondMechanical separating solutions for the chemical industry.<strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong> supports the chemicalindustry with high-performance and reliable processlines in a broad range of processes.Our modern civilisation is not conceivable withoutchemicals: whether synthetics, paints or lacquers, oiladditives or food additives: chemicals rule the world.There is practically no area of life that is not impactedby the groundbreaking developments of the chemicalindustry. However, the road to the final productis long. Complex processes are required to recoverthe substances in the organic, inorganic and petrochemicalindustries from which the huge range ofcommodities are produced. A recurring task in theseprocesses is the mechanical separation of substancesand phases. <strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong> has alreadybeen supporting the chemical industry for decadesin diverse separating duties. The process lines ofthe technology leader work with separators anddecanters and also with ceramic membrane filtration.The systems convince our partners worldwidewith the high quality of the end products, costeffectiveness,a conservative approach to resourcehandling and, last but not least, with maximum safetyfor people, machine and environment.Safety in the chemical industry enjoys a priorityexperienced in hardly any other branch of industry.Where concentrated acids, high pressures and explosivesubstances are part of everyday production, ourseparators and decanters show that they are capableof handling the safety risks involved. For liningthe solid-wall bowls, <strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong> usescorrosion-resistant special materials such as Incoloy825 or titanium palladium.Depending on the product, temperature and medium,machines in gastight and explosion-proof design inaccordance with the new ATEX 95 (RL 94/9/EC) directiveare also available.Current outstanding innovations of the companyinclude gastight clarifying and extraction decanterswith optimised machine geometry and high speeds.These compact developments combine explosionprotection with a significant increase in performance.A new feature on these gastight decanters is theproven <strong>Westfalia</strong> <strong>Separator</strong> ® varipond ® system. Thissystem enables the pond depth in the decanter tobe adapted optimally during ongoing operation,producing excellent separating results. The decanteralways operates at the ideal working point, even ifthere are variations in the feed concentration.Technology centre for process engineeringstrengthens investment securityOur specialists in the technology centre for processengineering in Oelde can run laboratory tests withthe original products of the customer. They determinethe industrial feasibility, are masters of the scale-upprocess, and backed up by the knowledge gained withmore than 3000 processes supported by <strong>GEA</strong> <strong>Westfalia</strong><strong>Separator</strong>, present a concept for an optimum processincluding the appropriate machines and components.Customers can also rent loan machines for long-timetesting. In this way, our customers receive a soundbasis for making future-proof investment decisions.And finally we also offer tailor-made service moduleswith our <strong>Westfalia</strong> <strong>Separator</strong> ® capitalcare concept –service provided by the original manufacturer. Bytaking advantage of this offer, the chemical industryensures maximum availability and process efficiencyof its plant, while at the same time still maintainingabsolute budget control.2<strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong>


Security for investments, products andprocesses<strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong> combines the top separatingtechnology services and the innovative strength of thecompany with comprehensive responsibility for thesecurity of investments, products and processes. Thisresults not only in high yields of the employed rawmaterials; but also in reliable process managementwhich makes efficient use of resources and thus alsoin the protection of people and environment. Maximumavailability including plannable maintenanceintervals for the separating technology installationsthroughout their entire life is the daily objective of<strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong>.These are the benefitsAll services from a single sourceCustomer- and application-oriented engineeringsupport for process development, designing theprocess accessories and the installation layoutby way of reliable scale-upReliable compliance with all agreedspecifications, budgets and delivery deadlinesComplete assembly and testing of theinstallations in the ISO 9001 certifiedproduction facilityOn-site assembly of certain installation typesis also possibleService network operating throughout the world… which provide every customer with the necessarysecurity.Important applications:Agar agarAluminium hydroxideAminesAniline dyesAsh leachingBarium sulphateBlack liquorCellulose and derivativesCatalyst separationDyesEthylenaminesFilter backflush liquidFungicides, etc.Gum arabicHerbicidesInkInsecticidesLignocelluloseLyesNitro compounds (nitration of aromaticsubstances in nitration installations)Petrochemical additivesPaintsPentaerithritPeroxidesPhosphoric acidPolyacetatesPolybutadiene, etc.PolycarbonatePolymerPrinters' inks, etc.PTA (purified teraphtalic acid)SaltsSodium bor hydridSuspensions with metals, oxides, hydroxidesand catalystsTall oilViscose, cellulose acetate, etc.


Nitro Aromatic CompoundsTNT – entirely safe.TNT with its almost legendary explosive poweris probably the best known of all nitro aromaticcompound substances; however, it is by no meansthe most important. Nitration of toluene is todayused primarily in the production of polyurethane,which has become much more important in recentyears. Nitration of benzene results in mononitrobenzene(MNB), which is the basis of a second keyinput product in the chemical industry, namelyaniline. Up to 95 percent of the entire global productionof MNB is thus used as the primary material forisocyanates (MDI), pharmaceuticals, rubber chemicalsand most of the dyes with which we are familiar.Nitro aromatic compounds are obtained in a multistage,large-scale process. Mononitration takes place inthe first reaction tank, and dinitration in a subsequentsecond tank. To ensure that the process proceeds in acontrolled manner, a mixture of highly concentratedsulphuric acid and nitric acid is added to the overflowof the corresponding stages. After nitration in thereaction tanks, the liquid is pumped to a separator sothat the nitrated aromatic compound can be separatedfrom the waste acid. After the reaction mixture ofthe second nitration stage has been separated, thedinitro aromatic compounds are pumped to a multistagewashing process to enable a high degree ofpurity to be achieved for the substances. The dinitroaromatic compounds are then recovered in a drier inthe form of a crystalline substance.Excellent team right downto the smallest seal<strong>Separator</strong>s with a solid-wall bowl design, increasinglyfrom the TTC series, are normally used to separate thenitro aromatic compound from the waste acid after thenitration process and also from water after washing.The purity of the nitro aromatic compounds obtainedin this way is excellent. Separation takes place in avery small space, thereby significantly increasing thesafety of the installation. Chamber-type separators ofthe type TKC 100 are successfully used in practicalapplications for cleaning the sulphuric acid.This increases the operating lives of the separators inthe nitration stages by up to 100 percent as sulphuricacid cleaned in this way significantly extends theintervals between the cleaning cycles of the solid-wallbowl machines.4<strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong>


With its aggressive media, the nitration process posesextremely stringent demands on the separator designin the nitration stages. A challenge that <strong>GEA</strong> <strong>Westfalia</strong><strong>Separator</strong> has successfully mastered: from the bowland all other components that come into contact withproduct right through to the smallest seal, everythinghas been consistently designed for this process.The problem is particularly acute when processingnitrated toluene or xylene from the waste acid; specialmaterial (Incoloy 825) is used in virtually all caseswhere the components come into contact withproduct. And with liquid centripetal pumps for bothphases, the separators meet the requirement forsafely discharging both the acid and the organic phaseunder pressure.Another popular benefit of the TTC separators isthe location of the discharge drain hole in the bottomof the bowl. This prevents the operator or servicefrom coming into contact with the extremelytoxic organic substances. Throughout the world,virtually all well-known manufacturers of nitroaromatic compounds use separators supplied by<strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong> – and most of them havebeen doing so for many decades. There are specificreasons why <strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong> has continuedto be the main supplier for this application. Thenew TTC generation continues this story of successby meeting the customers’ need for higher feedcapacities, increasingly strict installation requirementsand operator safety.Mixture of nitric acid and sulfuric acidAromaticAcid forrecirculationH 2OsteamH 2OsteamClarification ofFe sulphate fromsulfuric acidTKC 100-86-576Reactor formononitrationReactor fordinitrationExhaused acid torecovery station(H 2SO 4 + H 2O + organics)≈ 1.3TTC 150-01-517≈ 1.8CondensateTTC 150-01-517RecoverystationWash waterCaustic soda solutionWash waterDinitratedaromaticWashwaterCondensate1 st washing stepSour water2 nd washing stepAlcaline water3 rd washing stepTTC 150-01-517Dryer5<strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong>


PeroxideH plus variety.The areas of application for peroxide are extremelyvaried: organic peroxides are used as reactantsin the chemical industry. Hydrogen peroxide isused for the production of washing agents, forbleaching paper, cellulose, wood, textiles; as crudeproduct which will be converted into propyleneoxide for cleaning waste water and drinking water;in the medical industry as a disinfection agent;and finally for “bleaching” hair. Nowadays, morethan 95 percent of the huge quantities of hydrogenperoxide required for these processes are madeusing variations of the anthraquinon process.This process comprises the four main stages of hydration,oxidation, washing and concentration.Within this process, an organic working solutioncirculates the whole process. The working solutionis recovered in a one- or multi-stage cross-currentwashing step. An aqueous phase is added whichextracts impurities from the working solution.Subsequently, it can be removed from the organicphase by centrifugal means. Solid-wall bowl separatorswith disc stack are used in this step.In other process applications, an aqueous phaseis added to extract the impurities from an organicperoxide itself. Similar as above, solid-wall bowl typeseparators with disc stack are used to centrifugallyseparate both phases.Maximum safetyand separating efficiencyPeroxides can decompose even in the absence ofoxygen at comparatively low process temperatures.The separators are accordingly explosion-protected,and the temperatures at the critical points are permanentlymonitored. The design of the TTCseparators also provides new methods of furtherimproving separating and process efficiency. In themajority of the peroxide processes described abovethe light phase makes up the biggest portion ofthe complete flow rate, usually above 90 percent.Accordingly, the largest part of the separator’scapacity must be used for purifying the light phase.This is possible with the TTC series type separatorsfrom <strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong>, without having toaccept restrictions on other beneficial features, suchas discharge of both separated phases under pressure.Fresh washing agentWorkingsolutionPurified workingsolutionStatic mixerStatic mixerSolid-wall separatorUsedTTC serieswashing agentSolid-wall separatorUsedTTC serieswashing agent6<strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong>


XanthaneMicrobiological all-rounder.Numerous positive characteristics mean that thelong-chain polysaccharide xanthane is a productthat can be used universally. In baker’s products,xanthane is responsible for pore structure, greatervolume and an extended shelf life. It is used indesserts, chewing gum and ice cream as well as indairy and yoghurt products or fruit products toimprove the texture. Xanthane is also frequentlyto be found in cosmetic lotions, creams, shampoos,liquid soap and toothpaste and animal feeds whereit binds water or controls flow properties. It isalso used to thicken emulsions in the oil drillingindustry.This universal substance is the metabolic productof a specific type of bacteria. On an industrial scale,the bacteria are bred in large fermenters, and themetabolic products produced by the bacteria aresubsequently harvested. This is where <strong>GEA</strong> <strong>Westfalia</strong><strong>Separator</strong>’s expertise comes into play. The actualprocess of recovery downstream of the fermentertakes place primarily in a 2-stage process with separatorsand / or decanters, whereby the first stage is forclarification and the second stage, namely the washingstage, is used for dewatering the xanthane as faras possible.Minimum shearing forces,maximum marginTwo factors are particularly important in the separationprocess: the control of shearing forces andexplosion protection. Shearing forces have a majorimpact on the quality of the long-chain saccharide,and thus on the price of the product.<strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong>, therefore, uses a tailormade design to ensure gentle product treatment andhigh throughput. Decanters of the TCA series forinstance are used for this application. Particular attentionhas also to be paid to explosion proof protection,as the solvents used are alcoholic and pose a dangerof explosion. In this respect, <strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong>has been able to implement innovations focusing oncustomer benefit as a result of its many years of experiencewith explosion-protected processes; one methodinvolves nitrogen blanketing of the machines. Inaddition, <strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong> know-how ensuresmaximum safety and maximum product quality.<strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong> has, of course, implementedthe requirements specified in the ATEX guidelinesfor decanters and separators. Several machines havealready been successfully commissioned for thisprocess in accordance with the ATEX guidelines.<strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong> is without a doubt one ofthe leading suppliers of centrifuges for xanthaneproduction world-wide and by far the major supplierfor such centrifuges in Europe.7<strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong>


Petrochemical AdditivesSpecialists with stamina.Good lubrication is necessary for a long life; oil additivesreduce the viscosity of the lubricants and thusreduce wear and fuel consumption.Clarifying decanters and clarifying self-cleaningdisc stack separators are used for the production ofpetrochemical additives in an area that can almostbe described as traditional: after a precipitationreaction. This reaction is used to remove impuritiesfrom the carrier liquid, usually an organic solvent.The previously dissolved and unwanted componentsof the petrochemical additive can then be removedby centrifugal force.Depending on the pre-concentration, the separationprocess either uses decanters or separators or,frequently, uses a 2-stage procedure with decantersand separators. In general: if the solution has a highsolid content, a decanter is ideal; these machines aremore solids oriented than separators. If the valuablephase, which is discharged after the first separationstage, still contains unwanted suspended solids, theuser can install a polishing separator which removesextremely fine particles from the decanter overflow.The clarified liquid phase, with the dissolvedadditives, is treated in further processes.Meeting safety requirementsWith gas-tight, explosion-proof centrifuges accordingto ATEX standards, <strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong>guarantees maximum safety. <strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong>optimizes the centrifuges so that they are able to meetthe specific conditions present on every customer’spremises. The prime focus is not only on the separatingefficiency but also on sophisticated issues suchas solids transport in the centrifuges, which are indispensablefor continuous operation. Centrifugationtests and the experience of <strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong>warrants a perfect configuration for the installation.Contaminated oil additive,obtained from a reaction processTCA 501Oil additive solutionto further treatmentOil additivesolution + saltsSalts (disposal)Salts (disposal)TSE series8<strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong>


Catalyst RecoveryPrecious and carrying weight.Catalysts are chemical substances that speed upthe rate of a reaction and which do not undergoany change themselves; they can, therefore, berecovered and recycled. This is a valuable propertyas catalysts such as platinum, cobalt and manganesefor instance are simply too valuable to be used justonce. And their costs have increased significantlyover recent years. In addition, the product obtainedwith the catalyst generally has to be extremely pureand free of heavy metals and any traces of catalyst.Thirdly, simply disposing of the catalyst would haveenvironmental implications.Centrifugal separation is the most popular methodfor recovering catalysts that, subsequently, canbe recycled continuously back into the processimproving its cost-effectiveness, quality and environmentalcompatibility.Also nozzle-type separators especially from theTDC series including the entire package unit areincreasingly used for recovering the catalysts; theseprovide highest clarifying results with a defined solidconcentration in the nozzle discharge. The productcontacting parts of the entire machines are availablein various special materials for individual applications,different design pressures and explosion proofdesign.To ensure that every machine operates reliably,<strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong> uses its vast experience inconjunction with specific pre-trials, where necessary,selecting the correct centrifugal system and size.Compact challengeVery heavy solids often have to be separated whilerecovering the catalyst. However, this is only half ofthe challenge: some of the solids compact so stronglyon the wall of the bowl of a self-cleaning separatorunder the influence of centrifugal force that the dischargegap of the system may shift. <strong>GEA</strong> <strong>Westfalia</strong><strong>Separator</strong>’s metering piston mechanism is the righttool for handling solids that become so compacted. Inthis case, a complete discharge of the bowl ensures ahigh degree of operating reliability.If higher solid contents are required, decanters of differentsizes are used for obtaining maximum dewateringand clarification efficiency. Chamber-typeseparators, which are able to polish and concentratethe product at low feed quantities, are also used. Inthe newer generation of chamber-type centrifuges,the liquid is discharged completely from the drainholes of the bowl, the valuable catalyst remains inthe chambers and can thus be discharged manuallymore easily.9<strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong>


Drive Concepts for <strong>Separator</strong>sDifferent drive concepts are also available for the separators. Two drive conceptsare in the programme: flat belt and direct drive.Flat belt driveThis drive concept entails transfer of the motor powerto the spindle by means of an antistatic flat belt. Oilcirculation lubrication ensures that the bearings arecontinuously lubricated.Compared to the gear drive, which is still used inolder models, the motor power is transferred with upto 10 percent lower power loss. The belt itself can bereplaced quickly and in a service-friendly manner.Direct drive systemThe direct drive is an example of intelligent simplificationin separating technology. Wherever the upperlimit for gear loads has been reached or belt drivesare undesirable, our separators with direct drive permitvirtually loss-free power transmission. This boostin performance simultaneously reduces the costs ofenergy, wear, maintenance and space.The required power is transmitted directly to the bowlspindle by a 3-phase AC motor with frequency convertercontrol via a torsionally elastic clutch. The spindleassembly is likewise supported by rubber-metalcushions. This makes possible low-vibration runningat high bowl speeds.At a glance:Extremely space-saving designAvoidance of housing deformationHigh performance inputLow maintenance requirementFewer partsReduced noiseHigh process temperature more easilyachievableIntegration of a displacement system possibleFor ex-proof separators without N₂ blanketingof the drive areaFlat belt driveDirect drive system15<strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong>


Valve cabinetControl panelClosing waterOpening waterCompressed airDischarge with Metering PistonPrecisely metered discharge quantities.If certain heavy solids have to be separated, andif they also tend to become very compact whensubjected to the influence of centrifugal force,the metering piston ejection system is extremelyuseful. This mechanism ensures complete dischargesof the bowl and, in this way, allows a high level ofoperating reliability.Quantity of opening water is easy to setA further advantage is that the desired quantity ofopening water can easily be set with the meteringpiston. The metering device is filled with preciselythis quantity of water through the inlet valve;compressed air is then forced into the lower chamberof the metering device through the valve.When the opening water valve has been operated, thecompressed air acts on the piston of the meteringdevice, and the set quantity of water is injected intothe opening chamber. This arrangement means thatit is possible for very precise discharge quantities tobe achieved.The air pressure for the metering device should ideallybe 4 to 4.5 bar (g). The pressure transformer installedin the metering device ensures perfect discharge processes,thus overcoming line, valve and injectionchamber resistances.17<strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong>


The Pair of Centripetal Pumps forHigh Density DifferencesMaximum separating efficiency.The centripetal pumps are the real “dream team”of the TTC generation. These centripetal pumpsenable the separating zones to be set preciselyeven in conjunction with very high density differences.For example, this is the only way to achieveoptimum separating efficiency with nitro-aromaticcompounds. In processes where the lightphase is the valuable phase, the separating zonecan be positioned towards the periphery of thebowl, whereby the light phase can be allocatedmaximum clarifying area. At the same time, the twincentripetal pump is able to discharge the heavy phaseunder pressure in an enclosed system. This is a majoradvantage particularly in the case of explosive oraggressive media. Unlike processes that dischargeunder gravity, nothing can be discharged onto thehood of the separator, thereby avoiding the significantcost of making the hood corrosion resistant.No pump, no costsThe centripetal pump consists of a cylindrical discequipped with channels and is installed in theso-called centripetal pump chamber of the rotatingbowl. It is stationary, and its external periphery isimmersed in the rotating liquid. The liquid is dischargedtowards the centre of the pump through thechannels, and the rotational energy of the liquid isconverted into pressure. This means that an additionalpump is not necessary, thus achieving savingsin investment and operating costs.18<strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong>


Bowl Drain HolesSo that nothing is left over.The solid-wall bowl separators of the TTC generationare used wherever it is necessary to achievehighest separation efficiency of two liquid phaseswith a very low or negligible solids content. Nevertheless,preventing the possible removal of the solidsis often not possible. Complete protective clothingwas previously essential for this work. With the TTCgeneration from <strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong>, however,such protective clothing can normally be left on thepeg. This is because these machines are the onlysolid-wall disc-type separators in the world whosebowls are completely drained by gravity when themachines are shut down. Only small quantities ofmedium (often very toxic) remain in the bowl to becleaned manually. Proper washing cycles after stoppingthe bowl can reduce that quantity even further.The result: maximum safety even without full protectiveclothing.Simple and effectiveThe trick is extremely simple and effective: specialdrain holes are designed in such a way that,during operation, they are “dry” as a result of thecentrifugal forces. The liquid enters this dischargearea only when the centrifuge slows down; it candischarge completely from the bowl via the drainholes, and is then collected in downstream tanksvia the frame drain. Under certain circumstances,the drain holes provide the option to carry out CIP,draining the product first without the bowl having tobe opened. That offers the client a significant increaseof the production time and a decrease of the downtime.Rotary Brush Strainers and Wear ProtectionUpstream rotary brush strainers and a special coating for components which areat risk protect the separators against clogging and abrasion.Excessively large solid particles can clog centrifuges,especially of nozzle-type separators. This is reliablyavoided by installing a rotary brush strainer from<strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong> upstream. The product is fedinto the strainer insert through the inlet, and flowsthrough the strainer in the chamber to the discharge.The coarse solids are retained and scraped off the interiorof the strainer by the rotating brushes. They fallinto the conical base, from which they are dischargedmanually from time to time or automatically throughthe solids discharge.At a glance:Upstream rotary brush strainers preventclogging of the nozzlesReliable protection against abrasionSpecial coating against abrasionIn order to ensure that maximum performances arepermanently achieved, the nozzle-type separators arealso equipped with a special wear protection againstabrasion. This solution comprises coated wear platesas well as a coating on the distributor bottom and thebowl bottom.FeedDischarge,clarified liquidDischarge, solids19<strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong>


Ceramic Membrane Filtration –Ultra- and Micro-Fine Clarification<strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong> has achieved a new dimension of ultra-fine clarificationwith solutions comprising a centrifugal separation system and filtration technology.In addition to centrifugal separation systems,<strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong> also has an expert commandof membrane filtration with ceramic elementsfor ultra- and micro-fine clarification of particles. Thecompany is accordingly able to significantly expandproduct clarification within a process chain. Theintelligent combination of centrifugation and membranefiltration in an innovative solution furtherimproves the efficiency of the overall installation.Individual specificationsThe ceramic membrane installations continuously supplya clear filtrate with the specified degree of clarificationand the desired performance. The ceramicmembrane forms a mechanical barrier with a definedpore size.<strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong> provides a wide range ofceramic membrane modules in the pore size range ofultra- and mircrofiltration and with different membranematerials. The modules are mainly standardized,with variable channel diameters, element lengths andpore sizes. This membrane installation downstreamof the separator permits extremely fine clarificationof particles with a diameter of < 1 micrometer.At a glance:<strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong> solutions comprisingcentrifugation and membrane filtrationEverything from a single sourceIntelligent harmonizing of all componentsenhances process efficiencyWide range of ceramic membrane modulesIndividual configuration according to specificrequirements20<strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong>


DecantersThe result of decades of experience.When clarifier operation is no longer feasible dueto high proportions of solids in the suspension to beprocessed, decanters are used. The decanter designis based on decades of experience in centrifugalseparation techniques as well as intensive research anddevelopment by <strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong>. Decantershave been developed for high clarifying performanceand the maximum possible degree of solids dewatering.Essential conditions for this include, amongothers, high bowl speed and an enormously highscroll torque in conjunction with a control system tosynchronize differential speed and solids load.The product for decanting enters the decanterthrough the feed tube and the distributor conveys itinto the separating chamber where it is accelerated tooperating speed. The action of centrifugal forcequickly causes solid particles to sediment on the bowlwall.The bowl is of a cylindrical / conical shape. In thecylindrical section, this shape allows effective clarificationof the liquid, whilst in the conical section, thesolids are effectively dried.The scroll rotates slightly faster than the bowl shelland conveys separated solids continuously towardsthe narrow end of the bowl. Due to the conical shapeof the bowl here, the solids are lifted out of the liquidand, on passing through the “drying zone” which isno longer filled with liquid, freed from any adheringliquid by centrifugal force. The solids are thendischarged into the collecting chamber of the housingthrough openings in the end of the bowl. The liquidflows between the flights of the scroll to the other endof the bowl. The slight impurities still in the liquidare spun out by centrifugal force as the liquid flowsthrough the clarifying zone and is pumped by thescroll to the solids discharge together with the solidswhich have already been collected in the feed zone.The clarified liquid leaves the separation chamberunder pressure by means of centripetal pumps or isdischarged downwards under gravity.Depending on the decanter type, it may be drivenby a 3-phase AC motor for controlled torque startingor alternatively by 3-phase AC motors with frequencyconverter. This allows start-up current and currentpeaks on start-up to be reduced. The power is transferredby belts and gears.Light phase dischargeSuspensionSolids dischargeSection through a clarifying decanter21<strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong>


Innovative Drive Concepts for DecantersFlexible process management with simultaneous maximum availability are essentialrequirements for modern drive concepts.The variety of process engineering applications inwhich decanters from <strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong> areused requires different drive concepts. This is the onlyway to meet the corresponding product requirementsin an optimum manner. The product line thereforeincludes drive systems with and without the possibilityof simple regulation of the differential speed.The requirements for the machine and process butalso customer wishes determine what type of drive isused. In the case of decanters which are used in thefield of chemical industry, flexible and precise regulationof the differential speed is particularly important.This is the only way to achieve extremely high solidconcentrations and thus high separating efficiency.The 2-gear drive and the differential gear drive havetherefore become established in practice.2-gear driveThe advantage of the 2-gear drive which hasbeen developed and patented by <strong>GEA</strong> <strong>Westfalia</strong><strong>Separator</strong> is the facility for regulating the scroll drive.The differential speed is adapted automatically andextremely precisely as a function of the scroll torque– and thus as a function of the solids content in thebowl. Accordingly, the solids are discharged fromthe bowl with a constant concentration and in anextremely dry state. 2-gear drives are used wheneverthe volume of solids is not constant, when thesolids are difficult to convey and when very highrequirements are applicable with regard tothe residual water content of the solids.2-motor drive2-motor drives enable the differential speed tobe regulated cost-effectively under good operatingconditions; wide regulating ranges are possible. Thesecondary motor sets then input shaft of the gearin motion and generates the differential speed as afunction of bowl speed and gear transmission. Thedifferential speed can easily be regulated by changingthe motor speed. 2-motor drives are used wheneversolid volumes fluctuate significantly, whensolids are conveyed under difficult conditions and whenparticularly stringent requirements are applicablewith regard to residual water content.2-motor drive2-gear drive22<strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong>


Differential gear driveThe differential gear drive is recommended wheneverit is necessary to automatically regulate the scrollspeed in addition to regulating the bowl speed. Thiscan be achieved by means of two gears. The secondarymotor drives the central input shaft and generates thedifferential speed proportionally to its own speed. Asecond input shaft without any speed is connected tothe housing. This means that the differential speed isnot dependent on the bowl speed. Differential geardrives are used primarily in the lower range of thedifferential speeds.<strong>Westfalia</strong> <strong>Separator</strong> ® varipond ® –reliable mastering phase separationThe pond depth in the decanter is an importantparameter with which various performance parameterscan be influenced. The <strong>Westfalia</strong> <strong>Separator</strong> ®varipond ® system gives the user the opportunity to alterthe pond depth to adapt to specific conditions duringongoing operation. A so-called <strong>Westfalia</strong> <strong>Separator</strong> ®varipond ® disc dips into the clarified liquid phasedirectly in front of the regulating ring. This disc formsa hermetic chamber (“<strong>Westfalia</strong> <strong>Separator</strong> ® varipond ® ”chamber) together with the centripetal pump, towhich pressure can be applied through a hole in thefeed tube. Since the liquid level between the <strong>Westfalia</strong><strong>Separator</strong> ® varipond ® disc and the regulating ring isdefined by the overflow diameter, overpressure inthe <strong>Westfalia</strong> <strong>Separator</strong> ® varipond ® chamber has theeffect of enlarging the pond depth in the decanterbowl in accordance with the principle of the communicatingtubes. As a result, the clarification areais enlarged.Differential gear drive<strong>Westfalia</strong> <strong>Separator</strong> ® varipond ®The process operator consequently has a tool that permitsprecise adjustment of the dewatering and clarificationefficiency. This is indispensable for efficientand cost-saving decanter operation, particularly in thecase of changing feed conditions.Particularly in the case of gas tight decanters, the<strong>Westfalia</strong> <strong>Separator</strong> ® varipond ® system has the advantagethat it requires no mechanically adjustable partssuch as rotary leadthroughs. It therefore provides ahigh level of protection against discharging, harmfulgases.23<strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong>


Centrifuges for High Temperatureand High Pressure ApplicationsHot products.<strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong> has found a solution tothis problem through continuous high-temperatureclarification with specially designed separators. Byway of example, nozzle separators can only separateparticles suspended in viscous liquids effectivelywhen their viscosity is reduced by increasingthe temperature. In the case of some productstreams, the optimal separating conditions arearound 190 °C. Since many carrier liquids evaporateat these temperatures at atmospheric pressure, thepressures are around 10 bar.The pressure-stressed components hood, solidscatcher and protective hood have been rated to meetthe specific requirements of the European PressureEquipment Directive and the American ASME code.The pressure-specific segregation of the product spacefrom the drive chamber is by means of a double-actingslide-ring packing. Suitable materials of Super Duplexand Super Austenite are used as standard. Suitableelastomers like FKM and FFKM are available as gasketmaterials.Every component is subjected to a comprehensivequality check to also meet the stringent demands inchemical sectors.Many applications in the chemical industry requireoperating the process at elevated temperatures, forexample:Hot wax clarificationProduction of aminesSome petrochemical additivesFood additivesFluid gases<strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong> self-cleaning disc stackseparators are successfully used in such applicationsat process temperatures up to 140 °C. This proveshigh mechanical reliabilty.Special care is taken on the choice of materials,especially gaskets. Development of new polymermaterials now makes it possible to use polymers forthe bowl main gaskets instead of expensive steel-onsteelgaskets.24<strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong>


Wear Protection in Decantersand <strong>Separator</strong>sRobust armour plating.Many processes expose decanters and separatorsto extreme material strain. For maximum wearprotection, <strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong> installs armourplating as required to all points of a decanter whereincreased levels of wear can be expected, particularlywhen the machine is used for processing very abrasivesolids.One possible solution is spray cladding in whichcarbide is welded onto the exposed parts of thecentrifuge, for example:The vane of a decanter scrollThe distributor of different centrifuge typesThe sliding piston of a self-cleaning separatorFor protection of a decanter scroll, <strong>GEA</strong> <strong>Westfalia</strong><strong>Separator</strong> also offers the possibility of using tilesinstead of spray cladding. Tiles are generally usedfor highly abrasive products.However, these ports are not protected in the sameway as even hard metal welded on to the surface inthis particular area would erode over a relatively shortperiod and would require expensive repair work.Elegant and customer-orientedInstead, <strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong> uses specialsintered hard metal sleeves that provide a muchhigher abrasion resistance. These sleeves wear downon one side but can be easily turned around. Usershave to replace the sleeves only when both sidesare worn. This requires much less maintenancecompared with welding and results in considerablyhigher availability of the decanter. An elegant andcustomer-oriented method of ensuring that wear onthe solids discharge is manageable.Another wear point, which is particularly wellprotected by <strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong>, is the pointat which the solids are discharged through the solidsdischarge ports.25<strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong>


Explosion-Protected CentrifugesAvoiding sparks.Centrifuges are used in the chemical industry forclarifying and separating readily flammable liquids.Theoretically, such applications can resultin critical concentrations of solvent vapours andoxygen inside the centrifuge that can cause explosionsor fires. However, the vapours must also beprevented from escaping so as not to pose a risk tothe health of the operators. Both these risks can beprevented reliably by using gas-tight centrifugesfrom <strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong>. No sparks, no staticcharges, no hot bearings – the test criteria of thestrict European ATEX standard are of course implementedin all <strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong> explosionprotectedcentrifuges. In addition, before the startof operation, the centrifuge is purged with inertgas and blanketed with a slight excess pressure sothat no further oxygen is able to penetrate. This isbecause fire is not possible without oxygen. Whenprocessing sensitive liquids, the necessary inertgas atmosphere in the separator is automaticallymonitored throughout the entire operation.Nothing is able to penetrate this barrierAn essential design feature of the gas-tight separatorsfrom <strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong> is the gas-tightsealing chamber that separates the drive area withthe motor from the product chamber. This sealingchamber is blanketed with inert gas, and the connectingspindle is protected with dynamic specialseals. The sealing chamber reliably prevents the solventfrom passing from the product chamber to thedrive area or into the surroundings. This is beneficialnot only from the point of view of fire and healthprotection, it is also not possible for solvent todilute the oil, which would diminish its lubricatingefficiency and thus pose a risk to the drive unit.The same is also true in reverse: no oil is able to penetratethe product chamber and thus have a negativeimpact on the quality of the valuable product.ATEX 95 (directive 94 / 9 EC)A directive for machines operating in hazardoussurroundings has been in force in Europe since1 July 2003. This affects numerous applications in thechemical and pharmaceutical industries, particularlywhere gas-tight machines are used. According to thedirective, the first step is to carry out a risk assessmentof the relevant machines to identify any present orpotential risks.The measures are documented and the documentationis submitted to an Entitled Body. In specificterms, this means that <strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong>centrifuges are now equipped with failsafe vibrationmonitoring equipment, often a bearing temperaturemeasurement as well as an inert gas supply unit.All electrical equipment must have been awardedan ATEX certificate or a manufacturer declaration.This directive is only applicable to new machines. Aseparate directive ATEX 137 (directive 1999 / 92 EC) isapplicable for operators of installations in hazardousareas. In this way, operators have also been obliged tocarry out risk assessments for existing installations.Machines and installations must have been assessedby no later than 1 January 2006. <strong>GEA</strong> <strong>Westfalia</strong><strong>Separator</strong> offers its customers support for assessingand where reasonable converting these centrifuges.26<strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong>


<strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong> improves inertgas conceptRequirements with regard to safety and reliabilityare becoming more stringent for separators anddecanters used in zones with a risk of explosion. Theexisting inert gas concept is constantly improvedto meet these requirements. The latest Europeanstandards, as well as <strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong>’spractical operating experience, are incorporated in theconcept. As has been the case with most existing concepts,the atmosphere in the separator is displacedwith inert gas before every start-up and the excesspressure is maintained during operation to meet therequirement for minimum inert gas consumption.The fittings and measuring devices used have beensubjected to an extensive test and have also beenoptimized as far as investment costs are concerned.The new inert gas supply facility complies not onlywith the familiar directive 94 / 9 EC (ATEX) but alsowith the TA Luft, i. e. product leakages from theequipment are reduced to a minimum using state-ofthe-arttechnology.<strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong> places great emphasis oncomplete and easy-to-understand operator documentationas well as a carefully performed conformityassessment procedure (CE symbol). The company alsoprovides information concerning the correct installationof separators and decanters in zones that areexposed to the risk of explosion.27<strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong>


Special MaterialsFrom case to case and always optimum.The proper tool for the job; this is the principle used by<strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong> for selecting materials. Thisis applicable particularly for components that comeinto contact with product, such as the bowl, scroll ordisc stack. Strength, corrosion resistance and hygienicspecifications are important criteria in this respect. Ingeneral, the quality of the material must increase asthe requirements become more stringent. The standardmaterial is the tried-and-tested stainless duplexsteel, which has high strength and excellent corrosionresistance. On the other hand, super duplex steel isthe preferred material for more complex applications.For particularly “tough” applications, <strong>GEA</strong> <strong>Westfalia</strong><strong>Separator</strong> uses special alloys such as Incoloy 825,Titanium or Hastelloy C4. The load-bearing parts(bowl bottom, bowl top and bowl lock ring) can alsobe made of 1.4501 super duplex material.1. Inserting the lining in the bowl bottomMore would be wasteA genuine <strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong> speciality isthe lining of solid wall bowls with Incoloy 825,Hastelloy C4 or even titanium palladium. Thisknow-how is unique to <strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong>throughout the world. In this process, sheets ofthe appropriate special material are incorporatedin the bowl top and bowl bottom to ensure longcorrosion protection. The load-bearing bowl partshowever continue to be made with standard materialsto permit high bowl speeds. This procedure hasspecific advantages: if it is really necessary, the liningcan be replaced; the use of the expensive specialmaterial is reduced to an absolute minimum.2. Dye penetration test after welding the lining3. Bowl bottom with lining in place28<strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong>


Technology Centre for Process Engineering -the Reliable Basis for Decision-MakingCustomer-specific test series in Central Process Engineering provide a reliable basisfor decision-making for all investments in mechanical separation technology.No product to be separated is identical with another.In many cases, it is therefore necessary to performtest series before the correct decision can be taken fora specific installation. <strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong> hasset up the Central Process Engineering department(CPE) for this purpose. Depending on the specifictask involved, test series can be run with the originalproduct of the customer in a mobile pilot installationon site or in the laboratory at <strong>GEA</strong> <strong>Westfalia</strong><strong>Separator</strong>. The specification of the customer withoperating temperature, throughput capacity, clarifyingor separating efficiency and other factorsconstitute additional important information necessaryto enable a representative and reliable analysis.After every test series, the customer receives informativedocumentation in which the technical and economicdata are detailed.Focus on investment protectionThe results of Central Process Engineering can beused to precisely identify what machine type andwhat model from <strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong> are mostsuitable for the specific task. This procedure avoidspoor investments right from the very beginning. Thecustomer achieves a reliable basis on which he cantake the correct investment decision.At a glance:Test series with the original productsof the customerPractical and representative in the laboratoryof <strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong> or in pilotinstallations on siteDetailed test documentationSpecific machine recommendationDetailed mass balanceTotal cost analyses29<strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong>


<strong>Westfalia</strong> <strong>Separator</strong> ® capitalcare –Maximum Process Efficiency, InstallationAvailability and Budget Security<strong>Westfalia</strong> <strong>Separator</strong> ® capitalcare combines decades of service experience for mechanicalseparation technology.Wherever separating technology tasks have to becarried out, <strong>Westfalia</strong> <strong>Separator</strong> ® capitalcare assurescomprehensive services right from the very beginning.In close cooperation with the customer, solutionsare identified to meet their needs.The partners benefit not only from traditional servicessuch as inspection, maintenance, original spareparts and repair work provided by the original manufacturer;they also benefit from pro-active solutionswhich avoid risk, e. g. online and offline monitoringwith <strong>Westfalia</strong> <strong>Separator</strong> ® wewatch ® .Accompanying modernization or upgrading to stateof-the-arttechnology also offer the option of boostingperformance as required.Training provided on site or in the modern trainingcentre of <strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong> ensures that thecustomer‘s employees receive training in the properhandling of the high-tech installations. This providesadditional safety.Authorized workshops worldwideAnd if problems occasionally occur or if a spare partis required at short notice, the specialists are able toattend to the customer quickly. This is ensured by aglobal network with more than 50 sales and servicecompanies as well as 60 further sales partners. Authorizedworkshops are able to service every locationin the world at short notice.30<strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong>


Maximum availability<strong>Westfalia</strong> <strong>Separator</strong> ® capitalcare accordingly makesfor maximum process efficiency and installationavailability as well as budget security. And thesebenefits are provided throughout the entire life cycleof the entire installation.Absolute budget reliabilityPermanent efficiencyService from the original manufacturer:Service engineers quickly on siteExtensive service networkRisk avoided by service providedby the original manufacturerPro-active solutions which avoid riskUpgrading to boost performanceStaff trainingIn addition to traditionalservices such as maintenanceor repair, <strong>Westfalia</strong> <strong>Separator</strong> ®capitalcare also providessolutions which avoid risk andwith which the installationavailability can be pro-activelyassured.31<strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong>


Beverage TechnologyDairy TechnologyRenewable Resources<strong>Chemical</strong> / Pharmaceutical TechnologyMarineEnergyOil & GasEnvironmental TechnologyEngineeringSecond Hand MachineryOriginal Manufacturer ServiceThe information contained in this brochure merelyserves as a non-binding description of our productsand is without guarantee.Binding information, in particular relating to capacitydata and suitability for specific applications, can only beprovided within the framework of concrete inquiries.<strong>Westfalia</strong> ® , <strong>Westfalia</strong> <strong>Separator</strong> ® , varipond ® andwewatch ® are registered trademarks of<strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong> GmbH.Printed on chlorine-free bleached paper9997-1073-020/0810 ENPrinted in GermanySubject to modification<strong>GEA</strong> Mechanical Equipment<strong>GEA</strong> <strong>Westfalia</strong> <strong>Separator</strong>Werner-Habig-Straße 1 · 59302 Oelde (Germany)Phone +49 2522 77-0 · Fax +49 2522 77-2828www.westfalia-separator.com

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