DRYCAKE:CBBDECANTERCENTRIFUGES

Themarketfordecantercentrifugesisverycompetitive.Therearemorethana dozenmanufacturerswithverylittletodistinguishthedifferentequipmentfrom oneandother.WiththeuseofaninnovativedesignDRYCAKE'sCBBcentrifuges hascreatedtheirownadvantageinthemarket.Theintentofthisdocumentisto outlinethoseadvantages,whileatthesamealsoprovidinganexplanationofhow centrifugesoperateandtheiradvantages.AtthisJuncturehowever,Iwantto stressthatDRYCAKEcompetesonprice,performance,andmaintenance.The performanceandmaintenanceadvantagesoftheCBBcentrifugedonot compromiseDRYCAKEspriceadvantage.

SOMEOTHERDEWATERINGTECHNOLOGIES:

BeltFilterPress FournierPress PlateandFramePress BaggingSystems(DRYCAKEDRAIMAD) ScrewPress(DRYCAKESLUDGLESS) DewateringBins Geotube

Whiletherearealotofoptionsoutthere,thecentrifugeiscurrentlythe preferreddewateringtechnologies.However,itisalwaysgoodtoinformoneself ontheotheroptionsonthemarketplace.

CENTRIFUGEOPERATIONALPRINCIPLES:
Adecantercentrifugebehaveslikeagravitysettlingtank, thedifferenceisthecentrifugalforce:itimprovesthesettling timeandefficiency!!

GRAVITYSETTLINGTANK

Inagravitysettlingtank,thesolidssettlebytheforceofgravity,whicharethen dischargedoutoneendandtheclarifiedliquidareskimmedoffandcomeoutthe otherend. AlsothesettlingareaisincreasedbyvirtueoftheGforceworkingin360degrees towardstheoutsideofthebowl.

CENTRIFUGELIKEAGRAVITYSETTLINGTANK

Gforceisdefinedastheratiobetweenthecentrifugalacceleration createdinsidethebowlandtheearthgravityaccelerationg=9.81m/s2 Acentrifugeworkslikeagravitysettlingtank,exceptinsteadofoperatingat1G, thecentrifugeoperatesatseveralthousandGthusreducingthesettlingtime. TheBowlrotatesat~3000RPM*,andtheScroll/Screwrotatesat~3010RPM, creatingadifferentialspeedof10RPM(30103000).Thesolidsaremovedoutof thecentrifugeatthisspeedof10RPM.Theclarifiedliquidcomesouttherearend ofthecentrifuge,likeinagravitysettlingtank. TheBowlandScrewRPMSwillvarydependingonthesizeofthecentrifuge.The differentialspeedcanbesetaccordingtheapplication,andthedesiredretention time.(thetimethesludgestaysinsidethecentrifugebeforedischarge) Theliquidoutletlevelissetbyaliquidlevelweirplate.

EquivalentArea(Ae)

R=bowlradius L=distancebetweenfeedpointandliquidoutlet

Area=2RL
Thesettlingabilityindicatesthedecantersettlingcapacity,andiscalculatedas thesurfaceareaneededforasettlingtanktoachievethesametask.

Centrifugalacceleration
Ac=centrifugalacceleration =angularvelocity(radians/sec) n=rotationspeed(rpm) r=radius

Ac r

2 n 60
TheangularvelocityisrelativetotheRotationSpeed Thecentrifugalaccelerationisrelativetotheangularvelocityandthe diameterofthebowl.(angularvelocityisusuallyexpressedinGforce)

CENTRIFUGE HowitWorks

Solidsdischarge:Thisiswherethedewateredsolidsdrop.Normally,ascrew
conveyorwithavalveoradivertergateispositionedbelowthedischarge.Thisis becauseforthefirstfewsecondsafterstartup,liquidwillcomeoutofthesolids dischargeofacentrifuge.

Solidsdeposited:Thesearethesettledsolids.Theyformanannular,360
degree,shapearoundthebowl,andbeingconveyedforwardbythescroll/screw ofthecentrifugeataraterelativetothedifferentialspeed.

Liquidsdischarge:Thisistheliquidsdischargeendofthecentrifuge,thisliquid
isstilldirty,andissentbacktotheheadofplant.Thewaterlooksclearorslightly trouble,withausualcapturerateof9598%.

FeedPipe:Thisiswherethesludgeisfed,onesomemachine,thefeedpipeis
ontheotherendofthemachine.Thesludgeisfeduponhalfwaythroughthis feedpipe,atwhichtimethesludgeisreleasedandbythecentrifugalforce,the solidssettlealongtheoutsideofthebowl.Thisisadjustableforoptimization.

Clarifiedliquidpond:Thisistheseparatedliquidpartofthecentrifuge,once
theliquidreachestheoutletlevel,theliquidbeginstodischarge.

CylindricalSection:90%ofthedewateringoccursinthissection. Beach(Conicalsection):Thissectionisdesignedtoexertadditionalforceon
thesolids,squeezingoutthelastdropsofliquidaswearenotonlyapplyingthe centrifugalGforcebutalsopushingthesolidsuphill.Itisdesignedtoelevatethe solidsabovethewaterlineintothedischargechamber. Theangleofinclinationcanvaryfrom8to15degreedependingonthesludge characteristics.

Gearbox: Thecentrifugeisequippedwithadrivesystemcomposedofanelectric
motor,ahydraulicmotor,hydraulicpumpandacyclogearbox.Theelectricmotor providesthepowerrequiredtoturnthecompleterotatingassemblydrivingthe drumdirectlyandthescrollthroughthehydraulics.Controllingthedifferential speedbetweenthedrumandthescrollisPLCcontrolled.ThePLCcontrolsthe workingcycleaswellastheprotectionincaseoftorqueoverload.

DECANTERFEEDZONE

PolymerInjection:Thepolymerisusuallyinjectedinlinerightbeforethesludge feedpumpbeforegoingintothefeedpipe. FeedZone:Thisisthepointatwhichthesolidsarereleasedintothecentrifuge. BaffleDisc:Thisplateserverstwofunctions. 1. Withoutabaffledisc,theliquidlevelcannotbesethigherthan thesludgedischargelevel.Since,theliquidlevelisoneofthe factorsindeterminingthecapacityofacentrifuge.Thebaffle thereforeallowsasmallermachinetodewateralargervolume. 2. TheGforceislowestattheverycenterofthecentrifuge.The bafflediscallowsthecentrifugetoexertmorepressureonthe sludge.Thisisdonebyformingaplug;thecentrifugeis completelyfilledwithsludgeinthebeachsectionbeyondthe baffledisc.Withoutthebaffledisc,thiswouldnotbepossibleas thesludgewouldgotothecenterandtherewouldbenobaffle disctoprotect.Thisespeciallyhelpswithperformancewith viscoussludgethathasatendencytosplashbacklikeyoghurt. Withabaffledisc,ifyouchoosetosettheliquidlevelhigherthanthesolids dischargelevel,thenuponstartupliquidwillcomeoutofthesolidsdischarge untilaplugisformed.Also,iftheplugislostduringoperation,thesamewill happenagain.Thisiswhyqualitycontrols,especiallytorquecontrol,areof utmostimportanceandwhywerecommendahydraulicbackdrive.

Decanterwithvariabledifferentialspeed (Hydraulicbackdrive)

DecanterwithElectricBackDrive

DifferentControlRegulation

Asmentionedbeforetorquecontrolisessentialtooptimal performance.Hydraulicbackdriveshaveaflatperformancecurve; electricbackdrivesontheotherhandhaveperformancepeaks,and dontperformaswelloutsidecertainparameters.Hydraulicare thereforealwayspreferabletoelectricbackdrives.

DECANTERREGULATIONANDOPTIMIZATION

PerformanceOptimizing

Tooptimizetheperformancesetthefollowingparameters: Q=feedrate d=flocculation =viscosity n=RPM n=differentialspeed (Rr)=Ponddepth

PerformanceOptimizing
Influenceofflocculation,rotationalspeedandfeedrateon separationefficiency

CBBBENEFITS Scroll:wearresistentprotection

WithSolidSteelbarsifthereiswearonthescroll,itcanbefixedwith aweld.Thehollowsteelbarsthatsomeothermanufacturersuse cannotbefixedifdamaged,andrequirethecompletereplacementof thescroll.

SCRAPER

Solidsbuildupinthesedimentroomisoneofthemajorreasonsthatacentrifuge stalls.TheCBBcentrifugesareequippedwithaseparatescraperroomand continuousfullgeared,independentlydrivenlowspeed(5RPM)solidsscraperto preventthisfromhappening Thedischargeofacentrifugeisthrownagainstthewallsofthesedimentroom withaforceover1000G.Normally,thesedimentfallsdownbecauseofgravity, butwithalumsludgeandotherstickysludges,thesedimentbuildupandclogthe discharge. Ifthedischargeisclogged,nosolidscanleavethecentrifuge,andthebowlofthe centrifugewillfillupcompletely,causingthecentrifugetocometoastop.Itwill thenbenecessarytoremovethescrollandcleanoutthebowl.Incertain applications,thismightrequirea30tonpulley.

Someothermanufacturersalsohaveascraperbutitrunswiththebowl/scroll assemblywhichresultsinexcessivewearinthescraperbladesandcancause increaseinlossofbalance.Othersmayuseachaindrivenscrapermotorresulting insealingproblemsinthedischargechamber. OurScraperisfullygeared,usesballbearings,andoperatesindependentlyfrom thebowlandthescroll.ThisfeaturesetsthescraperoftheCBBcentrifugeapart fromeveryothermajormanufacturer.

ADJUSTINGTHEWEIRPLATE

Allothermajormanufacturersmakeuseofseveraldifferent bothersomeweirplatestochangeliquidlevels.Theseareusually halfcrestmoonsthataredifficulttochangeandareoftenlostin storage. CBBonlymakesuseofoneplate.So,whentheliquidlevelsdoneed changingtheplateisexactlywhereyouneedit,onthemachine. ChangingtheliquidlevelsisalsoeasierontheCBBbecauseofthe threesectionhingedcover,whichprovidedquickandeasyaccessto theweirplate.

IntegratedHydraulicReservoir

Oneofthebiggestconcernswegetfromoperatorsinregardsto hydraulicbackdrivesisthelocationandconnectionofthehydraulic tank.Typicallyahydraulicunitisplacednexttothecentrifugeswith thehydrauliclinesrunningonthegroundtothecentrifuge. CBBhasaddressedthisissuebysimplyusingthelegsofthecentrifuge ashydraulictank.Thisreducesthefootprintofthecompletesupply, andremovesany,potentiallyunsafe,connectionlineslyingaround. IneffectCBBoffersazerofootprinthydraulicbackdrive.

DISCHARGEBUSHINGREPLACEMENT
Thedischargebushingsareveryeasytoreplaceduetoourthree sectionhingedcoverandtheuseofstandardtools. Wecanalsorotateourdischargebushingstogetmorelifeoutof them.Thewearonthebushingsisalwaysonthesameside,sosimply rotatethebushinginplace1/4turntogainupto4timesmorewear life.