Operation and Maintenance of

Separators and Decanters

New Zealand Rendering Workshop

August 2015 - Invercargill

Sascha Wieking
Sales & Technical Manager

GTech Separation - Australia

 Basics of Centrifugal Separation

Function of Separators

Separator Maintenance and Safety

Function of Decanters

Decanter Maintenance and Safety

Basics of
Centrifugal Separation
 Basic Theory of Centrifugation

All separation methods that use gravity or centrifugal force occur because there is a
density difference between a minimum of two media.
The density difference is the main factor that makes centrifugal separation work.
However other factors also affect separation efficiency.
Stokes law is a fundamental law of physics that applies to settling.
Types of Centrifugal Separation

Separation in Centrifuges is divided in these main 3 groups

Factors influencing separation velocity and efficiency:

particle size

density difference

Viscosity

Clarification area

Gravitational force

Flow rate and retention time

Tendency to emulsification / ph
 Stokes law

2
Increasing the particle size (D) increases the velocity Vs = D * (d1-d2) * g
squared (minimising shear, fining agents) 18

2
Increasing the density difference ((d1-d2)) increases Vs = D * (d1-d2) * g
the velocity (different oils and fats, temperature) 18

2
Decreasing the viscosity () increases the velocity Vs = D * (d1-d2) * g
(different oils and fats, temperature, pH) 18

2
Increasing the g force increases the velocity Vs = D * (d1-d2) * g
18
Centrifugation

~10,000 g
 The g-force

The maximum g-force of a bowl depends on the working diameter

of the bowl and the bowl speed and is limited mainly by the bowl
material (type of stainless steel) and the density of the feed
product.
A separator with 500mm inner bowl diameter running at 5150rpm
creates 7,500 g.
A decanter with 500mm inner bowl diameter running at 2500rpm
creates only 1,800 g.

( 2 n) r 2

9.81 3600
n = bowl speed [1/min]
r = bowl radius [m]
Sedimentation

In a stationary settling tank liquids of different densities along with

the solids will form a deposit above each other after a certain
settling time. This is called as Sedimentation. Because the
density of the solids are higher compared to water the solids will
sink much faster to the tank bottom. The liquid with the lowest
density will float on top after a while: the oil.

dirty oil in a settling tank a few hours later

Sedimentation

Big and heavy particles will settle down quite fast to the tank
bottom. This will happen even faster with low viscosity oil as well
as higher the difference in density is between the oil, the water
and the solid particles.

Hot Oil Cold Oil

Sedimentation surface area and path

The sedimentation becomes more effective

with a higher clarification surface area and a
smaller / shorter sedimentation path.
The design of the settling tank 1 is much better
compared to tank 2 with regard to the
clarification efficiency and speed.

 Separator bowl disk stack

The disk stack is acting like a very high number

of flat shallow settling tanks above each other.
There are spacers on top of each disk acting as
distance pieces. Because of the short
sedimentation path a disk stack separators is
very efficient. The dirty oil will enter the disk
stack from the outer diameter. The clean oil is
being discharged in the centre.
Equivalent Clarification Area

In a disc-type separator the installation of a large number of conical discs

increases the equivalent clarification area of the separator

T
2
3g

* w * z *t * * r o r i
2 3 3

w 2 * * n
Angular velocity

Disc type separators like the PX413 separator have around ~50,000m2
And the 2080 decanter has only around ~5,000m2
 Solids Bowl Self-Cleaning
Separator Separator
Up to 0.5 % v/v Up to 5 % v/v

Solids Bowl Solids Bowl

Separator Separator
Up to 25 % v/v Up to 60 % v/v
Function of Separators
Separator Drive

Separators are, aside from the product which is being treated,

subdivided into the design of the drive and the bowl:
flatbelt drive or gear drive
 Separator Bowl

Separators are, aside from the product which is being treated,

subdivided into the design of the drive and the bowl:

self-cleaning manual cleaning (solid wall bowl)

Video
centripetal pump

Centripetal pumps are acting as transfer pumps. Because of that the

separator motor current during separation is much higher compared to
separators without centripetal pump.
centripetal pump

A Centripetal pump is a non-

rotating impeller tightly
connected with the separator
hood.

The Centripetal pump turns

rotation of the liquid into
delivery height (pressure).
Because of that the liquid can
be discharged to the service
tank without additional
transfer pump.
 disc stack

The solids will be collected against the upper wall of each

interspace and slide down to the sludge holding space of the
bowl. For best sliding efficiency of the solids the bottom side of
disks are super finish polished by the factory and the bottom
surface should not be scratched nor damaged because this will
result in reduced efficiency.
 disk stack, separation line

In order to achieve the highest efficiency the entire disk stack

(clarification surface) needs to be designed for the phase which
needs to be cleaned: Oil or Water.

Oil: separation line Water: separation line

outside the disc stack inside the disk stack
Gap/mm
Gap /mm History if Hydraulic Bowl Ejection Systems
3.0

2.5 1990

2.0

1.5

1.0
1975

0.5

1965
Time
0
0 0,02 0,04 0,06 1 1,4 1,6 1,8 2 2,2 2,4 2,6 2,8 3 Sec
Hydraulic systems

Double piston system with fixed discharge size from Westfalia and others

Double piston system with adjustable discharge size from Westfalia and others

Single operating slide system with springs from Alfa and GTech and others

Single operating slide system without springs from Alfa and GTech and others

Ball / Piston Valve system used by Alfa, Westfalia, GTech and others
Operating water quality:

hardness: < 12 dH up to 55 C separating temperature

< 6 dH above 55 C separating temperature

chlorine ions: < 100 mg/l

pH-value: 6,5 - 7,5
sediment content: max. 10 mg/l
particle size: max. 50 m

Pressure: 2,0 - 2,5 bar

Water supply: 3.000 l/h
Separator Maintenance
 In general Two maintenance stops per year
Small service for the bowl inspection
- Exchange of bowl gaskets
- Inspection for corrosion and wear
(i.e. discharge ports, wear liners)
- Cleaning

Large service (incl. small service)

additionally
- exchange of the bearings
- inspection of the driving parts
(exchange of worn out gear parts or belts)

Regular lubrication oil change

- standard oils : every month oil is cheap
 Some Golden Rules

Separators and Decanters need lubrication

If this is not ensured, major damage can result in
extensive repair costs Always check lubrication before start-up

Separator and Decanter always have to be up to operational speed before product can be fed

Feed has to be shut down first before shutting down the Separator or Decanter

Never open any machine while parts (bowl, motor, etc.) are still turning (be aware of clutches)

Sufficient machine monitoring is recommended, which can be manual or automated

Operating Water Quality is one of the most crucial factors for a long reliable working life of
every Separator
Function of Decanters
Sedimentation

Sedimentation +
centrifugal force

Sedimentation + centrifugal force +

continuous solids discharge
Decanter Sedimentation

With continuous flow into a static sedimentation tank, solids will

build up and overflow
A scraper conveying system to remove solids and a drying zone
improves the design

A decanter centrifuge is very similar to this, however the machine is

rotating at thousands of RPM
Video
Pond Depth

Pond Depth

The maximum pond depth is determined by the inner bowl diameter (D)
minus solids outlet inner diameter (Ds )
Pond Depth

Cake Solids

The liquid ring under high g-force adds weight onto the solids and helps
compress the cake thus releasing more liquid.

1 liter of water @ 2,000 gs weighs 2 ton. The deeper the liquid ring the
greater the compressive forces acting on the sludge cake.
Decanter Maintenance
Scroll Wear Protection

Wear Parts need to be regular inspected and exchanged

if needed before major damage is conveyed to the
Major and expensive Bowl and Scroll Conveyor Parts

e.g. flighting and feed and discharge ports

 Maintenance Schedule

Daily Monthly
Check for normal operation of machine Clean locks on hood
Main Bowl Bearings Greasing Clean grease collection chambers
Clean housing / catcher of cake deposits
Weekly
Check for normal operation of machine Twice Yearly
Conveyor Bearings Greasing gear box re-grease
drive belt check and tension
check wearing bushes, wear liners and vanes in
the area of the discharge ports.
check wear and tear on bowl / scroll conveyor
Maintenance Schedule

Yearly
Check wear on drive parts and replace if worn
Replace drive belts
Check vibration isolators. Replace if worn
Replace bowl bearings on liquid / solids side.
Repack with grease
Replace scroll bearings on liquid side. Repack
with grease

4 Yearly
Replace vibration isolators

Manufacturers Instruction
Re-lubricate / replace motor bearings
 Some Golden Rules

Separators and Decanters need lubrication

If this is not ensured, major damage can result in
extensive repair costs Always check lubrication before start-up

Separator and Decanter always have to be up to operational speed before product can be fed

Feed has to be shut down first before shutting down the Separator or Decanter
Dont feed and flood a stopped centrifuge

Never open any machine while parts (bowl, motor, etc.) are still turning (be aware of clutches)

Sufficient machine monitoring according to WS standards is required to obtain full OEM warranty
(everything related to the mechanical integrity of the decanter is supplied from WS)

Operating Water Quality is one of the most crucial factors for a long reliable working life of every
Separator this is not important for Decanter
Good cleaning and flushing is important to prevent accessing corrosion
Health and Safety

CAUTION: High Speed Rotating Equipment

Centrifuge rotate at high speeds

and produce great kinetic energy,
which is equal to the force of a
motor vehicle at 100 km/h
Unintentional use or disregard to
the safety instructions contained in
the manuals can cause extreme
damage, serious injury and
possibly harm or kill
Safety stickers (left) must always
be attached to machine and in
clean condition
DO NOT REMOVE GUARDS UNTIL
COMPLETELY LOCKED OUT

Before opening or working on the machine, please ensure the

machine has come to a complete standstill and is appropriately
locked out. Follow correct site procedures
Health and Safety

DO NOT: CHECK:

Increase the speed of the machine Operating and maintenance

Run the machine without product manual or experts if in doubt
for more than 60 minutes (danger
of overheating bowl)
Run the machine with excessive
vibration
Wear appropriate hearing
protection and PPE

Oil lubrication and grease system

is operated properly
Local New Zealand Manufacturer and Supplier
of Rendering Specific Equipment and Service:

Separators
Decanters
Grinders
Pumps