PIERALISI Decanter Technology1

PIERALISI Centrifuge Training Centrifuges for Solid-Liquid, Liquid-Liquid and 3 Phase Separation 3-Phase
Decanter: A continuous settling centrifuge
Presented by: Prof. Dipl.-Ing. M. H. Kopf
July 2010
PIERALISI Decanter Technology
Decanter: a continuous settling centrifuge

What we are talking about:
July 2010

Overview and basic principle:
A DECANTER is also named solid-bowl conveyor centrifuge. The latter name already describes very y well the main p parts of the machine and their functions. Centrate Discharge Ch b Chamber Gear Box Scraper Conveyor y Scraper Drive
Bowl
Setting Differential speed

July 2010
Feed Pipe Solids Discharge chamber

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Process technologies with a decanter:
Clarifying of liquids with simultaneous settling of feed-solids Sludge thickening Dewatering of crystalline solids, sludges and pasty solids Wet classifying for particulate solids Sorting S ti of f solids lid (using a special, density-adapted fluid) 3-Phase-separation, 3 Ph ti (liquid / liquid / solid dispersions) Extraction

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July 2010

You could think of a decanter as the result of a geometry-change with which the settling area of a flat settling g tank has be transformed to a concentrical cylinder y wrapped pp around a center-line.
Feed
Solids discharge
Liquid discharge
July 2010

Overview and basic principle
You could think of a decanter as the result of a geometry-change with which the settling area of a flat settling g tank has be transformed to a concentrical cylinder y wrapped pp around a center-line. Doing that, the solids-scraper shown below is transformed to a conveyor.
Conveyor
Feed
Solids discharge Liquid discharge

July 2010 PIERALISI Decanter Technology
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You could think of a decanter as the result of a geometry-change with which the settling area of a flat settling g tank has be transformed to a concentrical cylinder y with wrapped pp around a center-line. The tank-bottom forms the bowl.
Bowl
July 2010

Main parts parts, schematic cross section:
July 2010

The main parts, parts 33 D cut:
Effluent weirs Bowl Bowl Solids outlet
Gear-box
Feed inlet
Feed tube Main drive motor Secondary motor (differential speed)
July 2010

Applying G-force: G force:
As the bowl is rotating a centrifugal acceleration is developed, the effect of which is similar to the g gravitational acceleration in the earth field only y the magnitude g is very y much different.
G-force: > 2.500 x g
July 2010
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Basic calculations:
Pond dept Mean radius
h Niv = (re ri )
rm = (re + ri ) / 2
G-force: C-Value
rm 2 C= r g
PIERALSI Decanter Technology
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July 2010

Sizing and scale scale-up: up: Theory of equivalent settling area
The eq equivalent i alent settling area is the prod product ct of m multiplying ltipl ing the settling area with the C-value. Remember: the settling g area is the area onto wich particles p are settling g and on which the vector of the driving force stands rectangular.
= 2 rm lcyl c (rm )
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Sizing and scale scale-up: up: The pond volume
The pond Th d volume l (blue (bl colured) l d) is i calculated l l t d as a circumferrential i f ti l ring i with ith the: th - the inner bowl diameter as outer diameter and - the inner liquid diamter as inner diameter - the length g is the cylindr. y length g as minimum.
Vpond = re ri lcyl
2 2
July 2010
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Sizing and scale scale-up: up: Important remark
Since the Si th diameters di t and d the th length l th to t be b taken t k into i t account t for f calculation l l ti can be b varied, i.e. depend on the piont of view and the basic assumptions made, there are different equations calculating for the same parameter. In example p we have 7 different calculations to g get and at least 3 for the p pond-volume.
July 2010
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Dewatering on the conical extension: Crystalline products
Conveyor C flight
Product: - crystalline particles - rel. low fitration resistance
Decanter bowl: - shallow pond
Dewatering: - by drainage - liquid flows back into the pond through the cake porosity
July 2010
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Dewatering on the conical extension: Sludges and pasty products
Product: - pasty products - high filtration resistance
Conveyor C flight
Decanter bowl: - deep pond
Dewatering: - by sediment compression - liquid flows to cake surface and (if possible) meanders back ito pond.
July 2010
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Influences on the separation: Machine based parameter
Bowl diameter: pond volume / residence time, max. speed / G-force ( ) Slenderness ration (l/d): length of clarification zone (cyl. Length) /residence time y of conical extension: Geometry slippage force, torque-level, dewatering-kinetics y g geometry: y Conveyor pitch, flight-angle, number of flights quality y of the bowl and the conveyor y flights: g Material and surface q friction forces / slipping
July 2010
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Influences on the solids transport and dewatering: Number of flights
The geometry, e.g. the number of flights is important with respect to the solids conveying Especially for crystalline products, conveying. products the dewatering will be influenced by the cake formation/ geometry in front of the flight. Rule of thumb: a double flight conveyor decreases the cake height by half.
Single flight
Double flight
July 2010
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Influences on the separation: Hydraulic-lift-disc Hydraulic lift disc
Discharging pasty products like cell-biomass or sludges often requires a helping hand by employing hydraulic pressure. pressure This led to the development of the so-called hydraulic-lift-disc (orig. baffle-disc). The result of using a baffle-disc is both better sludge conveying and higher dry-solids via a press-dewatering.
Radius < neutral Neutral line
Compressing Co p ess g gap

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Conveyor design: Baffle Disc and flights
July 2010
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Influences on the separation: Effluent discharge; 2 and 3 3-phase phase
The discharge of effluent via paring device enables for foam-free and gas-free discharge under d pressure and d for f an in-process i adjustment dj t t of f the th pond-dept d d t as well. ll Heavy phase
Light phase
2-phase, p , paring disc
3-phase, p , conventional
3-phase, p , paring device
July 2010
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Influences on the separation: Hard surfacing
To comply with the abrasion properties of many solids, a special surface protection is needed. Below, the maximum surface protection is shown: Tungsten Carbide Tiles.
July 2010
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Process demands: Sealing systems
To comply with the process demands regarding containment, e.g. ATEX regulation, different sealing g systems y are on the market
Lip-seal
Espey-Seal: Multi-chamber seal

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Influences on the separation: Operational parameter
Throughput: g p Residence time of liquid- and solid-phase in the centrifugal field, i.e. the clarification zone and the dewatering zone. p Bowl speed: G-force, shear-force, vortices Differential speed (n): p y / residence time, , dry-solids, y , dewatering g Solids capacity Weir or paring-device setting: Pond dept, dry beach,

July 2010
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Influences on the separation: Differential speed n
Differential speed I Increasing i the th differential diff ti l speed d results lt in: i Decreasing of solids residence time in the dewatering zone, increasing of solids capacity (if possible in terms of dewatering kinetics). Increasing of residual moisture Increased turbulence in the clarification section, possibly resulting in p efficiency y subsequently q y demanding g a reduced capacity. p y decreased separation
Gear-box Getriebe
Planetary gear-box gear-box, 2- or 3-stage

Differential speed control 1. and 2. Stage
July 2010
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Gear Box
Getriebe
Pinion
n =
nBowl nPinion i
Differential speed n: n Bowl n Conveyor
July 2010
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How to set differential speed:
Variable n via a special secondary d motor setting i the h pinion speed.
Variable n via a hydraulic drive (Rotodiff) setting the pinion speed.
July 2010
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Influences on the separation: Product based parameter
Density y difference of the p phases to be separated p Settling velocity, capacity Particle- or / and droplet-size and shape; PSD, g velocity, y, sediment compressibility, p y, cut-size Settling Physical-chemical properties of the phases involved Materials to be used, product sensitivities Flow behavior and viscosity of the carrying fluid Flow-behavior Solids concentration in feed Conveyor geometry, capacity Sediment behavior flow-behavior, filtering-resistance, torque requirement
July 2010
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need a break
July 2010
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PIERALISI Centrifuge Training Centrifuges for Solid-Liquid, Liquid-Liquid and 3 Phase Separation 3-Phase

Decanter: A continuous settling centrifuge

Presented by: Prof. Dipl.-Ing. M. H. Kopf

PIERALISI Decanter Technology

Decanter: a continuous settling centrifuge

PIERALISI Decanter Technology

Decanter: a continuous settling centrifuge

Setting Differential speed

Feed Pipe Solids Discharge chamber

Decanter: a continuous settling centrifuge

Decanter: a continuous settling centrifuge

PIERALISI Decanter Technology

Decanter: a continuous settling centrifuge

Solids discharge Liquid discharge

Decanter: a continuous settling centrifuge

PIERALISI Decanter Technology

Decanter: a continuous settling centrifuge

PIERALISI Decanter Technology

Decanter: a continuous settling centrifuge

Feed tube Main drive motor Secondary motor (differential speed)

PIERALISI Decanter Technology

Decanter: a continuous settling centrifuge

G-force: > 2.500 x g

PIERALISI Decanter Technology

Decanter: a continuous settling centrifuge

Decanter: a continuous settling centrifuge

Decanter: a continuous settling centrifuge

PIERALISI Decanter Technology

Decanter: a continuous settling centrifuge

PIERALISI Decanter Technology

Decanter: a continuous settling centrifuge

Product: - crystalline particles - rel. low fitration resistance

Decanter bowl: - shallow pond

PIERALISI Decanter Technology

Decanter: a continuous settling centrifuge

Decanter bowl: - deep pond

PIERALISI Decanter Technology

Decanter: a continuous settling centrifuge

PIERALISI Decanter Technology

Decanter: a continuous settling centrifuge

PIERALISI Decanter Technology

Decanter: a continuous settling centrifuge

Radius < neutral Neutral line

Compressing Co p ess g gap

Decanter: a continuous settling centrifuge

PIERALISI Decanter Technology

Decanter: a continuous settling centrifuge

2-phase, p , paring disc

3-phase, p , paring device

PIERALISI Decanter Technology

Decanter: a continuous settling centrifuge

PIERALISI Decanter Technology

Decanter: a continuous settling centrifuge

Espey-Seal: Multi-chamber seal

Decanter: a continuous settling centrifuge

PIERALISI Decanter Technology

Decanter: a continuous settling centrifuge

Planetary gear-box gear-box, 2- or 3-stage

PIERALISI Decanter Technology

Decanter: a continuous settling centrifuge