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

PIERALISI Decanter Technology

Decanter: a continuous settling centrifuge

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

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Feed Pipe Solids Discharge chamber

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Decanter: a continuous settling centrifuge

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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Decanter: a continuous settling centrifuge

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.

Feed

Solids discharge

Liquid discharge

July 2010

PIERALISI Decanter Technology

Decanter: a continuous settling centrifuge

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

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Decanter: a continuous settling centrifuge

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 with wrapped pp around a center-line. The tank-bottom forms the bowl.

Bowl

July 2010

PIERALISI Decanter Technology

Decanter: a continuous settling centrifuge

Main parts parts, schematic cross section:

July 2010

PIERALISI Decanter Technology

Decanter: a continuous settling centrifuge

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

PIERALISI Decanter Technology

Decanter: a continuous settling centrifuge

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

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Decanter: a continuous settling centrifuge

Basic calculations:
Pond dept Mean radius

h Niv = (re ri )

rm = (re + ri ) / 2

G-force: C-Value

rm 2 C= r g
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July 2010

Decanter: a continuous settling centrifuge

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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Decanter: a continuous settling centrifuge

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

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Decanter: a continuous settling centrifuge

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.

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Decanter: a continuous settling centrifuge

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

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Decanter: a continuous settling centrifuge

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.

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Decanter: a continuous settling centrifuge

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

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Decanter: a continuous settling centrifuge

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

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Decanter: a continuous settling centrifuge

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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Decanter: a continuous settling centrifuge

Conveyor design: Baffle Disc and flights

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Decanter: a continuous settling centrifuge

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

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Decanter: a continuous settling centrifuge

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.

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Decanter: a continuous settling centrifuge

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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Decanter: a continuous settling centrifuge

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,

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Decanter: a continuous settling centrifuge

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

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Decanter: a continuous settling centrifuge

Influences on the separation: Differential speed n

Gear Box

Getriebe

Pinion

n =

nBowl nPinion i

Differential speed n: n Bowl n Conveyor

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Decanter: a continuous settling centrifuge

Influences on the separation: Differential speed n
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.

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Decanter: a continuous settling centrifuge

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

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Decanter: a continuous settling centrifuge

need a break

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