Industrial Centrifuge Basics | Turbine Repair — Houston Dynamic Services

An industrial centrifuge is designed to use intense centrifugal force generated by mass rotation to meet the needs of various applications. They are generally used for large scale fluid separation applications. Think of an industrial centrifuge as a larger version of a lab centrifuge used to mix samples at a much larger scale using a flow-through design that often allows separated solids and/or liquids to continuously exit the unit.

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Types of Industrial Centrifuges

Industrial centrifuges come in many types according to the needs of each industry and its desired application. However, there are two main types of industrial centrifuges:

1. Filtration Type Centrifuges – This centrifuge uses a rotating basket with perforations to allow liquid to pass through while keeping the solids in the basket. It works with a lower rotational speed and is generally chosen to separate large quantities of coarse solids from a liquid. For example, a filtration centrifuge would be used to separate crystallized sugar from syrup.
2. Sedimentation Type Centrifuges – A sedimentation centrifuge, sometimes called a solid bowl centrifuge, has a solid bowl with no perforations. Solids accumulate along the bowl wall with lighter liquids separating and exiting a liquid outlet passage. This feature often produces a three-phase separation or liquid/solid separation in a fluid mix. Solid bowl centrifuges are further subcategorized into decanter and disc stack centrifuges.

Decanter Industrial Centrifuge Basics

A decanter centrifuge is an industry staple because it separates solids and liquids. It is an essential tool in water waste facilities as well as the oil and gas drilling, chemical, hemp, manufacturing, and food processing industries. Many of these industries would not be able to function or would have to charge outlandish prices for their products without decanter centrifuges. In fact, decanter centrifuges can rotate anywhere from 1,000 to 4,000 times the normal gravitational force, which greatly decreases the required time for many separation processes from hours to seconds.

Industrial Centrifuge Maintenance Basics

The maintenance you put into industrial centrifuges can come back to you tenfold. Industrial centrifuges of all types are large, powerful machines, and designed to perform to certain parameters. The right amount of maintenance coupled with expert know-how allow these centrifuges to provide decades of consistent and reliable performance. Inadequate maintenance practices will inevitably cause the centrifuge to break down more often, which can cost big in both repairs and lost production. Ignored maintenance also come with the added costs of extra power to run the machine, extra stress on the system, warranty voids, and even shortened lifespan.

Each industrial centrifuge has its own schedule and tasks for maintenance as outlined by the owner’s manual. These usually include lubrication, alignments, regasketing, testing CIP (clean in place) chemicals, calibrations, and regular inspections – along with any other number of tasks. Centrifuges also need repairs as the years pass to keep them running their best.

Houston Dynamic Supply Industrial Centrifuge Repair

When I went to donate blood last month, my curiosity drove me to talk to a nurse about the machine that separates plasma from blood cells: the centrifuge. It works at high speed, sinking cells from the blood to the bottom of the centrifuge tube, leaving clear plasma at the top. Then I indicated that I would like to know about the different classifications of centrifuges. She said I could learn about the decanter centrifuge, a very common one, so I'm going to share it with you.

Decanter centrifuges compete with other separation technologies such as filter presses, screw presses, etc. While all of these devices have advantages, decanter centrifuges also have some specific advantages. The following is a list of the advantages of decanter centrifuges over filtration methods.

How does it work

Decanter centrifuges work by applying a high centrifugal force to a solid and liquid slurry. The rotating conveyor belts push out the heavier solids that have settled on the decanter walls. The lighter fluid leaves the decanter through a liquid outlet at the other end of the drum.

The drum has a concentric vortex which rotates at a different speed from that of the decanter drum. This speed difference allows the vortices to transport separated sludge.

The figure below shows a cross-section of a typical decanter centrifuge.

Advantages

1. Process adaptability:

Decanter centrifuges can easily handle product changes. They produce consistent separation results even at different flow rates. These centrifuges can handle process fluid mixing changes without degrading the final product quality.

2. Compact size:

The decanter centrifuge has a smaller footprint than a belt filter press of similar capacity. This small size allows the decanter centrifuge to be installed in a small space.

3. Airtight design:

The basic design of a decanter centrifuge consists of a rotating bowl in an enclosed chamber. This design prevents odors and other undesirable fumes and gases from contaminating the operating space.

4. Low labor costs:

Separating the fluid through the decanter is a virtually automatic process. This process requires minimal manual attendance service, thus reducing the associated labor costs.

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5. Long service life:

Rugged design and construction are the main features of the decanter centrifuge. In addition, the high quality structural materials help the decanter centrifuge operate reliably for long periods of time.

6. Easy and quick installation:

The decanter centrifuge system is self-contained and therefore easy to install. The speed and ease of debugging enables them to increase productivity in a short period of time.

7. Three-phase separation:

In addition to separating solids from liquids, three-phase decanter centrifuges (triangulators) can separate immiscible liquids. This separation occurs simultaneously with the separation of solids.

8. Easy adjustment of stage:

Decanter centrifuge users can quickly and easily adjust sludge dryness or centrifuge clarification. This ease of phase quality adjustment is an added benefit that filtration equipment lacks.

Disadvantages

Compared with other solid-liquid separation equipment, decanter centrifuge has some disadvantages. Here is a list of the major restrictions.

1. Money expenditures:

Decanter centrifuges cost more than filters and similar separators. Performance improvements and wear prevention options add further to this cost.

2. Separation of light particles:

Centrifuges use the difference in specific gravity between solids and liquids to separate. When solids (such as biological cells) have a specific gravity close to that of liquids, the decantometer cannot separate them.

3. Power requirements:

A high-horsepower motor powers the decanter centrifuge. These drive motors require a higher operating current than the filter.

4. Noise and vibration

Decanter centrifuges have heavy rotating bowls. The rotation of the weight causes vibration, which creates noise. These centrifuges can produce noise levels in the range 70-80 dB.

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