Centrifuges for Metallurgy: Crud treatment, PLS

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Centrifuges from GEA Westfalia Separator for Metallurgy
Crud treatment, PLS clarification and recovery of organic components
engineering for a better world
GEA Mechanical Equipment
Reliable Processes
No company is more proficient in centrifugal separation technology than
GEA Westfalia Separator. The comprehensive know-how in the design,
production and process integration of separators and decanters is essential for
optimum results as far as the recovery of base metals is concerned.
GEA Westfalia Separator Group took advantage of the
From initial advice, basic and detailed engineering
natural principle of centrifugal force by mechanical
right through to the commissioning of the installa-
means as early as in 1893. Since building the first cen-
tions, GEA Westfalia Separator Group offers a perfect
trifuge, the company has developed into a global tech-
combination of process knowledge, sound knowledge
nology leader which today masters more than 3000
in plant construction, first-class products and tech-
process engineering applications. Also the corporate
nologies. The result is reliable process management
partners in the field of metallurgy and metal concen-
with maximum availability of the centrifuges which
tration benefit from this comprehensive know-how.
are used.
Whether crud treatment, PLS clarification or recov-
Whatever objectives are relevant: the solutions from
ery of organic components: the separating technology
GEA Westfalia Separator Group mean that success
machines, systems and process lines set standards for
can be planned. Agreed performances are attained
performance, service life as well as for economic and
reliably and permanently.
environmentally sound operation.
Centrifuges from GEA Westfalia Separator Group
Plan your success
concentrate customer benefit:
Thanks to the many years of experience and continu-
• Optimize process results
ous investments in research and development, the
• Reduce production costs permanently
company offers its customers a crucial technological
• Maximize production capacities
edge. GEA Westfalia Separator Group’s Central
• Protect people and environment
Process Engineering facility is available for complex
trials in order to create a reliable decision-making
basis for investments.
2
Investment security right from the very beginning:
in addition to crud treatment and PLS clarification
in the extraction of base metals, GEA Westfalia
Separator Group also has skills in the processing of
bulk mining products.
3
Stable Process Conditions Due
to Centrifuges
Separators and decanters from GEA Westfalia Separator ensure better
efficiency for the liquid extraction of base metals.
Metals such as copper, nickel and zinc are extremely
In this way, it is possible to recover the solvent with
important commodities. Liquid extraction with acid
such high quality that it can be recycled back to the
has become established as the standard method for
extraction stage without a negative impact on the effi-
recovering such metals. However, the formation of
ciency of the process.
crud in the settling tanks is a problem; crud is an
emulsion layer comprising aqueous and organic com-
The use of centrifuges therefore provides
ponents, air and solids. Because the emulsion is stable
a double benefit:
under normal conditions of gravity and has a con-
On the one hand, large quantities of solvent are recov-
siderably negative impact on the effectiveness of the
ered. On the other hand, crud formation is minimized
extraction process, it has to be continuously removed
as a result of continuous removal of the crud. This
from the recovery process, or must be prevented from
is the only way to achieve constant efficiency in the
occurring.
extraction stage and thus stable process management
with maximum results.
One possibility is to remove the crud in the extraction stage from the process. For this purpose,
GEA Westfalia Separator Group has developed special 3-phase decanters designed for the tough requirements of the product. In an initial stage, these decanters separate the emulsion which has previously been
drawn off from the tank into solids, aqueous phase
and solvent. Water and solids are disposed of. The
organic phase, however, is enriched with activated
clay and is then passed through a 2-phase decanter.
4
PLS Clarification –
the Most Innovative Alternative
PLS clarification with nozzle-type separators from GEA Westfalia Separator goes one
step further: it does not permit crud to form.
In addition to the traditional crud and clay treatment
Nozzle-type separators from GEA Westfalia
with decanters, GEA Westfalia Separator Group also
Separator Group reliably remove those insoluble
offers an alternative process: PLS clarification with
particles. Particles which are too large for the nozzle-
special nozzle-type separators. Compared to crud
type separator are removed in an upstream rotary
treatment, the advantage of this innovative process
brush strainer. In this simple and intelligent manner,
is that impurities which are responsible for the forma-
crud is prevented before it can occur.
tion of crud are removed from the process at an early
stage. Crud cannot form.
In addition, high-performance separators from
GEA Westfalia Separator Group can be used before
PLS clarification takes place between the organic wash-
electrolysis to remove the aqueous phase and a small
ing and extraction stage. The PLS (Pure Liquid Solution)
percentage of solvent from the process. The advan-
from leaching contains insoluble solids such as mica or
tage is that the electrolyte bath can be used for a
clay which are responsible for the formation of crud.
longer period of time before it has to be replaced.
Metal ore
Metal ore
Leaching
Leaching
PLS clarification
Solvent extraction
Crud treatment
Clay treatment
Solvent extraction
Organic recovery
Organic recovery
Electro winning
Electro winning
Metal product
Metal product
Crud treatment / Clay treatment
PLS Clarification
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More Than Just a Centrifuge
GEA Westfalia Separator offers a comprehensive range of services to the
base metals industry.
GEA Westfalia Separator Group supports its custom-
GEA Westfalia Separator caretechnology
ers in crud treatment and PLS clarification from the
goes further
initial product test in the decision-making process
The intensive cooperation with the customers
right through to 24-hour service after the centrifuges
works in accordance with the philosophy of
have been installed. Together with Central Process
caretechnology. The concept combines the top
Engineering in Oelde, product tests are carried out
separating technology services and the inno-
to determine how the product can be separated most
vative ability of the company with comprehen-
effectively and what materials which come into con-
sive responsibility for the security of investments,
tact with product have to be used. In addition, initial
products and processes.
recommendations are also provided with regard to the
design of the process, and cost estimates are made.
caretechnology stands not only for a high yield of
The optimum process design is developed by the pro-
the employed raw materials; it also stands for reli-
cess experts in close cooperation with the customer.
able process management which makes efficient
use of resources and thus also for the protection
Thus, GEA Westfalia Separator Group project manage-
of people and environment. Maximum availability
ment offers all services from a single source – from
including plannable maintenance intervals for the
the individual installation layout right through to the
separating technology installations throughout their
commissioning of the installations and comprehen-
entire life is the daily objective of GEA Westfalia
sive service options. The involvement of all parties
Separator Group.
and resources means that it is always possible for customer requirements to be met, and in many cases even
These are the benefits:
exceeded, in terms of cost and production efficiency.
• All services from a single source
• Customer- and application-oriented engineering
• Support for process development, designing the
process accessories and the installation layout
by way of reliable scale-up
• Reliable compliance with all agreed specifications, budgets and delivery deadlines
•����������������������������������������������
Complete assembly and testing of the installations in the ISO 9001 certified production facility
• On-site assembly of certain installation types is
also possible
• Service network operating throughout the world
… which provide every customer with the necessary
security.
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GEA Westfalia Separator caretechnology
combines top separating technology
performance with comprehensive responsibility for reliable process management.
7
Decanters for Efficient Crud and
Clay Treatment
Robust and flexible: 2- and 3-phase decanters from GEA Westfalia Separator set
standards for crud treatment and solvent recovery.
Decanters from GEA Westfalia Separator Group are
All decanters from GEA Westfalia Separator Group
always used when the solid content in a suspension to
are characterized by robust processing so they oper-
be pro-cessed is greater than 20 % (by volume). Their
ate reliably under the most difficult conditions. In
main features are high separating efficiency, high-
addition to application-specific corrosion and wear
performance and reliability. With bowl diameters of
protection, all parts of the decanter which come into
200 to 750 mm, GEA Westfalia Separator Group covers
contact with product are made from high-quality
the complete range of capacities.
duplex stainless steels and are specially armoured.
Organic
phase
Crud
Aqueous phase
Solids
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Different alloys can be chosen for the design of the
3-phase decanter
decanter depending on the chloride ion content in the
The 3-phase decanter separates the crud into solids,
aqueous phase. If required by the product or if desired
aqueous phase and organic phase. In the cylindrical
by the customer, special materials can of course also
section of the bowl, the aqueous and the organic
be used.
liquid phases are simultaneously separated and clarified, whereas the conical part of the bowl is used for
Sophisticated drive concepts ensure precise adjust-
dewatering the solids. The scroll conveys the solids to
ment of the differential speed, which guarantees a
the solids discharge. The aqueous phase is discharged
high separating efficiency. The differential speed is
under gravity while the solvent is discharged from the
automatically regulated while the machine is still
decanter by means of a paring disc under the exclu-
operating, so that the decanter can be adjusted quickly
sion of air.
and flexibly to cope with fluctuating feed conditions.
Thus, the solids are discharged with a constant con-
At a glance:
centration and in an extremely dry state.
• Decanters with bowl diameters of
200 – 750 mm cover all operating sizes
GEA Westfalia Separator varipond® –
• Robust design for permanent availability
variable adjustment of the pond depth
• High-quality duplex steels and special armouring
If the density conditions in the suspension, the crud,
for maximum corrosion and wear protection
change as a result of external factors, e.g. dust, it
• Different special materials can be chosen
can also be necessary to adjust the pond depths
• Inline adjustment of pond depth while the
in the decanter. With the varipond system this can be
installation is still running due to varipond®
®
carried out while the installation is still running. Production interruptions are avoided.
Born to run
The decanters from GEA Westfalia Separator Group
are characterized by intelligent and compact design
which ensures rapid access to all maintenancerelevant parts. This reduces the time needed for
maintenance and service so that the decanter is back
at work in virtually no time.
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Recovering the Solvent in the
2-Phase Decanter
Innovation with added value: by switching over to a 2-phase process, the 3-phase
decanters can also be used for recovering the organic phase.
Organic
phase
Suspension
(clay and solvent)
Clay
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In addition to crud treatment, decanters have a fur-
phase recovered in the decanter is discharged under
ther function to play in the processing of base met-
pressure by means of a paring disc.
als: the recovery of solvent with high quality so that
it can be recycled to the extraction process. In these
In consequence, this results in “clean” extraction
cases, GEA Westfalia Separator Group offers its cus-
agent for permanently efficient extraction.
tomers the possibility to use the same decanter first in
3-phase design for crud treatment and then in 2-phase
At a glance:
design for recovery. The advantage is that the cus-
• Possible use of the decanter for 3-phase
tomer only has to invest in one machine. However,
the operations can only be carried out successively.
and 2-phase processes
• Continuous recovery of the organic components
• Permanently “cleaned” extraction agent
2-phase decanter
The repeated use of extraction agents leads to a deterioration in effect as a result of ion saturation of the
radicals. In order to “clean” the radicals, absorption
agents such as clay are added. The suspension to
which clay has been added is fed into the decanter,
where it is split into two phases.
In 2-phase decanters, the clay is removed from the
suspension so that the customer receives a virtually
solids-free clarified organic phase. The solid-wall bowl
of the 2-phase decanter illustrated in the diagram
has a cylindrical section for efficient separation and
clarification of the suspension as well as a conical
section for efficient dewatering of the separated clay.
The product is continuously fed into the rotating bowl
via the feed tube and is accelerated to bowl speed.
The clay sediments on the interior wall of the bowl
due to centrifugal force; it is then scraped off by the
armour-plated scroll and conveyed to the solids discharge. The level of liquid in the bowl and thus the
lengths of the clarifying and dewatering zones can be
varied depending on the feed conditions. The organic
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0-point drive
The 0-point drives are part of the standard program.
They feature a very simple design and are therefore
cheap to purchase and operate. 0-point drives are
used when the solids volume is constant, the solids
are easy to convey and the requirements regarding the residual water content of the solids are not
very stringent, in other words, bowl and differential
speed regulating facilities are not necessary. This is
because alteration of the differential speed can only
be achieved by changing the gear transmission or the
bowl speed.
Exchangeable pulley drive
The exchangeable pulley drives are also part of the
standard program. They are also very cheap to purchase and feature a simple design. The input shaft of
the drive is set in motion by the main motor via a second belt drive. This generates the differential speed as
a function of bowl speed and gear transmission. This
can be easily changed by replacing the belt pulleys.
2-motor drive
The 2-motor drives enable the differential speed to
be regulated cost-effectively under good operating
conditions; wide regulating ranges are possible. The
secondary motor sets the input shaft of the gear in
motion and generates the differential speed as a function of bowl speed and gear transmission. The differential speed can easily be regulated by changing
the motor speed. 2-motor drives are used whenever
solid volumes fluctuate significantly, when solids are
conveyed under difficult conditions and when particularly stringent requirements are applicable with
regard to residual water content.
Hydro-drive
The hydro-drive works in a way which is similar to
that of the differential gear drive. The difference is to
be seen in the design.Instead of the mechanical gear,
a rotating hydromotor is installed; this is supplied
with hydraulic regulation by a pump unit. Because the
differential speed is proportionate to the conveyed
quantity of oil, automatic regulation can be provided
without any problem.
12
Innovative Drive Concepts for Decanters
Flexible process management with simultaneous maximum availability are essential
requirements for modern drive concepts.
The variety of process engineering applications in
also customer wishes determine what type of drive is
which decanters from GEA Westfalia Separator Group
used. In the case of decanters which are used in the
are used requires different drive concepts. This is the
field of metal extraction, flexible and precise regula-
only way to meet the corresponding product require-
tion of the differential speed is particularly important.
ments in an optimum manner. The product line there-
This is the only way to achieve extremely high solid
fore includes drive systems with and without the pos-
concentrations and thus high separating efficiency.
sibility of simple regulation of the differential speed.
The 2-gear drive and the differential gear drive have
The requirements for the machine and process but
therefore become established in practise.
2-gear drive
The advantage of the 2-gear drive which has been developed and patented by GEA Westfalia Separator Group
is the facility for regulating the scroll drive. The differential speed is adapted automatically and extremely
precisely as a function of the scroll torque – and thus
as a function of the solids content in the bowl. Accordingly, the solids are discharged from the bowl with a
constant concentration and in an extremely dry state.
2-gear drives are used whenever the volume of solids
is not constant, when the solids are difficult to convey
and when very high requirements are applicable with
regard to the residual water content of the solids.
Differential gear drive
The differential gear drive is recommended whenever it is necessary to automatically regulate the scroll
speed in addition to regulating the bowl speed. This
can be achieved by means of two gears. The secondary
motor drives the central input shaft and generates the
differential speed proportionally to its own speed. A
second input shaft without any speed is connected to
the housing. This means that the differential speed is
not dependent on the bowl speed. Differential gear
drives are used primarily in the lower range of the
differential speeds.
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Decanter Wear Protection –
No Chance for Abrasion and Corrosion
GEA Westfalia Separator uses highly resistant duplex steel and special armour-plating
for all parts which come into contact with product.
Crud treatment and recovery of organic components
One possible solution is spray cladding, in which car-
expose decanters to extreme material strain. The low
bide is for instance welded on to the vane of the scroll
pH value of the process (pH 2) and high operating tem-
or areas in the distributor. The advantage of this solu-
perature in conjunction with a range of high chloride
tion is that the protecting material combines with the
concentrations result in corrosion. The only way to
base material in the welding process.
tackle this problem is to use an extremely high quality
material. GEA Westfalia Separator Group therefore
GEA Westfalia Separator Group also offers the possi-
uses highly resistant duplex or super-duplex stain-
bility of using tiles instead of or in addition to carbide
less steels for manufacturing all components of the
plating. Tiles are generally used in conjunction with
decanter which come into contact with product.
highly abrasive products. GEA Westfalia Separator
Group also has the know-how for cladding certain
This material is not affected by pitting, and also fea-
areas with ceramics in order to provide special pro-
tures higher abrasion protection than stainless steel
tection.
which is normally used. In permanent contact with
abrasive particles in metallurgy, this wear protection
Depending on specific requirements, GEA Westfalia
is an essential advantage.
Separator Group offers wear and corrosion protection in the form of
In addition, all places at which increased levels of
• Carbide cladding
wear can be expected have to be provided with spe-
• Tiles
cial armour-plating in order to ensure permanent
• Ceramics
operation of the decanter. The most suitable form of
• Use of high-quality steels
armour-plating according to the specific application
• Rubber linings
is defined in close cooperation with the customer.
• Coatings
GEA Westfalia Separator Group
tackles problems posed by
abrasive particles with special
armourplating for all decanter
components which are at risk
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Decanters from GEA Westfalia Separator –
Convincing Right Through to the Smallest Detail
Machine portfolio
>> GEA Westfalia Separator Group as a complete-range
provider for a range of 600 – 350,000 l / h
Special materials
>> Parts which come into contact with product can be made of
specific application-related materials, thus ensuring optimum
resistance and product-neutral properties
GEA Westfalia Separator varipond®
>> Automatic system for infinitely variable adjustment of the liquid
level while the machine is running in order to adjust for product
fluctuations in the feed
>> Assures maximum dry substance values and separating efficiency in
conjunction with different feed conditions, resulting in lower power
consumption
>> Assures optimum conveyance of highly viscous liquids – enhances
conveyance efficiency
>> Intelligent self-control
Separating zone adjustment
during operation
>>Assures optimum separation and clarification efficiency while the
Explosion-protected and gas-and
pressure tight designs available
>> Can be used for instance in explosive areas or for processing
Six scroll drive versions
>> Drive versions tailored to meet the requirements of the specific
machine is running
explosive or toxic products
process ensure maximum clarification and dewatering efficiency as
well as cost-effectiveness of each individual application (energy
and investment costs)
>> All scroll drive versions are selected in accordance with productspecific characteristics
Adjustable bowl speeds
>> Automatic adjustment of bowl speed to changing process
conditions
Wear protection
>> Better availability, lower maintenance costs
Rotor concept
>> Maximum speed, g-forces and g-volumes permit maximum
throughputs and clarifying efficiency
15
Nozzle-Type Separators for Efficient
PLS Clarification
Continously operating nozzle-type separators from GEA Westfalia Separator are the
first choice for efficient PLS clarification.
Nozzle-type separators discharge concentrated sus-
The size of the bowl diameter and thus the number
pensions continuously via nozzles which are installed
of nozzles are linked proportionately to the potential
on the periphery of the bowl. The product flows via
concentration of the concentrate. The concentration
the feed into the bowl, where it is separated into
increases in conjunction with increasing throughput,
concentrate (underflow) and centrate (overflow). The
high initial concentration of the product, declining
disc stack which is installed in the bowl increases the
solids content in the discharge, small nozzle diameter
equivalent clarification area and thus the perform-
and a low bowl speed.
ance of the separator.
The task is to achieve a balance between these factors
and the equivalent clarification area as a standard
measure for the clarifying performance of the bowl,
Product feed
in order to make sure that the remaining solid content
in the concentrate permanently meets the customer‘s
requirements.
With the online analysis facility which is offered by
GEA Westfalia Separator Group and which is based
Centrate
on measurement of the concentration of the product
upstream and downstream of the nozzle-type separa-
Concentrate
tor, it is possible to adjust the clarifying performance
of the centrifuge very precisely. The figures resulting
from the concentration measurements are used for
automatically carrying out adjustments to the feed
capacity and the concentrate recycling. This achieves
constant concentration of the discharged suspension.
Fluctuations in the process results can thus be reliably excluded.
At a glance:
• All operating sizes covered
• Continuous method of operation
• With concentrate recycling before the nozzle in
order to increase the concentration
• Sophisticated online analysis for stable process
conditions
• Direct drive for optimum energy efficiency and
low service costs
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Separators Used for Cleaning the
Refining Stream
Separators from GEA Westfalia Separator assure higher process efficiency.
Separators can be used for cleaning the product
• Closed feed and discharge for the product phases
stream and removing the remaining solvent before
• CIP cleaning for reliable operation with
electrolysis stage. The advantage of this solution is
that the electrolyte bath has to be replaced much less
constantly high yields
• Explosion protection design (ATEX compliant)
frequently – with a positive impact on operating and
disposal costs.
This separator is equipped with a self-cleaning disctype bowl. The solution itself is separated in the disc
stack into a light and a heavy liquid phase. At the
Product feed
same time, the solids which accumulate in the bowl
space are removed by centrifugal force. At regular
intervals, the bowl opens automatically via the piston
Aqueous
phase
valve and ejects the solids. The light liquid phase (solvent) flows towards the centre of the bowl through
the disc stack, and is discharged via drill holes in the
hood. The heavy liquid (aqueous phase) flows to the
Solvent
periphery of the bowl via the separating disc, and is
also discharged under gravity. The new generation
of separators for liquid-liquid separation covers the
entire range of possible capacities. They feature a high
Solids
motor performance and optimum dynamic qualities
with low energy consumption. Further advantages are
to be seen in the high reliability, simple operation and
low maintenance costs. The process is suitable for
recovering copper, nickel, cobalt and uranium.
All advantages at a glance:
• Self-cleaning bowl for automatic discharge
• Hydrohermetic product feed for gentle treatment
• Flexible adjustment of the separating zone for
maximum separating efficiency of the liquid
phases
• Direct drive for optimum energy efficiency
and low service costs
17
Drive Concepts for Separators
Different drive concepts are also available for the separators. Two drive concepts are
in the programme: flat-belt and directdrive.
Flat-belt drive
In this solution, the motor power is transferred to the
spindle by means of an antistatic flat-belt. Oil circulation lubrication ensures that bearings are continuously
lubricated. This also means that the separator does not
have to be shut down for an oil change. Compared to the
gear drive, which is still used in older models, the motor
power is transferred with up to 10 % lower power losses.
The belt itself can be replaced quickly and in a servicefriendly manner without the bowl or motor having to be
dismantled beforehand.
Direct drive system
The direct drive is an example of intelligent simplification in separating technology. Wherever the upper limit
for gear loads has been reached or belt drives are undesirable, our separators with direct drive permit virtually
loss-free power transmission. This boost in performance
simultaneously reduces the costs of energy, wear, maintenance and space. The required power is transmitted
directly to the bowl spindle by a 3-phase AC motor with
frequency converter control via a torsionally elastic
clutch. The spindle assembly is likewise supported by
rubber-metal cushions. This makes possible low-vibration running at high bowl speeds.
At a glance:
• Extremely space-saving design
• Avoidance of housing deformation
• High performance input
• Low maintenance requirement
18
Rotary Brush Strainers and Wear Protection
Upstream rotary brush strainers and a special coating for components which are at
risk protect the separators against clogging and abrasion.
Excessively large solid particles can clog the nozzles
of the separators. This is reliably avoided by installing
a rotary brush strainer from GEA Westfalia Separator
Group upstream.
The product is fed into the strainer insert through the
inlet, and flows through the strainer in the chamber
to the discharge. The coarse solids are retained and
scraped off the interior of the strainer by the rotating
brushes. They fall into the conical base, from which
they are discharged manually from time to time or
automatically through the solids discharge.
Special coating against abrasion
In order to ensure that maximum performances are
permanently achieved, the nozzle-type separators are
also equipped with a special wear protection against
abrasion. This solution comprises coated wear plates
as well as a coating on the distributor bottom and the
bowl bottom.
At a glance:
• Upstream rotary brush strainers prevent
clogging of the nozzles
• Reliable protection against abrasion
• Maximum separation performance in the
overall process
• Maximum maintenance intervals
Fine particles
Product feed
Coarse particles
19
Separators from GEA Westfalia Separator –
Convincing Right Through to the Smallest Detail
Machine portfolio
>> GEA Westfalia Separator Group supplies a complete machine portfolio
(capacity up to 500,000 l / h) with compatible hydraulic performance parameters / performance reserves – the right separator for
every customer requirement
Modular total concept
Operating the separators
>> Customized solutions and delivery as required by customers
>> Personnel-friendly operating of the separators and, if required, 100 % remote-monitored operation possible, thus enhancing operational reliability and availability
>> Combination of maximum robust nature and reliability
>> Low water consumption as no cooling necessary for the drive and Special materials
Discharge and feed design
the slide ring packings
>> All product-contacting components, hood, solids chute and frame coating can be supplied in application-specific materials, resulting in optimum resistance and product neutrality
>> Feed design can be adapted to product requirements
>> No product mixing / contamination possible in the discharge line. Flat-belt drive / direct drive
Product is discharged foam-free and under pressure, if necessary up to 10 bar – no discharge pumps necessary, savings in terms of plant units
>> Drives are low-wear and service-friendly. The drive‘s belt does not have to be subsequently tightened. Minimum bearing load
(adjustment-free) assures longer service lives of bearings
>> Flat-belt drive transmits the drive force with extremely low loss-
es, and is up to 10 % more effective compared with a gear drive – with the benefit of minimum power consumption
>> Simple and service-friendly belt change without bowl and drive assembly
>> Use of lubricants approved for food applications
>> Available in explosion-protected design and ATEX-compliant
>> Special drives possible if required by customer
General
>> Flow-optimized design (minimum flow resistance, minimum
shearing forces) of all bowl parts assures optimum separating and
clarifying results with minimum product damage
>> Maximum speeds (g-forces) / equivalent clarification areas achievable
20
Ceramic Membrane Filtration –
Ultra-Fine Clarification for Nano Particles
GEA Westfalia Separator has achieved a new dimension of ultra-fine clarification with
hybrid solutions comprising a centrifugal separation system and filtration technology.
In addition to centrifugal separation systems,
GEA Westfalia Separator Group provides a wide range
GEA Westfalia Separator Group also has an expert
of ceramic membrane modules in the pore size range
command of membrane filtration with ceramic
of 1 to 1400 nanometers and with different membrane
elements for ultra-fine clarification of particles
materials. The modules are mainly standardized, with
with a size of up to one nanometer. The company
variable channel diameters, element lengths and pore
is accordingly able to significantly expand product
sizes. This membrane installation downstream of the
clarification within a process chain. The intelli-
separator permits extremely fine clarification of par-
gent combination of centrifugation and mem-
ticles with a diameter of < 1 micrometer.
brane filtration in an innovative GEA Westfalia
Separator hybrid solution further improves the effi-
At a glance:
ciency of the overall installation.
• hybrid solutions comprising centrifugation
Individual specifications
• Everything from a single source
The ceramic membrane installations continuously
• Intelligent harmonising of all components
and membrane filtration
supply a clear filtrate with the specified degree of
enhances process efficiency
clarification and the desired performance. The
• Ultra-fine clarification for particles of up
ceramic membrane forms a mechanical barrier with
to 1 nanometer
a defined pore size.
• Wide range of ceramic membrane modules
• Individual configuration according to specific
requirements
GEA Westfalia Separator hybrid boosts
the efficiency of the overall installation by
means of an intelligent combination of centrifugation and membrane filtration in an
innovative hybrid solution.
21
Automation Systems – Plug-and-Play
GEA Westfalia Separator has extensive experience in the drive and control
technology of separation systems. Customer-specific automation of centrifuges and
membrane filtration means that their operation is particularly simple, reliable and safe.
Solutions from GEA Westfalia Separator Group combine
The visualization options always ensure optimum user-
tried-and-tested process and machine technology with
friendliness. WinCC or Intouch can be used for up to
the latest drive and control technology.
five visualization facilities in the process line, and can
also be combined with each other.
The automation concepts are customized in all regards
to meet the individual requirements – from advice pro-
Whether a simple notification signal or a complex
vided by experienced engineering specialists, compact
process data exchange arrangement is required: the
control units for individual machines and powerful PC-
connection to existing installations or processes via
based installation controls right through to comprehen-
software is nowadays almost obligatory.
sive original manufacturer service.
The specialists from GEA Westfalia Separator Group
High compatibility
use the best-known systems such as Profibus DP / PA
In addition to the company‘s own compact control
or Industrial Ethernet as well as additional connections
units, the S7 control units from Siemens constitute the
such as DeviceNet, ControlNet or Modbus for this pur-
core item of installation automation. However, compo-
pose. Fully automatic operation of the installation can
nents from Allen Bradley, Group Schneider, Mitsubishi,
also be supported by remote data transfer by means
Modicon or Telemechanique can also be used and com-
of Internet, modem or GPRS. With GEA Westfalia
bined with each other as required.
Separator wewatch®, an independent and comprehensive service concept is available for remote diagnosis.
With these advantages …
• Connection via software with Profibus DP / PA,
• Strong competence in drive and control technology
• Individual automation concepts
Industrial Ethernet or other systems
• Support for remote transmission and
• Advice provided by engineering specialists
diagnosis (wewatch®)
• Compact control unit from a wide range of manufacturers
… customers benefit from user-friendliness and
• Up to five visualizations in the process line
security.
• Comprehensive control possibilities from a simple
reporting signal right through to complex
process data interchange
22
Central Process Engineering –
the Reliable Basis for Decision-Making
Customer-specific test series in Central Process Engineering provide a reliable basis
for decision-making for all investments in mechanical separation technology.
No product to be separated is identical with another.
Focus on investment protection
In many cases, it is therefore necessary to perform test
The results of Central Process Engineering can be
series before the correct decision can be taken for a
used to precisely identify what machine type and
specific installation. GEA Westfalia Separator Group
what model from GEA Westfalia Separator Group are
has set up the Central Process Engineering depart-
most suitable for the specific task. This procedure
ment (CPT) for this purpose.
avoids poor investments right from the very beginning. The customer achieves a reliable basis on which
Depending on the specific task involved, test series
he can take the correct investment decision.
can be run with the original product of the customer
in a mobile pilot installation on site or in the labora-
At a glance:
tory at GEA Westfalia Separator Group. The specifi-
• Test series with the original products of the
cation of the customer with operating temperature,
customer
throughput capacity, clarifying or separating efficien-
• Practical and representative
cy and other factors constitute additional important
• In the laboratory of GEA Westfalia
information necessary to enable a representative and
reliable analysis.
Separator Group or in pilot installations on site
• Detailed test documentation
• Specific machine recommendation
After every test series, the customer receives informa-
• Detailed mass balance
tive documentation in which the technical and eco-
• Total cost analyses
nomic data are detailed.
23
Excellence • Passion • Integrity • Responsibility • GEA-versity
GEA Group is a global engineering company with ­multi-billion euro sales and ­operations in more than
50 countries. Founded in 1881, the company is one of the largest providers of ­innovative equipment and
­process technology. GEA Group is listed in the STOXX® Europe 600 Index.
GEA Mechanical Equipment
GEA Westfalia Separator Group GmbH
Werner-Habig-Straße 1, 59302 Oelde, Germany
Phone: +49 2522 77-0, Fax: +49 2522 77-2828
www.gea.com
The information contained in this brochure merely serves as a non-binding description of our products and is without guarantee. Binding information, in particular relating to capacity data and suitability for specific applications, can only be provided within the framework of concrete
inquiries. Printed on chlorine-free bleached paper · Printed in Germany · Subject to modification · Westfalia®, Westfalia Separator ®, varipond® and wewatch® are registered trademarks of GEA Mechanical Equipment GmbH. B_BL-13-01-0023 EN
We live our values.
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