Westfalia Separator Food Tec GmbH Mechanical Separation Division Oils and Fats Processing Technical Details of RSE-Separators Westfalia Separator Food Tec GmbH Mechanical Separation Division Oils and Fats Processing Theoretical background of separation Basics for separation of 2- or 3-phase systems: In solid suspensions ( clarification) : • density difference between liquid and solids In liquid / liquid mixtures ( separation ): • liquids are insoluble in each other • density difference between the liquids Westfalia Separator Food Tec GmbH Mechanical Separation Division Factors influencing separation velocity: • particle size • density difference • viscosity • gravitational force Factors influencing separation efficiency: • flow rate and retention time • tendency to emulsification Oils and Fats Processing Theoretical background of separation Westfalia Separator Food Tec GmbH Mechanical Separation Division Oils and Fats Processing Theoretical background of separation Calculation of the throughput capacity Legend: D = particel size ∆ρ = density difference η = dynamic viscosity ω = angle velocity tgζ= disc angle D * ∆ρ Q = ---------18 * η 2 g = gravitational force 2π * g * ---- * ω2 * tgζ * z ( r13 - r23 ) 3g product related machine related z = number of discs r1 = outer disc radius r2 = inner disc radius Westfalia Separator Food Tec GmbH Mechanical Separation Division Oils and Fats Processing RSE-Separators • Requirements of the industry on modern centrifugal separators: • lower noise level • reliable bowl discharge system • ability to discharge viscous gums or soaps • optimum separating efficiency • higher flexibility • higher throughput capacities Westfalia Separator Food Tec GmbH Mechanical Separation Division • < 80 dB(A) meets the requirements in Europe and USA • only in exceptional cases lower levels are expected • heat insulation comes along with noise insulation !!! • high internal temperature when the machine runs without product feed !!! Oils and Fats Processing RSE-Separators – Noise Level double shell hood Double shell sludge catcher Westfalia Separator Food Tec GmbH Oils and Fats Processing RSE-Separators – Noise Level Mechanical Separation Division Noise level of different separators 90 RSA 150 85 RSE 150 sound pressure in dB 80 RSE 250 75 70 65 60 55 50 62,5 125 250 500 1000 2000 4000 8000 16000 frequency in Hz Average sound pressure: RSA 150 - 86 dB(A) – no noise reducing measures RSE 150 - 80 dB/A) – gear drive, double shell hood RSE 300 - 78 dB(A) – belt drive, double shell hood Westfalia Separator Food Tec GmbH Mechanical Separation Division • Requirements: – Exact and fast opening – Wide opening gap – No tilting of sliding piston (even opening gap) – Wear protection • Realisation: – Fully hydraulic system – Opening water injection by piston valve – Two piston valves – Wear liners in discharge ports Oils and Fats Processing RSE-Separators – Desludging Mechanism Westfalia Separator Food Tec GmbH Mechanical Separation Division Oils and Fats Processing RSE-Separators – Desludging Mechanism Advantages of the metering piston : • accurate discharge volume • independent from PLC cycle times • independent from operating water pressure Closing water Opening water Westfalia Separator Food Tec GmbH Mechanical Separation Division Oils and Fats Processing RSE-Separators – Desludging Mechanism 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Metering device Valve for compressed air Opening-water valve Opening-water-filler valve 5- Non-return valve Closing-water valve Injection chamber for closing-water Injection chamber for opening–water Closing-chamber Sliding piston Piston valve Drain hole for closing water Metering Piston Westfalia Separator Food Tec GmbH Mechanical Separation Division Oils and Fats Processing RSE-Separators – Desludging Mechanism Piston valve in closed position Piston valve in open position Closing water Opening water Westfalia Separator Food Tec GmbH Mechanical Separation Division Oils and Fats Processing RSE-Separators – Desludging Mechanism Piston valve: new design with combination gaskets Outer ring : Teflon Inner ring: FKM Westfalia Separator Food Tec GmbH Oils and Fats Processing RSE-Separators – Desludging Mechanism Mechanical Separation Division Desludging diagram 10 8 6 4 type of disludging: partial discharged volume: 5 l 0,5 0,45 0,4 0,35 RSA 150 RSE 150 0,55 bow l opening tim e 0,3 0,25 0,2 0,15 0,1 0,05 0 0 2 Westfalia Separator Food Tec GmbH Mechanical Separation Division Oils and Fats Processing RSE-Separators – Desludging Mechanism Operating water quality: hardness: < 12° dH up to 55 °C separating temperature < 6° dH above 55 °C separating temperature chlorine ions: pH-value: sediment content: particle size: pressure: Water supply: < 100 mg/l 6,5 - 7,5 max. 10 mg/l max. 50 µm 2,0 - 2,5 bar 3.000 l/h Cooling water limitation for most of the machines : max. 1 bar pressure Westfalia Separator Food Tec GmbH Oils and Fats Processing RSE-Separators – Desludging Mechanism Mechanical Separation Division New protection for sliding piston RSE 300: „fused“ surface Westfalia Separator Food Tec GmbH Mechanical Separation Division Oils and Fats Processing RSE-Separators – Desludging Mechanism Protection for discharge ports RSE : „Wear liners“ Westfalia Separator Food Tec GmbH Mechanical Separation Division • Requirements: – Low oil losses – Low soap content on oil – Ability to discharge viscous gums or soaps • Realisation: – Sealed feeding chamber – Smooth handling the liquid in the feed – Various disc stack designs – Bowl flush Oils and Fats Processing RSE-Separators – Separating Efficiency Westfalia Separator Food Tec GmbH Mechanical Separation Division Hydrohermetic Vapor Seal • barrier to prevent vapors from rising out of the feeding chamber into the lower centripetal pump chamber • positive effect in case of higher separating temperatures (> 90°C), washing, miscella refining Oils and Fats Processing RSE-Separators – Separating Efficiency Westfalia Separator Food Tec GmbH Mechanical Separation Division Oils and Fats Processing RSE-Separators – Separating Efficiency Hydrohermetic Feed • lower soap content < 500 ppm after neutralisation (150 - 300 ppm achieved) < 50 ppm after one washing • feed pressure 1 - 2,0 bar necessary • range of throughput has to be defined Westfalia Separator Food Tec GmbH Mechanical Separation Division Oils and Fats Processing RSE-Separators – Separating Efficiency Feed, product Discharge light product phase Discharge heavy product phase Separationzone Westfalia Separator Food Tec GmbH Oils and Fats Processing RSE-Separators – Separating Efficiency Mechanical Separation Division feed bar Discharge heavy product phase bar Discharge light product phase Pressure increasing at discharge Pressure in feed increase Separationzone Filling level increase Westfalia Separator Food Tec GmbH Mechanical Separation Division Oils and Fats Processing RSE-Separators – Separating Efficiency Comparison of a standard to a hydrohermetic feed 900 soap content in ppm 800 700 600 500 RSA 200 400 RSE 200 300 200 100 0 1. / 2. / 3. / 4. / 5. / 6. / 7. / 8./ 9. / 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. S S S R R R R R R /R /R /S /S /R /R /R /R /R /R /R /R /R /R /S /S /S /R /R /R test day / kind of oil (R - rapeseed, S - soyabean) Average reduction of soap content by the hydrohermetic feed: 20 % Westfalia Separator Food Tec GmbH Oils and Fats Processing RSE-Separators – Separating Efficiency Mechanical Separation Division Disc stack designs oil phase gap 0,7 - 1,5 mm Soap/water phase gap 0,7 - 1,5 mm Disc stack ( long discs only ) Application : neutralisation washing winterisation oil phase gap 0,7 - 1,5 mm gum phase gap 2 - 3,5 mm Disc stack ( alternating long / short discs ) Application : acid degumming water degumming Westfalia Separator Food Tec GmbH Mechanical Separation Division Oils and Fats Processing RSE-Separators – Separating Efficiency Bowl Flush • useful for dilution of soaps and gums or • to flush out excess caustic soda Westfalia Separator Food Tec GmbH Mechanical Separation Division • Requirements: – Use of the machine for different feed stocks and processes without alterations • Realisation: – Fine Tuner: • Adjustable upper centripetal pump Oils and Fats Processing RSE-Separators – Flexibility Westfalia Separator Food Tec GmbH Mechanical Separation Division Fine Tuner • optimal adjustment of the separating zone during operation • easier handling during start-up (no break-overs) • no break-overs after desludgings (lower losses) • lower power consumption • high flexibility (miscella refining and winterisation without exchange of parts) Oils and Fats Processing RSE-Separators – Flexibility Westfalia Separator Food Tec GmbH Oils and Fats Processing RSE-Separators – Flexibility Mechanical Separation Division Zulauf Discharge light product phase Ablauf schwere Phase Fine Tuner Trennzone Separationzone Westfalia Separator Food Tec GmbH Oils and Fats Processing RSE-Separators – Flexibility Mechanical Separation Division Zulauf Discharge light product phase Opening of the AblaufTuner Fine schwere Phase Fine tuner Trennzone Separation zone Separation zone moves outside → clean oil phase Westfalia Separator Food Tec GmbH Oils and Fats Processing RSE-Separators – Flexibility Mechanical Separation Division Zulauf Closing of the Fine Tuner Discharge light product phase Ablauf schwere Phase Fine tuner Trennzone Separationzone Separation zone moves inside → cleaner heavy phase Westfalia Separator Food Tec GmbH Oils and Fats Processing RSE-Separators – Flexibility Mechanical Separation Division Fine Tuner Drive Positioner Pneumatic drive Gear box Westfalia Separator Food Tec GmbH Mechanical Separation Division Oils and Fats Processing RSE-Separators – Flexibility Setting Range of the Fine Tuner • Assumptions: separating zone unchanged specific weight of heavy phase 1g/cm³ • min. specific weight of light phase: 0,74 g/cm³ • max. specific weight of light phase: 0,94 g/cm³ Westfalia Separator Food Tec GmbH Mechanical Separation Division Oils and Fats Processing RSE-Separators – Drive Systems • Gear Drive – With fluid clutch and direct starting of motor or – With rigid coupling and frequency converter for the motor (requirement for ATEX) – Available in gastight design for inert gas blanketing (miscella refining, Biodiesel) Gastight frame – Limited motor size 45 kW Worm wheel drive Westfalia Separator Food Tec GmbH Mechanical Separation Division Oil Cooling Unit for gear driven separators • bigger oil volume for longer service intervals • longer lifetime of the gears due to lower oil temperature • less wear off due to a continuous filtration of the lubricating oil • in combination with synthetic oils oil change intervals of >2000 hours Oils and Fats Processing RSE-Separators – Drive Systems Westfalia Separator Food Tec GmbH Mechanical Separation Division Oils and Fats Processing RSE-Separators – Drive Systems technical data: gear oil cooler oil temperature in / out oil flow rate flow rate cooling water cooling water temp. In/out filter tank volume motor power °C l/min l/h °C um ltr. kW 125 / 80 2 900 20 - 48 30 12 0,37 external gear oil cooling/filtering aggregate in combination with synthetic oils extension of the oil change cycle to > 2000 hours Westfalia Separator Food Tec GmbH Oils and Fats Processing RSE-Separators – Drive Systems Mechanical Separation Division Lubricating oils for separators with gear drive: Alternatives to CLP 220 Supplier Aral Food grade 1) Mineral oil based Degol BG 220 Avia Synthetic oils Degol PAS 220 Syntogear EP 220 BP Energol GR-XP 220 Enersyn HTX 220 Castrol Alpha SP 220 Alphasyn HG 220 DEA Intor HCLP 220 Esso Gear Oil FM 220 Total Fina Elf Lubriplate SFGO-220 Spartan EP 220 Spartan Synthetic EP 220 Giran P 220 Fuchs Renolin Unisyn CLP 220 Klüber Klübersynth GEM 4-220 Mobil DTE FM 220 Mobilgear 630 SHC 630 Shell Cassida GL 220 Omala Oil 220 Omala Oil HD 220 Meropa 220 Syngear 220 Texaco Remarks: 1) approval acc. to USDA H1 Westfalia Separator Food Tec GmbH Mechanical Separation Division Inert Gas Blanketing Oils and Fats Processing RSE-Separators – Drive Systems to ventilation system N2 Nitrogen Control Unit N2 Operating water Westfalia Separator Food Tec GmbH Mechanical Separation Division Hood chamber blanketing and flushing Gear box blanketing and flushing Sealing chamber blanketing Inert Gas Blanketing Unit Oils and Fats Processing RSE-Separators – Drive Systems Westfalia Separator Food Tec GmbH Mechanical Separation Division • Flat Belt Drive – No clutch, no coupling – Standard motor with frequency converter – Spindle cartridge for easier maintenance – Drive can be blanketed with inert gas – Nevertheless no approval for NFPA 36 regulations !!! Oils and Fats Processing RSE-Separators – Drive Systems Westfalia Separator Food Tec GmbH Mechanical Separation Division • New design with Direct Drive – no gears – no belt • Standard motor – speed equal to bowl speed – in case of RSA 300: 4800 rpm • Bowl and upper housing identical to RSE 300 belt driven • Ideal construction for ex-proof environments and/or miscella refining – nitrogen blanketing possible Oils and Fats Processing RSE-Separators – Drive Systems Westfalia Separator Food Tec GmbH Mechanical Separation Division • Oils and Fats Processing RSE-Separators – Drive Systems Requirements for ATEX regulations ( Status ??) – Direct coupling without clutch shoes requires frequency controlled motor for gear driven machines – Two independent speed measurements required – Double vibration monitoring – ATEX approval for Turbo clutch has passed !