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What is a disc stack centrifuge?

A disc stack centrifuge separates solids and one or two liquids simultaneously. A set of conical plates (disc stack) is added to the bowl of a centrifugal separator. A disc centrifuge uses centrifugal force to separate liquids with a lower concentration of solids and relatively small particle sizes. In a rapidly rotating high-speed centrifugal separator, the gravitational force (g force) is replaced by centrifugal force, which can be thousands of times greater. The conical discs (disc stack) increase the surface settling area (surface area) which seeds up the separation process.

With a disc stack centrifuge, mechanical separation of different liquid phases and solids can be carried out on a rapid, continuous basis.

Sedimentation and separation are a continuous process and very fast. When liquid and solid particles in a liquid mixture are subjected to the centrifugal force in a centrifuge bowl, it takes only a few seconds to achieve what takes many hours in a tank under the influence of gravity. Depending on your separation process and your required separation efficiency, a disc stack centrifuge bowl can be set up as a clarifier bowl or purifier bowl.

Basic principle of disc stack centrifuge

The basic principle behind a disc stack centrifuge is the separation of different components in a mixture based on their density difference. This is achieved by spinning a bowl containing the mixture at high speeds, which generates a centrifugal force that causes denser particles or liquids to move outwards towards the bowl wall while less dense fluids move towards the center.

A disc stack within the bowl contributes to higher separation efficiency by substantially increasing the separation area in the separator bowl. The conical discs in the stack create a series of narrow channels through which the fluid must pass. As the fluid moves through these channels, denser particles or liquids are forced outwards towards the bowl wall while less dense fluids move towards the center.

Once separated, the different components can be removed from the disc stack centrifuge for further processing or disposal.

Self-cleaning separator is for applications that require continuous processing.

The suspension to be separated is fed into the self-cleaning separator bowl from the top through a feeding pipe and enters the disc stack. Separation takes place in the disc stack; the solids are separated out in the solids holding space.

The heavy liquid phase and solids phase are forced towards the periphery of the bowl, while the light phase flows towards the centre of the bowl, from where it is pumped out under pressure for further processing.

The heavy liquid phase is led over a top disc into a chamber where a centripetal pumps it out of the self-cleaning disc separator.

Solids collected in the solids holding space and is discharged intermittently and automatically. The solids holding space is of double conical form and incorporates ejection ports which can be opened and closed by hydraulically lowering and raising the sliding piston. The discharge is achieved by a hydraulic system, which at preset suitable intervals forces the sliding bowl bottom to drop down, thus opening the solids discharge ports at the bowl periphery. The solids is collected in the lower frame hood, and leaves the self-cleaning separator via a hydra cyclone.

During production the accumulated solids can be ejected instantaneously at preset intervals by lowering the sliding piston. At the end of the production phase the self-cleaning separator is automatically cleaned in place. Operation can be fully automated by installing suitable control units.

Conventional material data of Self-Cleaning Disc Separator

All parts coming in contact with the product are made of austenitic Cr-Ni-Mo steels or, in the case of highly stressed bowl parts, of martensitic Cr-Ni-Mo steels or duplex alloys.

Standard equipment of Self-Cleaning Disc Separator

Self-Cleaning Disk Separator consists of a frame with a base that contains a horizontal drive shaft, worm gear, lubricating oil bath, vertical bowl spindle, inlet and outlet devices, revolution counter, vibration-isolating base plate, and AC motor. The bowl is fixed on top of the spindle, inside the space formed by the upper part of the frame, the solids collecting cover, and the frame hood. The hood carries the liquid discharge system.
All parts in contact with the process liquid are made of stainless steel.

Cleaning-in-place (CIP) of Self-Cleaning Disc Separator

Once the centrifugation process has been completed, the Self-Cleaning Disk Separator can be cleaned-in-place. The cleaning solution is circulated through the centrifuge and the connected system. Total ejections are initiated during CIP manually or automatically on the control unit via an external CIP control.

Control system of Self-Cleaning Disc Separator

The following systems are available for controlling the automatic bowl ejections:

– Time-dependent control.
Recommended for use with products in which the solids loading remains constant.

– Photoelectric control using turbidity measurement.
This automatic ejection system can be used as an alternative. If a preset turbidity level is exceeded, a signal is sent to the control unit which triggers the solids ejection process. This control system is recommended for use with translucent products with fluctuating solids loading or if the throughput varies. This monitoring system can be installed on every standard Self-Cleaning Disc Separator.

Nozzle Separator Nozzle separator is continuously operating disc centrifuge, for concentrating solids and clarifying liquids. Concentrated solids phase is discharged continuously through nozzles. Nozzle separators are built as centrifugal clarifiers and separators. they are more solids-orientated than self-cleaning separators. When they are configured to function as clarifiers, they are called concentrators. They are used to thicken solids from suspensions. Working principle of nozzle separator The products containing the liquid and the solids is introduced to the rotating nozzle centrifuge bowl from the top via a feeding pipe, and is accelerated in a distributor before entering the disc stack. Separation takes place between the discs. The disk stack, consisting of a large number of disks placed one above another, splits the liquid into thin layers, thereby reducing the settling distance for the solid particles. The light phase moves through the disc stack towards the centre of the nozzle separator bowl, and is discharged under pressure by a built-in centripetal pump. The heavy solid particles are collected at the bowl periphery and continuously discharged through the nozzles. Features of nozzle separator – Nozzle separator is able to handle high solids concentrations and viscosities. – Nozzle separator is able to adjust the discharge concentration by using special nozzles. – Nozzle separator is able to avoid shearing forces by using special structure. – Nozzle separator is able to extend the centrifugal separating time in the bowl. – Nozzle separator is able to prevent wear by using an innovative design of the separator bowl. – Cleaning-in-place at operating speed Standard equipment of nozzle separator Nozzle separator with AC motor, control unit, special tools, speed and vibration sensors, oil pressure switch, vibration dampening feet, foundation plate and standard set of spares. Conventional material data of nozzle separator All parts coming in contact with the product are made of austenitic Cr-Ni-Mo steels or, in the case of highly stressed bowl parts, of martensitic Cr-Ni-Mo steels or duplex alloys. Applications of nozzle separator Nozzle separators are absolute specialists in the processing of fermentation products in biotechnology, the pharmaceutical and food industries. The separated solids are discharged continuously through nozzles fitted at the bowl periphery. The nozzle separators are equipped with a hydraulically operated ejection system which enables both partial and total ejections to be triggered during product separation. – Classification of solids by size – Dewatering and washing of solids – Clarification of liquids with high solids content – Separation of two liquid phases and a solids phase – Purification or concentration of substances like antibiotics, china clay, starches, yeasts, quark etc. – Extraction of oil from oil sand or oil shale

Solids Retaining Separator Solids-retaining separator, also known as solid wall bowl centrifuge, features its solid wall bowl, or cylindrical bowl design. Compared with the self-cleaning separator, the solids-retaining separator with solid wall bowl is not able to periodically discharge the separated solids at full speed. Because there is no hydraulic system. So, all solids separated out shall be retained in the solid wall bowl, and it shall be removed manually. This is so called solids retaining separator. Features of solids retaining separator Solids-retaining separator is mainly designed for two purposes: – Separating one liquid from another liquid – Separating of trace solids from liquid (< 0.2% v/v) they are used almost exclusively for the separation of liquid mixtures with no or a very small solids content since the separated solids can only be removed manually. Because of the simplicity of the design, very high g force can be obtained, and the solids-retaining separator is thus very efficient in the recovery of fine particles. Special material cladding such as Hastelloy C4/276 or Titanium are used to meet corrosion resistance specifications. The load-bearing parts, including bowl bottom and bowl top, can also be of complete super duplex material. The product is fed into the solids retaining separator bowl through the feed pipe and into the distributor where it undergoes acceleration until it reaches the bowls rotating speed. The distributor then conveys the product to the rising channels of the disks stack where the separation between the heavy and light phases takes place. The disk stack, consisting of a large number of disks placed one above another, splits the liquid into thin layers, thereby reducing the settling distance for the solid particles. The light liquid phase flows towards the centre of the bowl, from where it is pumped out of solids retaining separator under pressure for further processing. The heavy liquid phase is led over a top disc into a chamber where an fixed or adjustable centripetal pump pumps it out of the solids retaining separator. The two pumps are surrounded by rotating liquid phases so, even if they are not rotating, they transfer the speed of the liquid into static pressure. The solids phase is forced to and deposited at the periphery of the bowl. Separated solids is collected in the space at the periphery of the bowl and removed periodically manually. Applications of solids retaining separator Solids retaining separator, solids-retaining centrifuges of the stacked-disc or cylindrical-bowl design, has been widely used for : – chemical products – pharmaceutics – dairy products – lubricating oils – fuel oils

Applications of disc stack centrifuge

– Beverage
Beer | Wine | Juice | Coffee | Tea | Soymilk
– Dairy
Skimming of milk and whey | Clarification of milk and whey | Bacteria removal from milk and whey | Concentration of cream
– Food
Oils and fats | Starch and protein
– Chemical
Organic chemical | inorganic chemical | petrochemical
– Pharmaceutical
Enzymes | Human vaccines | veterinary vaccines | Insulin from biomass | Human blood protein | Animal cell cultures
– Mineral oil
crude oil | residual oil | slop oil | fuel | lubricating oil | hydraulic oil | drilling fluid
– Environmental Technology
drinking water | municipal waste water | industrial waste water | sewage sludge

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