Mechanical Separation Division Oils and Fats Processing Technical Details of RSE-Separators PDF

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Westfalia Separator Food Tec GmbH Mechanical Separation Division Oils and Fats Processing Technical Details of RSE-Separators Westfalia Separator Food Tec GmbH Oils and Fats Processing Mechanical Separation Division Theoretical background of separation Basics for separation of 2- or 3-phase systems:...

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Mechanical Separation Division Oils and Fats Processing Technical Details of RSE-Separators Y CW

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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 !...