Centrifugal Separator Machine
Description
Technical Parameters
A centrifugal separator machine is a mechanical device that uses centrfugal action to separate components from liquid and solid particles or liquid and liquid mixtures, also known as a centrifuge. Mainly used to separate solid particles from liquids in suspension; Or separate two immiscible liquids with different densities in the emulsion (such as separating cream from milk); It can also be used to remove liquids from wet solids, such as using a washing machine to spin dry and wet clothes; Special high-speed tube separators can also separate gas mixtures of different densities, such as concentration and separatio of gaseous uranium hexafluoride; By taking advantage of the different settling velocities of solid particles with different densities or particle sizes in liquids, some settling centrifuges can also classify solid particles according to density or particle size. Centrfugal separators are widely used in various sectors such as chemical, petroleum, food, pharmaceutical, mineral processing, coal, water treatment, and shipbuilding.
Classification and process requirements
Industrial cetrifugal separators can be divided into three categories based on their structure and separatio requirements: filtration centrifuges, sedimentation centrifuges, and separators. Separators are only suitable for separating low concentration suspensions and emulsions, including disc separators, tube separators, and chamber separators.
When the frequency of the inverter is 30Hz, open the feed valve. When the material layer is checked to be full, close the feed valve and delay for 208. The solid and liquid substances will automatically separate, and the material layer will automatically descend. When the signal of the material layer being full disappears, open the feed valve again and load the solid and liquid mixture to be separated again. Repeat the above action three times in a row.
When the third full charge signal is generated, the feeding valve is closed and the frequency converter frequency is increased to 50Hz for high-speed separatio. The centrifugation time is set by the touch screen, and after the time is up, the frequency decreases to 40Hz.
Open the cleaning valve for cleaning, and the cleaning time, pause time, and cleaning frequency can be set through the touch screen according to the different types of separated objects. After the cleaning process is completed, it enters the spin drying process. At this time, the frequency converter rises to 50Hz, and the spin time is set by the touch screen. After the spin drying is completed, centrifugal separator machine enters the unloading process.
Due to the excessive thickness of the material layer after spin drying, the scraper adopts segmented timed rotation for unloading, that is, the scraper rotates (time can be set) for one stop for 4 seconds and the scraper descends to scrape the material, repeating the above actions until the last time the scraper descends to the limit position. After triggering the limit switch, it rises to the top and triggers the upper limit switch to stop.
Products Description
A centrifugal separator has a cylinder called a drum that rotates at high speed around its own axis, usually driven by an electric motor. After the suspension (or emulsion) is added to the drum, it is quickly driven to rotate at the same speed as the drum, and under the action of centrfugal force, each component is separated and discharged separately. Usually, the higher the drum speed, the better the separatio effect.
The working principles of centrfugal separators include centrfugal filtration and centrfugal settling.
● Centrifugal filtration: The centrfugal pressure generated by the suspension in a centrfugal force field acts on the filtering medium (filter screen or filter cloth), causing the liquid to pass through the filtering medium and become the filtrate; And solid particles are trapped on the surface of the filter medium, forming filter residue, thus achieving liquid-solid separatio. The filtering drum has holes on the circumferential wall and is lined with filtering media on the inner wall.
● Centrifugal sedimentation: The principle of rapid settling and layering of components with different densities in a suspension (or emulsion) in a centrfugal force field is used to achieve liquid-solid (or liquid-liquid) separatio. The settlement type drum has no holes on the circumferential wall.
Figure shows four typical settling type rotary drums. After the suspension (or emulsion) is added to the drum, solid particles (or denser liquids) settle towards the drum wall, forming sediment (or heavy separation liquid). The liquid with lower density gathers towards the center of the drum and flows to the overflow outlet for discharge, becoming the separatio liquid (or light separatio liquid). The drum is used for intermittent slag discharge, which is suitable for separating suspensions or emulsions with small particle size and low concentration of solid particles; The rotary drum in Figure 3b uses spiral continuous slag discharge to separate suspensions with high solid particle concentrations. In a drum with multiple layers of conical discs, the liquid is divided into several thin layers by the discs, shortening the distance of settling separatio, accelerating separatio, and improving separatio efficiency.
When the solid and liquid mixture to be separated enters the high-speed rotating drum from the feed inlet, under the action of centrfugal force, the mixture is filtered through the filter screen. The liquid separatio material is discharged through the discharge pipe, and the solid separatio material remains in the drum. When the solid separatio material in the drum meets the requirements specified by the equipment, the feeding is stopped, the solid separatio material is cleaned, and the washing solution is discharged. After the cleaning meets the requirements, the centrfugal separator runs at low speed, and the solid separatio material discharge device (scraper) is driven by an AC servo motor to discharge the solid separatio material, completing one working process.
Performance impact
Filtering centrifuge and settling centrifuge mainly rely on increasing the diameter of the drum to expand the working surface on the circumference of the drum; In addition to the circumferential wall of the drum, the separator also has additional working surfaces, such as the disc of the disc separator and the inner cylinder of the chamber separator, which significantly increase the settling working surface. The selection of a centrfugal separator for suspension or emulsion should be based on a comprehensive analysis of the size and concentration of solid particles in the suspension (or emulsion), the density difference between solid and liquid (or two liquids), liquid viscosity, the characteristics of the filter residue (or sediment), and the separatio requirements. The selection of which type of centrfugal separator to use should meet the requirements for the moisture content of the filter residue (sediment) and the clarity of the filtrate (separatio liquid).
The important indicator for measuring the separatio performance of a centrifugal separator machine is the separatio factor Fr. It represents the ratio of the centrfugal force experienced by the separated material in the drum to its gravity. The larger the separatio factor, the faster the separatio and the better the separatio effect. The Fr of industrial centrfugal separators is 100-20000, the Fr of high-speed tube separators is as high as 62000, and the Fr of analytical high-speed separators is as high as 610000. Another factor that determines the processing capacity of a centrfugal separator is the working area of the drum, and a larger working area also increases the processing capacity.
Development history
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In ancient China, people tied one end of a rope to a pottery jar, held the other end of the rope, rotated and shook the jar, generating cetrifugal force to squeeze out the juice of the berries in the jar. This was the early application of the principle of cetrifugal separation.
Industrial centrifuges were born in Europe, for example, in the mid-19th century, there were three legged centrifuges used for textile dehydration and suspended centrifuges used for separating crystalline sugar in sugar factories. These earliest centrifuges were operated intermittently and manually for slag discharge.
Due to the improvement of slag unloading mechanisms, continuous operation centrifuges emerged in the 1930s, and intermittent operation centrifuges also developed due to the implementation of automatic control.
In 1879, Laval of Sweden invented the first separator for separating cream from milk, which had a drum that was only a hollow cylinder. Later, conical discs stacked axially were added to the drum, significantly improving the separatio efficiency and increasing the processing capacity. This technological advancement led to the rapid development of disc separators. The speed of the centrifugal separator machine gradually develops from low to high, and the diameter of the drum gradually increases, improving the separatio effect and enhancing the processing capacity.
The research and development trend of centrifugal separators is:
Enhance separation performance, including increasing drum speed; Add new driving force during cetrifugal separatio process; Accelerate the speed of slag pushing; Increasing the length of the drum prolongs the cetrifugal settling and separatio time.
The development of large-scale cetrifugal separators mainly involves increasing the diameter of the drum and using double-sided drums to improve processing capacity, thereby reducing equipment investment, energy consumption, and maintenance costs per unit volume of material.
Improve the slag unloading mechanism to ensure continuous operation.
Add specialized and combined drum centrifuges to meet special and multiple separatio requirements.
In terms of theoretical research, the main focus is on studying the fluid flow conditions inside the drum and the mechanism of filter residue formation, as well as the calculation methods for minimum separatio degree and processing capacity. Research on stress distribution and strength calculation of complex shaped drum.
Research on optimal control technology for cetrifugal separation process.
Vibration fault handling
(1) Eliminate empty drum imbalance.
For a new centrifuge drum, balance calibration is carried out by installing the drum on the balance heart shaft, and it is generally necessary to first place it on the dynamic balancing machine for balance calibration. When the drum is installed on the actual shaft, its balance accuracy will significantly decrease, because the fitting conditions and concentricity between the drum and the balance shaft, as well as between the drum and the actual shaft, are different. About 60% of the vibration of rotating equipment is caused by rotor imbalance, and on-site dynamic balancing is the most effective way to eliminate the vibration caused by hollow drum imbalance.
(2) Isolate vibration.
After taking measures to eliminate the imbalance of hollowing, the vibration has been reduced, but the static force during unloading cannot be eliminated by the above method. Effective isolation measures can be taken to reduce the vibration transmitted from the foundation. Vibration isolator is a commonly used technical means for equipment installation and vibration reduction in small and medium-sized rotating separation machinery, generally divided into active isolation and passive isolation. According to the isolation theory, the machine can be regarded as an ideal mass body, and the isolator is composed of a massless spring and an ideal viscous resistor connected in parallel, with an absolutely rigid foundation. To achieve vibration isolation effect, it is only necessary to excite a frequency greater than twice the natural frequency. Due to the large distance between the assumption and the actual situation, the higher the excitation frequency, the greater the difference between them. Moreover, it is difficult to achieve vibration reduction of more than 20db with single-stage isolation. Even with small damping, the isolation effect can only remain within a certain range. Therefore, the anti analysis method can be used for vibration isolation research.
(3) Reduce fabric unevenness and sudden excitation vibration.
Two measures can be taken to solve the random vibration caused by uneven fabric and sudden excitation force during unloading, including dynamic shock absorbers and automatic balancing. The power damper can transfer vibration energy to the damper, thereby significantly reducing the vibration of the entire machine and foundation. But the power shock absorber cannot fundamentally eliminate the vibration source, and the periodic forces on the bearings have not decreased. Automatic balancing is the installation of a balancing device on the drum, which can quickly feedback the vibration signal generated by uneven or sudden force of the obtained fabric to the control mechanism before generating a damping force equal to or opposite to the unbalanced centrifugal separator machine inertia force, fundamentally eliminating the vibration source.
Conclusion
Centrifugal separator machines are indispensable in modern industrial processes, offering unmatched efficiency in separating heterogeneous mixtures. From food processing to wastewater treatment, their applications span diverse sectors, driven by innovations in design, materials, and automation. While challenges like energy consumption and wear remain, advancements in IoT, AI, and hybrid technologies are paving the way for smarter, more sustainable separation solutions. As industries prioritize resource recovery and environmental stewardship, centrifugal separators will continue to evolve, playing a pivotal role in the transition to a circular economy.
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