Decanter Centrifuge Machine
Description
Technical Parameters
The full name of the decanter centrifuge machine is the horizontal spiral settling centrifuge, which is a type of settling equipment with horizontal spiral discharge and continuous operation. According to different working principles and purposes, horizontal spiral centrifuges can be divided into horizontal spiral filtration centrifuges and horizontal spiral settling centrifuges. In practical applications, horizontal spiral settling centrifuges are more common. They use the principle of centrifugal settling to deposit solid particles in the suspension on the drum wall under the action of centrifugal force, while the liquid phase is discharged through the overflow port, thus achieving solid-liquid separation.
The decanter centrifuge is an efficient centrifugal separation equipment that plays an important role in various industries such as chemical, light industry, pharmaceutical, food, and environmental protection. In modern industrial production, solid-liquid separation is a common and critical process. Efficient solid-liquid separation technology is of great significance for improving product quality, reducing production costs, and protecting the environment, whether it is suspension separation in chemical production or sludge dewatering in the field of environmental protection. As an advanced solid-liquid separation equipment, the decanter centifuge has been widely used in many industries due to its high efficiency, continuity, and stability.
Working principle
Horizontal spiral centrifuge is a type of spiral discharge settling centifuge. It mainly consists of a high-speed drum, a screw conveyor with a hollow shaft that rotates in the same direction as the drum and has a slightly lower speed than the drum, and a differential.
When the suspension to be separated is sent into the drum by the hollow shaft, it is immediately thrown into the drum cavity under the centrifugal force generated by high-speed rotation.
The high-speed rotating drum generates strong centrifugal force, which throws solid particles with higher density than the liquid phase onto the inner wall of the drum, forming a solid layer (called a solid ring layer due to its ring shape);
Due to its low density and centrifugal force, water can only form a liquid layer inside the solid ring layer, known as the liquid ring layer.
Due to the different rotational speeds of the spiral and the drum, there is a relative motion (i.e. speed difference) between the two. The relative motion between the spiral and the drum is used to slowly push the sludge in the solid ring layer to the cone end of the drum, and after passing through the drying zone, it is continuously discharged through the outlet distributed around the circumference of the drum;
The liquid in the liquid ring layer is continuously 'overflowed' by gravity from the weir to the outside of the drum, forming a separated liquid.
Structural characteristics
Drum drum
The rotary drum is the core component of a horizontal centifuge, which is in the shape of a horizontal cylinder and consists of a cylindrical section and a conical section. It is usually made of high-strength materials such as stainless steel to withstand the strong centrifugal force generated by high-speed rotation. The cylindrical section of the drum is used for settling and separating materials, while the conical section is mainly used for discharging solid materials. In order to meet different processing requirements, the drum is also designed with different cone angles, such as 10 ° or 20 °.
Spiral Conveyor
The spiral conveyor is located inside the drum and has a certain speed difference from the drum. Its shape is compatible with the drum and decanter centrifuge machine is also a spiral structure. The main function of the screw conveyor is to push the solid material deposited on the drum wall towards the small end of the drum (the small end of the conical section) for slag discharge. In order to improve the wear resistance of spiral conveyors, special wear-resistant measures are usually adopted, such as spraying and welding hard alloy protective layers or embedding hard alloy wear-resistant plates.
Differential mechanism
The differential is a key device that controls the speed difference between the screw conveyor and the drum. By precise adjustment of the differential, solid materials can be smoothly conveyed and discharged by the screw conveyor, while ensuring sufficient time for the liquid part to separate inside the drum. Common differentials include involute planetary gear differentials, cycloidal pin wheel differentials, planetary gear differentials, or hydraulic differentials, which have the characteristics of large transmission ratio, high precision, and long service life.
Other components
In addition to the main components mentioned above, the horizontal screw centrifuge also includes a feed pipe, a discharge pipe, a slag discharge port, a liquid level baffle, a drive system, and a control system. The feed pipe is used to introduce the material to be separated into the appropriate position inside the drum; The discharge pipe has two outlets, one for discharging clarified liquid (usually located at the large end of the drum), and the other for discharging separated solid materials (through the slag discharge outlet at the small end of the drum); The liquid level baffle is used to adjust the depth of the liquid pool inside the drum, thereby controlling the separation effect; The drive system provides power for the drum and screw; The control system achieves automated control of the centifuge to ensure its stable operation.
Application area
Environmental Protection Industry
In terms of sewage treatment, the decanter centrifuge machine is used for sludge dewatering. With the increasingly prominent environmental issues, sewage treatment plants have higher requirements for sludge dewatering. The horizontal spiral centifuge has the characteristics of large processing capacity, automated operation, and good dewatering effect. It can reduce the moisture content of sludge from 98% to below 80%, shrink the volume by about 10 times, and greatly reduce the transportation and disposal costs of sludge.
Food industry
There are many applications in food processing. In starch production, it is used to separate impurities such as proteins and fibers from starch milk and improve the purity of starch; In meat processing, it is possible to separate the oil, blood, and solid meat residue from the meat slurry, which facilitates the production of high-quality meat products; In juice production, it is used to separate fruit residue from juice and clarify the juice.
Chemical industry
Used for separating suspensions and emulsions in chemical production processes. For example, in the production of synthetic rubber, the rubber particles and water in the rubber lotion are separated; In pigment production, separating pigment particles and solvents from pigment slurry ensures product quality.
Other fields
The decanter centrifuge is also widely used in industries such as pharmaceuticals, printing and dyeing, papermaking, mining, and electricity. In the pharmaceutical industry, it is used for solid-liquid separation in drug extraction and formulation processes; In the printing and dyeing industry, it is used for the treatment of printing and dyeing wastewater and the recycling of dyes; In the papermaking industry, it is used for the purification of pulp and the treatment of wastewater; In the mining industry, it is used for the concentration and dehydration of mineral slurry; In the power industry, it is used for the treatment of blast furnace gas washing water and sludge.
Liquid separation
Adopting involute planetary gear differential, with large transmission ratio and high precision.
The whole machine is equipped with mechanical and electrical dual overload protection devices, ensuring safe use.
The main motor with power frequency speed regulation is equipped with a hydraulic coupling, and the motor runs smoothly.
High quality stainless steel materials with strong corrosion resistance are selected for the parts in contact with materials.
The whole machine adopts an integral frame structure, which is safe and convenient to lift, and occupies a small area.
The explosion-proof level of power frequency and frequency conversion electrical appliances is Exd Ⅱ BT4, and the sealing performance of the control box is good.
Key selection points
The rotational speed of the centrifuge:
Generally, a decanter centrifuge machine should be at least 3000 revolutions per minute. The higher the speed, the higher the separation factor of the centifuge, and the better the separation effect. However, excessively high rotational speed can also increase the energy consumption and wear of the equipment, so it is necessary to choose the appropriate rotational speed based on the actual characteristics of the processed materials and separation requirements.
Material of centrifuge:
Different materials have different physical and chemical indicators such as wear resistance and corrosion resistance. The minimum material for centrifugal machines in foreign countries is generally 316L or duplex stainless steel, and ceramic composite materials must be used for abrasive components. When choosing a centrifuge, appropriate materials should be selected based on factors such as corrosiveness and wear of the material to ensure the service life and stability of the equipment.
Differential control of centrifuge:
Different differentials have different control accuracies and significant differences in lifespan and maintenance costs. The higher the differential accuracy, the better the adaptability to materials, so it is advisable to choose equipment with high differential accuracy. Meanwhile, the type and performance of the differential also affect the operational stability and separation efficiency of the centifuge.
Aspect ratio:
The larger the aspect ratio of the centifuge, the greater its processing capacity and the lower its moisture content. However, a large aspect ratio can also increase the manufacturing difficulty and cost of the equipment. Therefore, it is necessary to choose a suitable aspect ratio based on actual production needs and site conditions.
Control system:
Whether it is automated programming control is an important indicator to measure the advanced level of the horizontal screw centifuge. Domestic and foreign equipment manufacturers have basically achieved full automation control of the equipment. The automation control system can realize real-time monitoring, fault diagnosis, and automatic adjustment of the centifuge, improving production efficiency and product quality.
Installation power:
The installation power affects the control of energy consumption. Generally, domestic equipment has a higher energy consumption ratio, while foreign equipment has a lower energy consumption ratio. When choosing a centifuge, factors such as equipment processing capacity, separation efficiency, and energy consumption should be comprehensively considered to select products with high cost-effectiveness.
Processing and Manufacturing Technology:
The decanter centifuge is a separation equipment that requires high-precision processing. Enterprises without precision processing capabilities have high maintenance rates and limited processing capabilities for their products. Therefore, products produced by enterprises with good processing and manufacturing techniques and quality control systems should be selected.
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