Safety and efficiency –

the strongest compound

GEA centrifuges in chemical production
 Contents · 3

Introduction
The strongest compound 04
Separation in the chemical industry 06
Full safety  08
Full efficiency  10

Product development
Global test center network  12

Applications
Petrochemical additives 14
Chemical catalysts  16
Viscose  18
Polymers  20
Nitroaromatic compounds  22
Peroxides 24
Paints, dyes, inks  26
Zero Liquid Discharge  28

Technology
Centrifuge technology 30
Decanter centrifuges 34
Maximum-protection solutions 36

GEA Service
GEA Service – For your continued success  39
ONE GEA – ALL COMPETENCIES
From boosting oil wells or biochemical cell treatment to
the finished chemical product, from product development
to global production – GEA expertise and solutions cover
the entire range of chemical applications.
 INTRODUCTION · 5

The strongest compound

The GEA mission is to ensure uniquely efficient
and safety-protected production for the benefit of
the manufacturer.

Full efficiency
GEA offers pioneering concepts in chemical engineering to increase the feasibility
and reliability of processes, the reproducibility of results and the sustainability of
each process step. As modern life continues to depend on plastics, synthetic fabrics,
paints, fuels, and many other chemical products, GEA gives customers an edge in
competitive markets.

Full safety
Plant operators turn to GEA to ensure the highest level of safety in industrial
chemical processing to protect the plant’s personnel, operations and the environment
as well as the manufacturer’s investment and brand reputation.

Strong partnership
GEA has been supporting the chemical and petrochemical industries for decades
in a variety of separation tasks. The technology leader supplies disk stack and
decanter centrifuges for such process lines. The systems convince our partners
worldwide by the high quality of the end products, cost effectiveness and a
conservative approach to resource handling.
6 · INTRODUCTION

Separation in the chemical

industry
GEA has been supporting the chemical and petrochemical
industry in separating duties for decades.

A recurring task in chemical processes, often in multiple cycles, Modular customization options to fit any task
is the mechanical separation or clarification of substances and GEA provides centrifuges optimized for the task to meet the
phases or the extraction of substances. Centrifugation offers specific conditions present on every customer’s premises.
not only high yields from the employed raw materials but also Current machines are available in suitable design variants to
ensures reliable process management which makes efficient use fit specific processes and processed product. Different design
of resources. executions are available with ideally suited special materials
for a given purpose or hardfacing.
State-of-the-art centrifuge technology
Outstanding GEA innovations that have become industry- On the other hand, many GEA centrifuge models are equipped
leading standards include state-of-the-art feed and discharge to accommodate multiple process applications, saving efforts for
systems on disk stack, nozzle and solid-wall bowl centrifuges. plant management and maintenance.
GEA also offers decanter centrifuges with optimized machine
geometry and both high and low speeds for varying solid
contents.
 INTRODUCTION · 7

Important products:
• Agar-agar
• Aluminum hydroxide
• Amines
• Aniline dyes
• Ash leaching
• Barium sulfate
• Black liquor
• Cellulose and derivatives
• Catalyst recovery
• Dyes
• Ethyl amines
• Filter backflush liquid
• Fungicides, etc.
• Gum arabic
• Herbicides
• Ink
• Insecticides
• Lignocellulose
• Lyes
• Nitro compounds
• Petrochemical additives
• Paints
• Peroxides
• Phosphoric acid
• Polyacetates
• Polybutadiene, etc.
• Polycarbonate
• Polymer
• PTA (purified terephtalic acid)
• Salts (various)
• Sodium borohydride
• Suspensions with metals, oxides,
hydroxides, catalysts
• Tall oil
• Viscose, cellulose acetate, etc.
8 · INTRODUCTION

Full safety
Chemical production involves hazards hardly experienced
in any other industry – complex reactions, inflammable
materials, concentrated acids, heat, high pressure, risks of
decomposing and explosion.

GEA centrifuges are optimally protected, using six strategies to 3. ATEX 2014 / 34 / EC compliance
fulfill your specific process needs: GEA machines for use in explosive environments are monitored
and certified according to ATEX regulations.
1. Corrosion resistance
Strong, non-corrosive stainless steel alloys and nickel-based 4. Inert gas blanketing
alloys are selected for each centrifuge depending on the For numerous processes, units for blanketing the centrifuge
unique application. bowl with inert gas are available, reducing the oxygen content
inside the centrifuge below the critical level.
2. Wear protection
Hard-facing from durable materials, applied with sophisticated 5. Temperature control
processes, prevents mechanical failure and unnecessary wear on For products that can decompose at low temperatures,
machine parts. state-of-the-art monitoring at the critical points is available.

6. High process temperature

Special design features are in place for centrifuges used in high
temperature applications.
Typical hazards
• Nitrated organics such as MNT and
DNT can explode after exceeding a
certain temperature, independent of
the presence of oxygen.
• Peroxides can decompose in the absence
of oxygen even at comparatively low
process temperatures, enhancing the
explosion risk.
• Elevated temperatures are characteristic
of processes in the production of
petrochemical additives or catalyst
recovery.
• Critical concentrations of solvent
vapors and oxygen inside the
centrifuge can cause explosions
or fires.
• Vapor leakages must also be prevented
so as not to pose a risk to the health of
the operators.
10  ·  RESEARCH AND DEVELOPMENT
 INTRODUCTION  ·  11

Full efficiency
Chemical products such as polymers and peroxides are
often mass produced, which means that manufacturers
need to achieve both high-quality results and maximum
production to be profitable. This is where the industry
experience of GEA pays off to provide the ideally selected
and customized solution.

Higher yield
All chemicals are different and require different properties from centrifuges for
maximum-efficiency clarification, polishing or extraction. The GEA high-performance
centrifuges and decanters can be fine-tuned in each different case to achieve exactly
the right parameters and to obtain exact and pure separation results with fewer
processing cycles and higher yield from the same raw materials.

Adjustable parameters include bowl types and dimensions, disk stack and nozzle sizes,
bowl angles, integrated feed and discharge systems, automated control options, rotation
speed, and numerous other parameters. Decanter centrifuges are equally optimized to
achieve highest yields.

Reproducible results
Exact mechanical operation is one reason for ensured reproducible results with GEA
machines. The other reason for this are extensive monitoring and control options –
either between batches or even during operation.

Reliable operation
Robust operation and plannable service intervals for maximum availability throughout
the entire life cycle is a key characteristic of all GEA centrifuges and decanters.
12 · PRODUCT DEVELOPMENT

Global test center network

Innovate, partner and prosper with GEA

Driving your future Driving solutions Driving technologies

By combining advanced in-house From new product and feasibility trials Overcoming technical barriers throughout
technology with a thorough understanding to scale-up studies, training programs the entire process chain, there’s no limit
of the processing industries, we help our and process support, we believe that our to where the GEA global network of test
customers to maximize their development services greatly benefit anyone involved centers can take your research.
results, gain more know-how and in industrial R&D, equipment selection,
discover additional opportunities for their process optimization and product
applications. development.

The GEA global network of test facilities offers teams of experts On-site trials and test centers
who work closely with their customers to optimize procedures Centrifuges are available for process trials at the operator’s
and evaluate their products, enabling them to achieve their site to assess the feasibility and profitability of individual
process and production goals. process steps and combined operations.

GEA test center Separation In co-operation with the customer, GEA also develops and
At the GEA test center of competence, customers can test tests completely new processes. In this way, the GEA test
both new and established products in a wide range of centers also underline the innovation strength of GEA as a
separation operations or perform comparative process leading international technology group.
studies with our skilled operators. Other test programs in
GEA test centers around the world can be involved to test Prosper with GEA
entire manufacturing lines. Book your ticket to success at gea.com/contact
RESEARCH AND DEVELOPMENT  ·  13
14  ·  APPLICATIONS

Petrochemical
additives
Reliable removal of solids without clogging

Petrochemical additives increase the fluidity of lubricants,

reducing wear and energy consumption in mechanical
operations. The preparation of safely applicable additives
demands that inorganic salts and other contaminants are
removed from the product, typically by processing with decanter
and disk stack centrifuges. For this, GEA offers a specialized
machine portfolio characterized by particularly reliable
functionality.

Faster discharge for continuous operation

Unwanted solids, such as calcium salts or other inorganic salts,
GEA TSE SKID are typically present at varying concentrations in the organic
Perfect for effective polishing: carrier solvent of petrochemical additives. GEA decanter
The complete disk stack centrifuge centrifuges are able to effectively remove these solids due to the
with integrated controls and ports optimal design of their bowl geometries and discharge systems.
works alongside the GEA CF decanter
centrifuge to ensure the most A flat angle of the conical bowl section ensures that the
efficient removal of high and separated salts are discharged quickly, before they can clog
low solids concentrations. the machine. This prevents unplanned shutdowns.
 APPLICATIONS  ·  15

Maximum safety and efficiency

GEA optimizes each centrifuge for the treatment of petrochemical
additives to meet the specific conditions of the customer’s process.
Test runs at the production facility as well as the experience of
GEA experts ensure efficient operation of the centrifuge in the
process line.

With gas-tight, explosion-proof centrifuges according to ATEX

standards, GEA guarantees maximum safety.

Efficient polishing in a second step

Depending on the pre-concentration of the product, the separation For a higher solids removal rate, the product can be polished in
process uses decanter and disk stack centrifuges. Very frequently, a disk stack centrifuge. This second process step is marked by a
both machines are used in a 2-step process. If the additive less frequent discharge of solids, reducing both the consumption
solution has a high solid content, a decanter centrifuge is the of process liquid and the loss of valuable product during
ideal machine. These machines are best equipped to handle discharge.
great concentrations of solids and can typically remove the
solids content by 80 to 90 %. Both the initial separation in the decanter centrifuge and the
polishing step with a disk stack centrifuge thus improve the
overall efficiency of the production process.

PETROCHEMICAL additives
1

1 Contaminated oil additive, obtained

from a reaction process
3
2 2 Oil additive solution + salts
3 Decanter CF series
4 Salts (disposal)
5 Self-cleaning centrifuge,
4 DSE or TSE series
6 Oil additive solution to further treatment

Oil additives

1 Contaminated oil additive, 4 Salts (disposal)

16  ·  APPLICATIONS

Chemical catalysts
Safe recovery at any required temperature and pressure

Catalysts are chemical substances that accelerate the reaction The pressure-stressed components hood, solids catcher and
rate and do not change themselves. Typically, the catalysts must protective hood meet the requirements of the European Pressure
subsequently be removed from the reaction product, as they Equipment Directive and the American ASME code. A double
are often valuable recyclables, such as platinum, cobalt, and mechanical seal provides the necessary segregation of the
manganese, or in some cases materials that could be hazardous product space from the environment.
to the environment. For efficient recycling of the catalysts, GEA
offers highly suitable nozzle-type centrifuges that are not only Product-wetted parts are made of Duplex stainless steel.
reliable but also particularly safe in operation and able to handle Depending on centrifuge size, Super-Duplex and Super-Austenitic
high temperatures and pressures. steel can be selected as well. Special materials such as Inconel
625 and suitable gasket elastomers such as FKM and FFKM are
Explosion- and pressure-proof operation also available.
GEA nozzle centrifuges for recovering catalysts are marked by a
fully sealed, explosion-proof centrifuge bowl. This is important
because a number of recovery processes demand temperatures
of up to 180 °C to reduce the viscosity of the carrier fluid, which
in turn may require increasing the pressure to up to 10 bar to
prevent the fluid from evaporating. Thanks to their closed-bowl
concept, GEA nozzle centrifuges operate safely and without
problems under these conditions.

GEA TDC nozzle centrifuge

Plug and play: The explosion- and pressure-
protected centrifuges are suitable for operation
at up to 180 °C and resistant against wear and
tear. Each model can be supplied as a complete
package unit.
 APPLICATIONS  ·  17

Dependable performance
Nozzle-type centrifuges from GEA reliably provide highest
clarifying results with a defined solid concentration in the
nozzle discharge.

To adjust the solids content in the concentrate, the nozzle

output can be recycled to the centrifuge by means of an
external recycle pump. Compared to other recycle systems,
this method is independent from the centrifuge’s bowl speed.

If high solid contents need to be processed or catalyst solids

Protection against wear and tear must be dewatered to a high degree, decanter centrifuges
Catalysts are mainly inorganic material that cause wear on of different sizes from GEA offer an alternative technology
centrifuge parts. This is why GEA machines for this process are solution to ensure maximum efficiency.
equipped with state-of-the-art hardfacing.

The innovative nozzle design devised for GEA TDC centrifuges

further decreases the abrasive effect, significantly increasing the
lifetime of the centrifuge.

Simplified maintenance, long service life

GEA nozzle-type centrifuges feature special inspection covers
for simple inspection and replacement of the nozzles, making
it unnecessary to open the centrifuge bowl for maintenance
exchanging the nozzles.
18  ·  APPLICATIONS

Viscose
Recovery from filter reject with maximum service life

Viscose manufacturers advance their productivity by recycling Viscose recovery

the reject from the filter cleaning process to achieve a higher
yield of the in-demand product. Smart GEA centrifuges are 1

equipped to achieve this with minimal machine wear, optimizing

2
the efficiency of the system and the operational costs.
4
5
Faster discharge for less wear and fewer stops
The filters for the main process of viscose filtration are back- 6

flushed regularly for cleaning. Following that, the reject liquid is 3

centrifugally clarified to be subsequently recycled to the process, 7
removing sludge, sand and other suspended solids that have
not been discarded upstream with hydrocyclones. However,
these abrasive solids require careful attention to minimize wear, 8
particularly on the ejection system. Here, the ingenious GEA
hydrostop system on all GEA machines for viscose recovery 1 Viscose 6 Reject viscose,
Viscose recovery
offers a crucial advantage: The large stroke of the sliding 2 Filtration recycle to process
piston ensures a very fast ejection and shortens the contact 3 Refined
1 Viscose viscose 7 Waste
6 Reject viscose,
time between ejected solids and machine parts by the factor 10 4 Reject viscose
2 Filtration 8 
Srecycle
elf-cleaning centrifuge,
to process
compared to other ejection systems. The result is prolonged 5 Water
3 Refined viscose 7 DSE or TSE series
Waste
4 Reject viscose 8 Self-cleaning separator,
5 Water DSE or TSE series
 APPLICATIONS  ·  19

stand times of the centrifuge due to less maintenance and fewer

cleansing intervals.

Balanced abrasion patterns for increased lifetime

The sliding piston on these DSE machines, always a critical
part when handling abrasive solids, is designed to continuously
change its radial position relative to all other bowl parts. This
design feature leads to uniformly smooth abrasion patterns.
It reduces the typical formation of wear channels and thus
increases the service life of the wear parts.

Robust series concept

GEA centrifuges for viscose recovery are available in particularly
robust executions with only few necessary additions for
maximum service life. Vulnerable parts of the machine are
protected by exchangeable wear plates and/or hard facing.

As viscose continues to rank among the most used fabrics in GEA DSE SERIES
the world, GEA DSE centrifuges add efficiency and yield to the The equally smart and robust
manufacturer’s profit. machines offer long operating
times and a long service life,
meeting all requirements of
efficient viscose recovery.
20 · APPLICATIONS

Polymers
Extreme purity and minimum residual water

Polymers are among the most sought-after plastics, used in

countless industries and areas of life. In particular, polycarbonates
are a popular choice for many modern applications, from
construction to optical products, because of their superior
transparency and impact resistance.

The typical manufacturing process uses centrifuges in the

multi-stage wash cycle designed to separate the pure organic
polymer solution from the acidic wash liquid. Among the
most suitable GEA models are the TTC series of solid wall bowl
centrifuges for liquid-liquid separation and the TSE series
of self-cleaning disk stack centrifuges for liquid-liquid-solid
separation.

GEA TTC 300

Optimized for purity of the product and
safe operation: Solid-wall bowl centrifuges
with corrosion-resistant materials and
effective customization options.
 APPLICATIONS · 21

Optimized separation efficiency Risk-free, long-life operation

These GEA centrifuges provide outstanding separation All GEA centrifuges for polymer washing are optimized for
performance for maximum product purity. One major reason continuous operation. To avoid corrosion risks from increased
for this is that each machine can be tailored precisely to the chlorines contents all GEA centrifuges are made of duplex or
operator’s specifications and process requirements in terms super-duplex. GEA solid-wall bowl centrifuges can be cladded
of flow rates and phase ratios, as well as the densities and with special material such as Hastelloy.
viscosities to be processed.
For the safe processing of solvents, all centrifuges are available
The separation process not only aims for extreme purity, but in explosion-proof closed design, sealed from the atmosphere
also for minimal residual water content in the organic phase. and blanketed with inert gas.
These market demands are met by GEA technology that is
specially designed for high centrifugal speeds. Equipment for other polymer process steps
GEA disk stack and decanter centrifuges can also be used
for the clarification, classification and dewatering steps in
polymer production.

Polymer Washing
1
2

3 4 1 Polymer solution with impurities

2 Fresh wash water
3 Purified polymer solution
5 4 Used wash water
5 Suspended impurities
6 Centrifuge TTC (manual solids
6 discharge) or TSE

Polymer Washing

1 Polymer solution with impurities

2 Fresh wash water
3 Purified polymer solution
4 Used wash water
5 Suspended impurities
6 Separator, TSE series
22 · APPLICATIONS

Nitroaromatic compounds
Safe and efficient separation at just the right temperature

Important industrial products such as polyurethane (PU)

and other plastics, but also explosives or pharmaceuticals,
derive from nitrated aromatics, e.g. aniline or nitro toluene.
The nitration reaction to obtain these nitroaromatics involves
aggressive basic materials as well as explosive reaction
products, the hazards of which must be vigilantly controlled.
GEA centrifuges offer superior concepts to protect the safety
of process, plant and operators.

Nitroaromatic compounds are obtained in a multistage, large-

scale process. After repeated nitration in the reaction tanks, the
product is separated from the spent nitric acid, then undergoes Crucial temperature control
a multistage washing process to achieve a high degree of purity. Solid-wall bowl centrifuges from GEA are an excellent choice for
Solid-wall disk centrifuges from GEA can be applied to all of the main separation processes because of the excellent purity
these steps. In the final separation step, the nitroaromatic is of the nitroaromatic compounds obtained with a disk stack
separated from the water after washing. centrifuge. The level of control secured through this bowl design
and numerous functional options enables the plant operator to
safely adhere to the tight temperature limits that ensure a steady
process, but prevent the treated medium from decomposing.
This eliminates the risk of explosion.

The purity and yield of the nitroaromatics obtained with these

solutions is excellent. Separation takes place in a very small
space, significantly increasing the safety of the installation.
Centripetal pumps ensure the safe discharge of both the acid
and the organic phase.

GEA TTC 150

Safe, efficient and highly durable: These proven
solid-wall bowl centrifuges are now available
with robust and space-saving direct drive for
challenging separation tasks.
 APPLICATIONS · 23

Unique anti-corrosion armor Small, low-footprint machine solutions

A particularly critical factor in the aversion of safety risks and GEA nitroaromatic compounds are characterized by a wide
process errors is corrosion protection, made especially difficult bowl head, suitable for a sufficient overflow to accommodate
by the presence of strongly acidic media. To keep these hazards the typically high density difference (1.3-1.6). This also applies
at bay, all parts that come into contact with the product must, in to small, space-saving solutions such as the GEA TTC 150, the
principle, consist of Incoloy 825. GEA uses cladding with Incoloy use of which saves valuable space in the production facility.
825 for the loading part of the bowl to maintain the advantage
of maximum bowl speed with a Duplex or Super Duplex bowl Cost-saving acid recycling
while providing the corrosion resistance of the Incoloy 825. In addition, chamber-type centrifuges are successfully used
The problem is particularly acute when processing nitrated to clean the spent acids for recycling. This increases the
toluene (MNT, DNT), thus Incoloy 825 is typically used for all operation uptime of the centrifuges in the nitration stages by up
components in contact with those media. to 100 percent as sulfuric acid cleaned in this way significantly
extends the intervals between the cleaning cycles of the solid-
wall bowl machines.

NITROAROMATIC COMPOUNDS

Mononitration Dinitration Washing of dinitrated aromatics

9 2 2
1
11
15
16

3 12

10
6 13 14
7 17
18

19
5 15 20
7 4
8 4 14 21

15

4
22

Mononitration 8 Condensate Washing of dinitrated aromatics

1 Aromatic 9 Clarification of fe-sulfate from 15 Wash water
2 Mixture of nitric acid and sulfuric acid sulfuric acid 16 1st washing step: sour water
3 Reactor for mononitration 10 Centrifuge TKC / TKI 100 17 Caustic soda solution
4 TTC / TTI series centrifuge 18 2nd washing step: alkaline water
5 Exhausted acid to recovery station Dinitration 19 3rd washing step
(H2SO4 + H2O + organics) 11 Mononitrated aromatic 20 Washed dinitrated aromatic
6 Recovery station 12 Reactor for dinitration 21 Condensate
7 H2O steam 13 Acid for recirculation 22 Dryer
14 Dinitrated aromatic
24 · APPLICATIONS

Peroxides
Customized solutions for safe maximum-purity processing

Hydrogen peroxide is used as a disinfectant and bleach in Highest yield and efficiency
many industries, while organic peroxides are used as chemical The extensive customization options for GEA TTC models also
reactants. Nowadays, peroxide is also used for processes such make sure to achieving highest yields and flow rates with any
as HPPO converting HP (peroxide) into PO (propylene oxide). given process setup and volume.
Since the peroxide production process requires particularly
accurate separation results and reliable explosion control, GEA Special design modifications are available to optimize separation
TTC centrifuges are effectively customized to individual process efficiency, particularly with regard to the peroxide process: Since
conditions and production parameters. the light phase accounts for more than 90 percent of the total
flow, most of the centrifuge capacity should be used to purify the
Maximum accuracy of separation light phase. Only GEA TTC can be configured to ensure this
Peroxides are most commonly obtained using the anthraquinone without sacrificing other performance benefits.
process, which puts an organic working solution through a cycle
of hydration, oxidation, washing and concentration. To extract Safe operation and temperature control
impurities, an aqueous phase is added to the working solution or The peroxide process is always critical in that peroxides can
directly to the organic peroxides, then both phases are separated decompose even in the absence of oxygen at temperatures above
with centrifuges. Since further processing requires a very pure certain limits. Hydrogen peroxide is even used as space rocket
organic phase, the GEA TTC solid-wall bowl centrifuges are
specially customized for separation with maximum accuracy.

GEA TTC 300

All TTC centrifuges from GEA can be customized to ensure
maximum safety, efficiency and durability for any peroxide
process. Starting with small GEA TTC 10 models, the right
size can be chosen from a broad range.
 APPLICATIONS · 25

fuel. In order to minimize the risk of explosion in the separation

process, GEA centrifuges are explosion-proofed and the
temperatures at the critical points are permanently monitored.

Where flammable liquids are handled, the GEA centrifuges are

explosion protected according to European ATEX regulation.

The closed bowl is completely sealed off from the atmosphere,

blanketed with inert nitrogen and connected to the plant’s
vent system. The bowl design is also optimized for low-friction
operation to prevent heating.

Continuous, long-life operation

GEA TTC machines are designed and equipped for continuous
operation in peroxide processes.

Peroxides

2 6

3 3

5 5

4 4

1 Fresh washing agent 4 Used washing agent

2 Working solution 5 Solid-wall bowl centrifuge, TTC or TTI series
Peroxides
3 Static mixer 6 Purified working solution

1 Fresh washing agent 4 Used washing agent

2 Working solution 5 Solid-wall separator,
3 Static mixer TTC or TTI series
6 Purified working solution
26 · APPLICATIONS

Paints, dyes, inks

Classifying with exactitude and style

Almost every industrial product requires some form of coating

and/or coloring, and most are made of or accompanied by
printed materials. These facts clearly show the great economic
importance of paints, dyes and inks. GEA disk stack and
decanter centrifuges for classification tasks ensure optimum
quality and visually appealing results.

Great centrifugal force for small particle classification

Technically, paints, dyes and inks consist of a liquid phase
containing colorant particles. What seems uncomplicated at
first glance turns out to be a real challenge on closer inspection:
particles of just the right size have to be processed in order to
achieve the desired color or protective function.

Thanks to their design and extensive customization options,

GEA machines ensure that all process and production parameters
GEA DSE 120 are taken into account so that only the desired particle size class
Exact and safe classification is is retained in the end product. The small particles, often no more
the domain of this disk stack
centrifuge, available in sizes
from DSE 10. For classifying
solutions with higher solid
content, GEA CF decanter
centrifuges are available.
 APPLICATIONS · 27

than a few micrometers, typically require high speeds and large and the product chamber is gas-tight. The product chamber and
clarification areas in the centrifuge. In these applications, GEA drive chamber are blanketed with inert gas that reduces the
chamber bowl centrifuges and continuous disk stack centrifuges concentration of oxygen in the centrifuge to a non-critical level
have proven their benefit. and keeps it within safe parameters.

Effective, speedy discharge Decanter centrifuges are used for inks and paints with a high
To ensure maximum quality, the discharge system on GEA solid content. For classification of inks the decanter centrifuges
disk stack centrifuges is controlled by the GEA hydrostop are equipped with special control features to keep product
mechanism with operating water that does not come into temperatures below hazardous level. Explosion-proof design of
contact with the end product. The discharge system creates a these machines is provided if needed for the specific process
large discharge port for a particularly rapid discharge so that conditions.
sticky colors, dyes and inks will not clog the system.
In most cases, identical GEA models can be dedicated to most or
Safe operation all color variants of a given paint, dye or ink product in a plant.
When flammable organic solvents are used in a production
process, it is necessary to use explosion-protected centrifuges.
Machines from GEA are equipped with certified components
28 · APPLICATIONS

Zero Liquid Discharge

Zero Liquid Discharge (ZLD) at reproducible quality

Water consumption and water conservation are a major concern

in many areas of industrial operation. As a result, Zero
Liquid Discharge (ZLD) solutions have become a key factor
in successful processing. Manufacturers under pressure
to achieve exactly reproducible results can rely on advanced
decanter centrifuge technology from GEA to achieve their goals.

Reproducible results
In ZLD processes, decanter centrifuges are used to clarify the
spent process water and remove salts and other substances
so the liquid phase can be recycled as high-purity water to the
main process. GEA decanter centrifuges are designed particularly Customized for the task at hand
for efficient and reliable treatment of high-solid suspensions. The extensive experience of GEA in developing and customizing
All GEA machines for ZLD processes feature a flat pond design advanced centrifugal solutions gives every user an important edge
with 25 percent higher g-force at solid outlet than conventional in terms of reproducible results at minimum energy consumption.
centrifuges. All critical technical parameters, from centrifugal velocity to
cone angle and pond depth, are tailored to the task at hand by
Both the clarified phase and the removed solids are discharged GEA experts so that each customer achieves impeccable results
by gravity. In a typical continuous application, the solid content over a long service life.
in the liquid phase can be reduced to 0.1 percent or less.

GEA dryMaster – DECANTER

CENTRIFUGES FOR HIGH-SOLID LIQUIDS
Extensive adjustment options in this industrial centrifuge range
ensure reproducible ZLD results and advanced water savings.
 APPLICATIONS · 29

Protected from aggressive salts Economic and environmental advantage

In order to protect the machine and the operation from risks Clarification results of reliable and reproducible quality allow
due to corrosion, all wetted components that cannot be the plant operator to protect their main process from inadequately
manufactured from non-corroding materials can be protected clean water. Ensuring effective water management improves
by coating with suitable materials such as Hastelloy C, Duplex overall plant efficiency, saves operating costs and eliminates liquid
or Super Duplex stainless steel. waste streams, thereby protecting the environment.

Zero Liquid Discharge

10

11
9
10
4 5 6 8
2
1
12
3

13

14

15 16

1 RO reject to brine concentrator 6 Compressor 11 Process condensate

Zero liquid discharge
2 Heat exchanger 7 Brine concentrator blowdown 12 Plant steam
3 Distillate recycle to cooling tower 8 Crystallizer 13 Prime condensate
1 RO Reject to brine concentrator 7 Brine concentrator blowdown 13 Prime condensate
4 Distillate pump 9 Surface condenser 14 Crystallized solids
2 Heat exchanger 8 Crystallizer 14 Crystallized solids
5 Brine concentrator 10 Cooling water 15 Clarified decanter liquid to process
3 Distillate recycle to cooling tower 9 Surface condenser 15 Clarified decanter liquid to process
16 Suspended crystallized solids
4 Distillate pump 10 Cooling water 16 Suspended crystallized solids
5 Brine concentrator 11 Process condensate
6 Compressor 12 Plant steam
30 · TECHNOLOGY

Centrifuge
technology
Self-cleaning disk stack centrifuges
Self-cleaning centrifuges are used in many applications in the
chemical and petrochemical industry, meeting all demands for
continuous operation.

The centrifuges are equipped with a disk-type bowl and movable

sliding piston. The liquid is clarified fast and gently whereas
the solids are spun out into solids chamber. When the optimum
ejection point is reached, the movable sliding piston is opened
hydraulically. The solids are ejected in a fraction of a second
under operational speed allowing for maximum yield and
optimum energy consumption. The clarified liquid is discharged
foam-free and under pressure by means of a centripetal pump.
To prevent oxygen pick-up, these centrifuges can be delivered in
hydrohermetic (liquid seal) design.

Self-cleaning centrifuge for

optimum ejection intervals at
operational speed.
 TECHNOLOGY · 31

Centrifugal working principle • Innovative direct drive concept

The product to be separated enters the rotating centrifuge bowl – • No limitation of motor capacity
with a combined surface equivalent to 80 soccer fields. The • Motor control via frequency converter
higher density of the solids means they are forced towards the • Stress-optimized bowl design
bottoms and the outer solids discharge chamber. The remaining • Reduced weight, therefore reduced floor load
liquid in the disk stack is caught by a centripetal pump and • Easy top to bottom disassembly and bottom to top assembly
moved to the outlet pipe at the top end of the centrifuge. • Bayonet type nozzles for optimized flow pattern and reduced
service costs
Nozzle centrifuges • Continuous bowl speed and vibration monitoring
Nozzle bowl centrifuges are the optimum solution for products • External lubrication system for longer oil change intervals,
with a high solids content, e.g. polymers and plastics. They are better oil quality and simpler oil change
available with a washing system or concentrate recycling system • Monitoring and cooling of the lube oil feed
and direct drive in explosion-proof design. • Depending on size, available for high pressure applications of
up to 10 bar (g) overpressure and a temperature of up to 190  °C
The separated solids (concentrate) are continuously discharged • Process-wetted parts made of stainless steel alloys
through nozzles into the concentrate catcher. The solids • Special design available made of nickel-based alloy (depending
concentration depends on the throughput capacity, the feed on model)
concentration, the nozzle diameter and the bowl speed. The • Erosion protection
desired concentration can be adjusted by exchanging the nozzles
and regulating the throughput capacity. The concentrate flows To ensure that maximum performance is permanently achieved,
off under gravity from the concentrate catcher. the nozzle-type separators are also equipped with a special wear
protection against abrasion. This solution comprises coated wear
plates as well as a coating on the distributor bottom and the
bowl bottom.

• Upstream rotary brush strainers prevent clogging of

the nozzles
• Reliable protection against abrasion

Nozzle centrifuges are equipped with

a disk-type bowl with nozzles at the
periphery to discharge the concentrate
continuously.
32 · TECHNOLOGY

Solid-wall bowl centrifuges Only when the centrifuge slows down the liquid enters this
Solid-wall bowl centrifuges from GEA are used to achieve highest discharge area. The liquid discharges completely from the bowl
separation of two liquid phases with a very low or negligible and is collected in downstream tanks via the frame drain. CIP
solids content. Although the manual removal of solids cannot is facilitated as the product drains out without the need to open
always be avoided, protective clothing is no longer needed, as the bowl, for a significant increase of production time and
GEA provides the only solid-wall bowl centrifuges in the world decrease of downtime (also see next page).
where the bowls are completely drained by gravity. Only small
quantities of medium (often very toxic) remain in the bowl to be GEA hydrostop discharge system
cleaned manually. Proper washing cycles after stopping the bowl The GEA hydrostop discharge system can be adjusted precisely
can reduce that quantity even further. and reproducibly to specific solids concentration requirements.
This patented system discharges extremely quickly, reducing
The trick is extremely effective: Special drain holes keep “dry” the actual discharge time to less than one tenth of a second, and
during machine operation because of the centrifugal forces. permits partial discharge starting from one-minute-intervals.

GEA hydrostop system

Ejection via
metering piston

Former standard

0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2

With GEA hydrostop even small volumes can be discharged

reproducibly for much higher yields and better quality.
 TECHNOLOGY · 33

Centripetal pumps
The centripetal pumps enable the separating zones to be set
precisely even in conjunction with very high density differences.
This is the only way to achieve optimum separating efficiency
with nitroaromatic compounds. If the light phase is valuable, the
separating zone can be positioned towards the periphery of
the bowl, whereby the light phase can be allocated to the maximum
clarifying area.

At the same time, the twin centripetal pump can discharge the
heavy phase under pressure in an enclosed system. This is a
major advantage particularly in the case of explosive or aggressive
media. Unlike processes that discharge under gravity, nothing
can be discharged onto the hood of the centrifuge, avoiding the
risk of corrosion.

Metering piston ejection system for precisely metered discharge quantities. No electric pump, no costs: The mechanical centripetal pump
consists of a cylindrical disc equipped with channels and is installed
in the so-called centripetal pump chamber of the rotating bowl.
Metering piston discharge technology It is stationary, and its external periphery is immersed in the
The metering piston ejection system on GEA centrifuges offers rotating liquid. The liquid is discharged towards the center of the
advantages: pump through the channels, and the rotational energy of the
• When very precise partial ejections are not required liquid is converted into pressure. This means that an additional
• When only a low operating water pressure is available (2 bar) pump is not necessary, thus achieving savings in investment and
• When minimal operating liquid consumption is desired operating costs.

The mechanism ensures complete discharges of the bowl and, in

this way, allows a high level of operating reliability. After the
metering device has been filled with the exactly pre-set quantity
of water compressed air is led into the lower chamber of the
metering device. When the opening water valve has been operated,
the compressed air acts on the piston of the metering device, and
the set quantity of water is injected into the opening chamber.
This ensures very precise discharge quantities to be achieved.

The pair of centripetal pumps for maximum separating efficiency.

Image: solid-wall bowl
34 · TECHNOLOGY

Decanter centrifuges

Decanter centrifuges have been developed over decades by GEA The liquid flows to the opposite end. Remaining impurities
for high clarifying performance and the maximum possible are spun out by centrifugal force as the liquid flows through
degree of solids dewatering. Essential conditions for this include, the clarifying zone and is conveyed by the scroll to the solids
among others, high bowl speed and an adequate gear torque in discharge. The clarified liquid is discharged by centripetal
conjunction with a control system to synchronize differential pumps or gravity.
speed and solids load.
Decanter centrifuges are equipped with 3-phase AC motors
Decanter separation principle with frequency converter. This allows start-up current and
The product enters the decanter centrifuge through the feed current peaks on start-up to be reduced. The power is
tube and the distributor conveys it into the separating chamber transferred by belts and gear.
where it is accelerated to operating speed. The centrifugal
force quickly causes solid particles to sediment on the bowl The current GEA ecoforce decanter generation is extremely robust
wall. The cylindrical section of the bowl allows for an effective and uniquely combines excellent performance with a significant
clarification of the liquid, whilst the solids are dried in the reduction of power consumption. Machines can be adapted
conical section. The scroll rotates slightly faster than the bowl and even subsequently modified to individual process needs
shell and conveys separated solids continuously towards the with 2-phase or 3-phase design, varying gear sizes, lubrication
narrow end. Due to the conical shape there, the solids are lifted systems, differential speed ranges, bowl designs and
from the liquid, dewatered by centrifugal force and discharged. liquid outlets.

2-phase decanter centrifuge

1 Feed 5 Conical section
2 Clarified liquid discharge 6 Scroll
3 Solids discharge 7 Regulating rings
4 Bowl
7
6
4 1
5

3
 TECHNOLOGY · 35

x kW

GEA varipond
The pond depth in the decanter is an important parameter with
which various performance parameters can be influenced. The
GEA varipond system gives the user the opportunity to alter
y kW

the pond depth to GEA varipond adapt to specific conditions

x+y kW during ongoing operation. The GEA varipond disk dips into the
clarified liquid phase directly in front of the regulating ring.
This disc forms a hermetic chamber (GEA varipond chamber)
together with the centripetal pump, to which pressure can
GEA summationdrive with intelligent kinematics ensures high differential be applied through a hole in the feed tube. Since the liquid
speeds and torques, which enables processing of high solid capacities.
level between the GEA varipond disk and the regulating ring
is defined by the overflow diameter, overpressure in the GEA
GEA summationdrive varipond chamber has the effect of enlarging the pond depth
The decrease in power consumption of up to 30 percent is in the bowl according to the principle of communicating tubes.
mainly realized by the GEA summationdrive available as a As a result, the clarification area is enlarged. The process
standard in all GEA models. This high-torque drive with operator can thus adjust dewatering and clarification efficiency
intelligent kinematics for high differential speeds and constant with precision. Particularly in the case of gas-tight decanter
torques reliably provides the optimum differential speed for the centrifuges, the GEA varipond system has the advantage that
specific process, which in turn ensures maximum performance it requires no mechanically adjustable parts such as rotary
and high separating efficiency. joints. It therefore provides a high level of protection against
• Full torque up to the maximum differential speed for high discharging harmful gases.
solid capacities
• High efficiency since variable-speed motor feeds energy and
does not brake
• Automatic adaptation of the differential speed by frequency-
controlled motor
• Good accessibility to all drive parts
• Changing differential speed without replacing the
complete gear

GEA varipond system for efficient and cost-saving operation,

particularly in the case of changing feed conditions.
36 · TECHNOLOGY

Maximum-protection solutions

High-temperature and high-pressure applications Wear protection with robust hard-facing

Many applications in the chemical industry require operating Many processes expose decanter and disk stack centrifuges to
the process at elevated temperatures, for example hot wax extreme material strain. For maximum wear protection, GEA
clarification, production of amines, petrochemical additives, installs hardfacing as required to all points of a decanter where
catalyst recovery and fluid gases. increased levels of wear can be expected, particularly when the
machine is used for processing very abrasive solids.
As a solution, GEA offers continuous high-temperature clarification
with specially designed centrifuges. The pressure-stressed One possible solution is spray cladding in which carbide is
components hood, solids catcher and protective hood have welded onto the exposed parts of the centrifuge, for example:
been rated to meet the specific requirements of the European • The vane of a decanter scroll
Pressure Equipment Directive and the American ASME code. • The distributor of different centrifuge types
• The sliding piston of a self-cleaning separator
By way of example, nozzle separators can only separate particles
suspended in viscous liquids effectively when their viscosity is Other wear points particularly well protected by GEA are the
reduced by increasing the temperature, in some cases to around points at which the solids are discharged through the solids
190 °C. Since many carrier liquids would evaporate at these discharge ports, and the suspension inlet holes of the distributor.
temperatures at atmospheric pressure, the pressure must be kept However, these ports are not protected in the same way, as even
at around 10 bar. Pressure-proof segregation of the product space hard metal welded on to the surface in this area would erode
from the drive chamber is achieved by means of a double-acting over a relatively short period and would require expensive repair
slide-ring packing. Stainless steel alloys are used as standard work. Instead, GEA uses special sintered hard metal sleeves that
for process-wetted parts. Depending on model, nickel-based alloys provide a much higher abrasion resistance. These sleeves wear
are also available, as are suitable elastomers like FKM and FFKM down on one side but can be easily turned around. Users must
or other specific gasket materials. replace the sleeves only when both sides are worn. This requires
much less maintenance compared with welding and results in
Self-cleaning disk stack centrifuges are successfully used in considerably higher availability of the decanter. An elegant and
applications at process temperatures up to 140 °C. This proves customer-oriented method of ensuring that wear on the solids
high mechanical reliability. Special care is taken on the choice discharge is manageable.
of materials, especially gaskets. Development of new polymer
materials now makes it possible to use polymers for the bowl Special materials
main gaskets instead of expensive steel-on-steel gaskets. The proper tool for the job – this is the principle according to
which GEA selects materials, considering corrosion resistance
as well as mechanical strength. Because mechanical strength
can be extremely important, suitable centrifuge materials
are accordingly selected with utmost care and in some cases
specially developed by GEA experts.
 TECHNOLOGY · 37

Standard materials offered by GEA are stainless steel alloys and,

depending on the type of centrifuge, nickel-based alloys:
• Duplex or in some cases Super-Duplex for disk stack centrifuges
• Duplex, Super-Duplex or Hastelloy for decanter centrifuges
• Inconel for especially corrosion-proof components
• Hastelloy or e.g. Incoloy for solid-wall bowl centrifuges
with cladding

Explosion-protected centrifuges
Centrifuges are used in the chemical industry for clarifying and
separating flammable liquids. Theoretically, such applications
can result in critical concentrations of solvent vapors and
oxygen inside the centrifuge housing that can cause explosions
or fires. Furthermore, process vapors must not leak from the
centrifuge as not to pose a risk to the health of operators and
the environment. Both these risks can be prevented reliably
by using gas-tight centrifuges from GEA. No sparks, no static
charges, no hot bearings – the test criteria of the strict European
ATEX standard are of course implemented in all GEA
explosion-protected centrifuges. In addition, before the start of
operation, the centrifuge is purged with inert gas and blanketed
with a slight excess pressure so that no further oxygen can
penetrate. This is because fire is not possible without oxygen.
When processing hazardous liquids, the necessary inert
gas atmosphere in the centrifuge is automatically monitored
throughout the entire operation.
38 · TECHNOLOGY

An essential design feature of the gas-tight centrifuges from is displaced with inert gas before every start-up and the
GEA is the gas-tight sealing chamber that separates the drive excess pressure is maintained during operation to meet the
area from the product chamber. This sealing chamber is blanketed requirement for minimum inert gas consumption. The fittings
with inert gas, and the connecting spindle is protected with and measuring devices used have been subjected to extensive
dynamic special seals. The sealing chamber reliably prevents tests and have also been optimized as far as investment costs
the solvent from passing from the product chamber to the drive are concerned. The new inert gas supply facility complies with
area or into the environment. This is beneficial not only from the ATEX 2014 / 34 / EC directive but also with the TA Luft,
the point of view of fire and health protection, it is also not which means that product leakages from the equipment are
possible for solvent to dilute the oil, which would diminish its reduced to a minimum using state-of-the-art technology.
lubricating efficiency and thus pose a risk to the drive unit. In
reverse, no oil can penetrate the product chamber and impact GEA places great emphasis on complete and easy-to-understand
the quality of the valuable product. operator documentation as well as a carefully performed conformity
assessment procedure (CE symbol). The company also provides
According to the current ATEX 2014 / 34 / EC directive, a risk information concerning the correct installation of centrifuges
assessment of the relevant machines must be carried out to in zones that are exposed to the risk of explosion. Depending
identify any present or potential risks. Measurements are on the plant operation, the integration of a gas-tight centrifuge
documented and submitted to an Entitled Body. For this, GEA varies from plant to plant. With GEA expertise, our customers
centrifuges are equipped with failsafe vibration monitoring will find the optimum solution for their particular needs.
equipment and often also with a bearing temperature
measurement unit and an inert gas supply unit. All electrical
equipment carries an ATEX certificate or a manufacturer’s
declaration.

Improved inert gas concept

Requirements about safety and reliability are becoming more
stringent for centrifuges used in zones with a risk of explosion.
The inert gas concept from GEA is constantly improved to
meet these requirements. The atmosphere in the centrifuge

CE 346 package unit

 GEA Service · 39

GEA Service –
For your continued success
GEA Service offers dedicated teams of service experts. Our • Getting you started – Seamless support for instant
focus is to help our customers build, maintain, and improve productivity and performance
their performance, market presence and competitive edge for • Keeping it running – The cost-efficient way of
the entire life cycle of their plants and equipment. ensuring safety and reliability
• Constantly improving – Sharing our knowledge
Partnering with GEA gives you the benefit of our world- to safeguard your investment
renowned, customer-tailored service and recommended spares • Together with you – Enduring commitment to you
upgrade, modernization and optimization services. With our and your business
support you can be certain that every piece of GEA equipment
and technology will operate optimally from day one, and for
its complete lifespan, to give you maximum return on your
investment.
We live our values.
Excellence • Passion • Integrity • Responsibility • GEA-versity

GEA is a global technology company with multi-billion euro sales operations in more than 50 countries. Founded in
1881 the company is one of the largest providers of innovative equipment and process technology. GEA is listed in
the STOXX® Europe 600 Index. In addition, the company is included in selected MSCI Global Sustainability Indexes.

B_CP-18-05-0015 EN © GEA Westfalia Separator Group GmbH. All rights reserved. Subject to modifications.

GEA Germany
GEA Westfalia Separator Group GmbH
Werner-Habig-Straße 1 Tel +49 2522 77-0 sales.germany@gea.com
59302 Oelde, Germany Fax +49 2522 77-2488 gea.com