Decanter Training

Foodec 310 / 510

By:
Tetra Pak Dairy,
y, Beverage
g &
Prepared Food
Soya & Tea Centre
Contents of Training

• Foodec Decanter
• Decanter Anatomy
• Decanter Optimization
• Decanter CIP
• Maintenance
M i t & Operation
O ti Guide
G id
F d Decanter
Foodec D t
Foodec Decanter for soya milk
and other grains
Foodec Decanter
Cut Away View – Alfa Laval Decanter
Groove bowl with steep cone

Baffle disc
Full CIP enable system
Conveyor – Pro-T,Esbjerg, BD
Variable New
Pitch Replaceable
Inlet zone
DCC and Direct Drive system
Decanter Animation
D
Decanter
t A Anatomy
t
Why - Decanter Anatomy

X Learn
to use the right
g expression
p for the
components, so we all speak the same language
X To get an idea of how the decanter is built.
Main Component
¾ Bowl Heart of the Decanter
¾Screw Conveyor Body of the Decanter
¾ Gear Box Power of the Decanter
¾ Back Drive Intelligence
g of the Decanter
¾ Casing Attire of the Decanter
¾ Frame Foundation
¾ Covers Appearance
¾ Motor(s) makes the World goes round
 Main Component
Screw Conveyor - Heart of the Decanter

Choice of Body Flight Outlet hole for Feed Inlet for Inlet Pipe
Screw Conveyor
is:
Application
Dependant Screw conveyor with coarse pitch

Screw conveyor with fine pitch

We need a Bowl for the Screw Conveyor

Main Component
Bowl - Body of the Decanter

Big End Hub Cylindrical Part Conical Part Small End Hub

Solids Discharge
g
Openings

Let us make a Cut-Away and find the Liquid Discharge Openings

 Main Component
Bowl - Body of the Decanter

Solids Discharge
Liquid Discharge
Openings
Openings

Hole for Spline Shaft Hole for Inlet Pipe

and
Protecting Pipe
Cut Away view of the Bowl

Let us put a Screw Conveyor into the Bowl

Main Component
Fitting the Screw Conveyor - Bowl Preperation
We put on the solids discharge wear protection

We fit the inner race for conveyor bearings

Big end hub Small end hub

Let us now prepare the Screw Conveyor

 Main Component
Fitting the Screw Conveyor – Preparation

We fit the ball bearing afterwards Spring loaded bearing

is fitted hereafter

Protecting pipe
is fitted first
Here we fit the angular contact bearing
It takes the axial force from the solids transport Needle bearing
is fitted last

Now we can fit the Screw Conveyor into the Bowl

Main Component
Assembly of the Bowl - Conveyor

Cylindrical part Conical part

Big end hub Small end hub

Spline shaft

Screw Conveyor with bearings and protecting pipe

Now we can fit the Main Bearings to the Shafts

 Main Component
Assembly of the Bowl - Continued

Main Bearing - Gear Box End Main Bearing - Pulley End

(Roller Bearing for axial expansion) (Ball Bearing for axial fixing)

Gear Box (Power of the Decanter) and Pulley is next

 Main Component
Complete Rotating Assembly

Gear Box for Screw Conveyor

y Drive Pulley for Drive of Bowl

Size of Gear Box

is
Application dependant

A Frame (Building Foundation) is needed for the Rotating Assembly

Main Component
Frame - Building Foundation

Frame Design NX Decanters

The Frame has to stand on Rubber Dampers

The Frame has integrated Casing for the Bowl

i l di li
including liquid
id discharge
di h and
d solids
lid discharge
di h flanges
fl
Main Component
Frame - Building Foundation

Now assembly of the Complete Decanter can start

Rubber Dampers

We begin with the Rotating Assembly

 Main Component
Decanter in Assembly Department

Rotating assembly

Frame with Rubber Dampers

Now follows the Main Motor (Makes the World Go Round)

Main Component
Decanter in Assembly Department

Number of V
V-Belts
Belts
depends on Motor Size V-Belt Transmission

Diameter of Motor Pulley

determines the Bowl Speed

Main Motor Size depends on

Inlet Pipe is next Process Power Demand and type of Starter
 Main Component
Decanter in Assembly Department
Length and type of Inlet Pipe
depends
p on Screw Conveyor y
and Application
Holder for Inlet Pipe

Now the Back Drive System (Intelligence of Decanter) follows

 Main Component
Decanter in Assembly Department

Type of Back Drive System

depends on Gear Box and
Application Demand Flexible
Clutch

Let us Dress the Decanter! We put the Cover for the Casing on.
Main Component
Decanter in Assembly Department

Decanter with Complete Casing

Main Component
Decanter in Assembly Department

An Alfa Laval Decanter is born

D
Decanter
t Optimization
O ti i ti
 The Decanter Centrifuge Nomenclature

Differential Speed (Δn)

= bowl rpm - conveyor rpm Pitch
Liquid Δn
weirs N

Pond depth r Q
(R – r))

Pond B
Beach
h Solids
ports
 How to Optimise a Decanter
Δn
N

r Q

Process parameters Decanter Design (Set-up)

• Feed
F d rate
t (Q) • Bowl
B l speed
d ((g-force)
f )
• Particle Size (Polymer addition) • Conveyor differential (Δn)
• Viscosity (heating) • Pond depth (R- r)
 Process Parameters Influence
d (ρ p − ρ1)
2

Vc = ×rω 2
18 η
Feed Rate (Q) P i l Si
Particle Size Viscosity
Separation efficiency
Separation efficiency Separation efficiency
Separation efficiency Separation efficiency
Separation efficiency

Feed rate Particle size Viscosity

 Bowl Speed
p ((G - force))
Δn
N

r Q

Recovery of
suspended solids, % Cake solids, %

Bowl speed (N) Bowl speed (N)

 Pond Depth Steep Cone Decanter
Baffle Disc
Shallow Pond

Deep Pond

Solids recovery % Cake solids,

solids %

Shallow p
Deep Shallow Deep
p

+ ÷ + ÷
Conveyor Differential (Δn)
Dirty Centrate Δn Dry Cake

Clear Centrate
Δn Wet Cake

Too high differentials (Δn) Too low differentials (Δn)

• Clean centrate • Dirty centrate
• Wet cake • Dry cake
• The volume of the decanter is • High conveyor torque
not fully utilised
• Low conveyor torque
 Automatic Torque Control
Clear Centrate Dry Cake

Δn
Ideal operation

Constant conveyor torque is equal to constant sludge amount in the bowl

What to do What causes the change

When
Feed solids variations
Conveyor torque higher than setpoint IIncrease Δn
Δ Feed flow changes
Conveyor torque lower setpoint Decrease Δ n

Constant conveyor torque is equal to consistent performance

Decanter Optimisation

Summing Up:

• Sett Pond
S P dL Levell
• Set Flow Rate
• Adjust
j Back Pressure for Paring
g Disc
• Adjust Conveyor Differential (Δn) for optimum
dryness and clarification
• Notice Conveyor Torque - for Automatic Torque
Control
• If Process Performance is not acceptable then start
f
from the
th top
t again.i
D
Decanter
t CIP
Cleaning In Place (CIP)

Take a close look to the coming

picture and I hardly need to tell
you

Where does a decanter get dirty when used?

Pollution of the Decanter during Operation
Let’s take a look on the Casing
g
Mist from process liquid Mist from process solids
may accumulate in the will accumulate in the
casing casing
Pollution of the Decanter during Operation
Let’s take a look inside the bowl
A layer of solids form The conveyor body and the
between decanter body inlet area in the screw
and screw conveyor tip conveyor is dirty
High Speed CIP
We feed the decanter with full capacity and chemicals, but
what happens?
Velocity of the liquid is only high enough to clean the piping,
decanter inlet zone and paring disc.
Everything else is still dirty. WHAT CAN WE DO?
 High Speed CIP
Use CIP
CIP-pipe
pipe with nozzles in the casing to flush the dirt off the
external of bowl and inside the casing.
Clarified CIP liquid from decanter liquid discharge can be used for
the no
nozzles
les
The high bowl speed will provide the mechanical cleaning impact
onto the casing and bowl
High Speed CIP
Now the bowl external outside and inside the casing is clean
However the inside of the bowl & conveyor is still dirty
How do we solve the problem?
p

Use Low Speed CIP

Low Speed CIP
With tumbling of the decanter at approx 1g and CIP solution fed
to the decanter at low capacity. This acts like the washing liquid
in a washing machine.
Solids at the bowl is washed off
Conveyor body and flight is cleaned

Low speed tumbling Low speed tumbling

clockwise Ù counter clockwise
Typical CIP-Program for a Decanter
Maintenance
M i t &
Operational
Guide
 Daily Operational Checkpoints
Cleanliness. Look for oil spills, grease spots, liquid spills etc
Check machine vibration
Check bearing and general machine noise
Look for loose nuts, bolts or screws etc. Tighten if necessary
Check temperature of grease lubricated main bearings
Look for oil leaks from gearbox
Check conveyor torque
Check flexible connections for deterioration and leaks
Check general condition of vibration isolators
Weekly - Check the CIP Nozzles

E
Ensure th t there
that th is
i no blockage
bl k
SAFETY FIRST
1 ENSURE ELECTRIC POWER IS CUT
1. CUT-
OFF TO MACHINE

2. ENSURE MACHINE HAS COME TO A

STANDSTILL BEFORE OPENING
COVER

3. LOCATE GREASING POINT BY

LOOKING OUT FOR THIS SYMBOL
LUBRICATION SCHEDULE
ACCORDING TO SERVICE BULLETIN SB_9807_2
Main Bearings
Standard time interval for lubrication of main bearings is 300 operating
hours for operation temperatures less then 70 degrees C and 150
operating hours for higher then 70 degrees C.
For Foodec 310T – it is 9 grams or 6 strokes per lubrication
Conveyor Bearings
The conveyor bearings should be lubricated after every 2 x CIP.
For Foodec 310T – it is 24/500 X 30 grams or 2 strokes per lubrication

PLEASE REFER TO SERVICE BULLETIN FOR COMPLETE

LUBRICATION GUIDE
Lubricate Main & Conveyor Bearings

Main Bearing
Grease: SKF LGHP2
Lubricate when bearing
g
temperature is below 80
degrees C and at low speed

Conveyor Bearing
Grease: Texaco Cynus CSC EP2
Lubricate when machine at
standstill

Always use the recommended lubricants

Lubricate Main & Conveyor Bearings
Main Bearing
Grease: SKF LGHP2
Lubricate when bearing
temperature is below 80
degrees C and at low speed

Conveyor Bearing
Grease: Texaco Cynus CSC EP2
L b i t when
Lubricate h machine
hi att
standstill

Al
Always use the
th recommended
d d llubricants
bi t
Monthly - Remove feed tube and check for
clogging in feed inlet and cleanliness
 Decanter Venting

Air Flow is not possible due to BD seal

Air Flow is limited by the feed and discharge connection
Air Flow when discharges are open or correctly vented
Air Flow When venting is not correct
Venting is Important

CAUSE EFFECT
 Other Important Checkpoints
Check Belt Tensions
Check Gearbox Oil level and lookout for contaminants
Check Seating Torque of Main Bearing Pillow Block Bolts
Check for Corrosion – Inside Casing and Bowl Exterior
Check Wear Sleeves or Bushings
g at Solid Discharge
g for Abrasions
Check Function of Emergency Stop
Check Function of Vibration Switch
Check Function of Cover Switch
Change Gearbox Oil
Plan for Intermediate and Major Service
Remember the Motors Also Needs Servicing
REFER TO OM FOR COMPLETE
MAINTENANCE INSTRUCTIONS
Th k You
Thank Y