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CHAPTER 1
DESCRIPTION OF THE CENTRIFUGE

1.1 GENERAL EQUIPMENT DESCRIPTION

The ANDRITZ high performance centrifuge uses centrifugal force to separate liquids and solids.
Whether the centrifuge operates as a fully contained thickener or a dewatering device, precise
optimization is attainable with internal configuration options. The feed slurry is introduced to the
centrifuge through a stationary feed tube and is distributed into the rotating bowl. The solids are
separated from the liquid by centrifugal force. The action of a scroll conveyor, rotating at a
differential speed compared to the bowl, transports the solids to cake discharge ports. The centrate
flows axially back toward the feed end, exiting over adjustable weirs.

The maximum overall dimensions of the centrifuge are 317 inches long by 85 inches wide (with
shock absorber plate) by 90 inches high, excluding the oil lubrication unit. See Table 1-1.

The centrifuge is supplied complete and includes the frame, solid bowl decanter, conveyor tile
assembly, anti-vibration isolators, adjustable weirs, in-line drives and Cyclo gears, torque control
and electrical controls, and an oil lubrication unit. Duplicate parts are interchangeable.

All 316 stainless steel construction that requires welding is supplied with 316L grade stainless
steel.

Ancillary information such as brochures and illustrations are found at the end of this chapter.

TABLE 1-1. CENTRIFUGE CHARACTERISTICS

Length 317 inches
Width 85 inches with shock absorber plate
Height 90 inches
Weight with Drive 50,706 lb
Product Feed 4-Inch ANSI Flange
Solids Outlet Flange: 57.125 x 22.5625 inches ext
Centrate Outlet Flange: 57.125 x 16.1875 inches ext

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1.2 CENTRIFUGE PERFORMANCE

The D12LLU30CHP centrifuge continuously receives, flocculates, conditions, and thickens the feed
sludge specified herein, and neatly discharges the thickened sludge into a hopper or conveyor.

The centrifuge is designed to operate continuously or intermittently on demand. The centrifuge is

suitable for thickening the specified sludges continuously for 24 hours per day, 7 days a week, and
is designed to perform the required thickening operations as shown below.

TECHNOLOGICAL DATA
Medium to be thickened Primary and waste activated sludge
Blend ratio: 40–45 % primary/ 60–55 % WAS
Feed solids Primary: 0.3–0.6 %; WAS: 0.7–0.8 %; blend: 0.5–0.7 % TS

CAPACTIY REQUIREMENTS
Number of units 4
Hydraulic loading 1,000 to 1,500 gpm
Solids loading 3,503 lb/hr DS
Sludge volume index (WAS) 60–120
Machine type D12LLU30CHP thickening centrifuges with Easy Pond
Guaranteed cake solids 6.0 to 8.0 %
Guaranteed capture rate 90 %
Guaranteed polymer dosage 6.0 lb/dry ton of feed TSS

PERFORMANCE TEST CONDITIONS

Medium to be thickened Primary and waste activated blend
Blend ratio 40–45 % primary/60–55 % WAS
Blended feed solids 0.5–0.7 % TS
Hydraulic loading 1,000 gpm
Thickened sludge 6–8 % TS
Polymer dosage 6.0 lb/dry ton of feed TSS
Capture rate 90 %

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TABLE 1-2. DESIGN SPECIFICATIONS

Nominal absolute speed 1,400 rpm
Maximum safety absolute speed 1,800 rpm
SPEED
For maximum density of sludge 1.2
Variable relative speed 1 to 22 rpm
Bowls Duplex
Scroll Stainless steel 316 L
MATERIALS
Scroll flight coating REV 12
Seals in contact with product BUNA-N
Make — size/ratio ZS PN 624/360-53
CYCLO REDUCER
Lubrication ELF Carter EP 100
BLOCK BEARING Lubrication ELF Carter EP 68 Oil
Level Adjustment Plates 602 to 652 mm
LEVEL ADJUSTMENT
Conical bowl overflow 612 mm
DRIVE MOTOR BOWL SCROLL
Make Baldor Reliance Baldor Reliance
Type Custom Custom
Power 500 HP 75 HP
VFD BOWL SCROLL
Make AB PowerFlex 700 Series AB PowerFlex 700 Series
Power 500 HP 75 HP
BELTS XPC 3150 Set of 8
PULLEY RATIO 0.941
WEIGHT: 50,706 lb

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1.3 CENTRIFUGE COMPONENT DETAILS

The centrifuge components are described in the following sections. See Table 1-3 for materials of
construction for centrifuge components.

TABLE 1-3. MATERIALS OF CONSTRUCTION

Cast parts (bowl) Stainless Steel AISI 316L
Bowl Duplex (1.4470)
Frame Painted Steel
Cover Stainless Steel

1.3.1 Bowl

The bowl consists of a horizontal cylindrical conical assembly. See Table 1-4. The bowl is
manufactured from a centrifugal cast 316 or Duplex stainless steel. The bowl is machined and
balanced to withstand all centrifugal forces encountered at design operating speeds with adequate
safety factors. Bowl thickness in the cylindrical section is 1.14 inches and is 0.98 inches in the
conical section. The bowl is thoroughly inspected for cracks, shrinkage, porosity or other defects by
means of a liquid dye penetrate test as part of the construction process.

The inside bowl length is 173.23 inches with an inside diameter of 44.09 inches. The bowl is
supported on a cylindrical roller bearing at both ends of the centrifuge. Each end is fitted for
connection to the oil lubrication unit.

The pond depth in the centrifuge bowl is adjusted using weirs at the large diameter (front) end of
the bowl where liquid is discharged. Cake solids are discharged from the small diameter (rear) end
of the bowl, opposite from the liquid discharge.

Sludge feed is introduced to the bowl through a zone that evenly distributes the feed. The internal
scroll conveyor rotates at a slight differential speed from the solid bowl and is supported by grease-
lubricated ball bearings.

The bowl is manufactured with longitudinal strips and prevents circumferential slippage of
sediment solids that cause formation of a protective feed solids layer. Field-replaceable sintered
tungsten carbide inserts protect the solids discharge ports. The bowl drive is supplied with a
500 hp main drive motor that delivers 2,035 maximum G’s at 1,800 maximum rpm.

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TABLE 1-4. BOWL CHARACTERISTICS

Inner diameter 44.09 inches
L/D ratio 4
Total length 173.23 inches
Nominal speed 1,400 rpm
Maximum Speed 1,800 rpm
G-Value at maximum speed 2,035
Conical part angle 11 degrees
Equivalent surface at maximum "G"; conical bowl 19,773 square meters
excluded (212,835 square feet)
Equivalent volume at maximum "G"; conical bowl 4,278 cubic meters
excluded (1,130,128 gallons)
Total length of rotating assembly with pillow blocks 263.39 inches
Total rotating assembly weight with pillow blocks 24,516 lb

1.3.2 Main Bearings

Two main bearings support the entire rotating assembly. Pillow block bearings are supplied with
cylindrical roller and are equipped with connections to the oil lubrication unit. Bearings have an
AFBMA life of 100,000 hours minimum. See Table 1-5.

1.3.3 Scroll

The centrifuge includes a stainless steel horizontal cylindrical-conical scroll supported by a ball
bearing at the feed (front) end and ball bearings at the gearbox (rear) end and is equipped with
helical flights independently mounted concentrically within the centrifuge bowl. Bearings are
protected by seals and have external grease fittings for lubrication. The scroll feed zone is
internally coated with flame-sprayed tungsten carbide on the wearing surfaces. The scroll is driven
by a 75 hp back drive motor. See Table 1-5.

The scroll edge and face of the flights are protected against abrasion with replaceable sintered
tungsten carbide tile assemblies from the feed zone to the solids discharge of the scroll. Each tile
assembly is affixed to the conveyor flight by an electric-welding attachment procedure.

1.3.4 Base

The centrifuge is supported on a fabricated carbon steel base mounted on vibration isolators. The
vibration isolators are provided to isolate the centrifuge frame from the building structure. The
isolators are specifically sized for the bowl speed and service conditions so that they dampen 98%
of all vibration loads in all directions. Machined surfaces are provided at all points where support
loads are transferred to the base. Lifting holes in the base are provided as required for lifting the
base with an overhead crane.

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1.3.5 Casing

A one-piece stainless cover is constructed to act as a protective guard from the bowl assembly also
providing complete enclosure for both noise reduction and odor control.

This cover is fabricated with replaceable stainless steel wear liners in both the solids and liquid
discharge areas of the cover.

The bowl assembly cover is bolted directly to the main frame of the centrifuge.

1.3.6 Guards

OSHA-approved totally enclosed fiberglass guards are provided over belt drives and back drive
components for noise reduction.

1.3.7 Feed Tube

The feed tube is type 316 SS and is field replaceable.

1.3.8 Polymer/Sludge Feed Manifold

A polymer/sludge feed manifold assembly is provided for the injection of polymer into the feed
stream.

1.3.9 Cyclo Reducer

Each centrifuge is equipped with a two-stage Cyclo reducer that controls the differential speed
between the centrifuge bowl and scroll. The gear has a torque capacity to meet the expected service
conditions. A torque overload control is provided to initiate centrifuge shutdown in the event of
scroll overload. The gear ratio has been selected to handle the required solids loading and to be
consistent with satisfactory operation. The gear unit is oil lubricated. All standard units are
provided with seals of Nitrile-Butadiene-Rubber (NBR 3760). The power transmitting elements are
made of bearing steel, hardened, tempered, and ground. The torque capacity of this gearbox
exceeds the requirement of 220,000 inch-pounds.

1.4 CENTRIFUGE DRIVE MOTORS

The centrifuge motor information is summarized in Table 1-5.

1.4.1 Main Drive Motors

See Chapter 3, Centrifuge Operation.

1.4.2 Scroll Back Drive Motor

See Chapter 3, Centrifuge Operation.

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TABLE 1-5. CENTRIFUGE MOTOR DRIVE LIST

BOWL DRIVE:
Manufacturer: Baldor Reliance Inverter Duty
Model: Custom Part Number
500 hp, 460 VAC, 3-phase, 60-Hz, 1793 rpm, G5012Y frame, 1.0 service factor, TEFC, 40 ºC
ambient, continuous duty, oversized F-1 mounted main conduit box, separate 120 VAC space
heater terminated in separate conduit box located on F2 side; 563 amps; Class F insulation;
Motor Data: inverter spike-resistant wire; 100-ohm PT 100 RTDs, two per phase (six total) brought to a single
conduit box mounted on the F2 side; a single 100-ohm RTD mounted on each bearing (two total)
and wired directly to the COP; insulated bearings provided; provisions are made for mounting three
accelerometers and wiring each directly back to the COP; 10:1 constant torque.
Paint: RAL 5011, Andritz dark blue

SCROLL(BACK) DRIVE:
Manufacturer: Baldor Reliance Inverter Duty XE Premium Efficiency
Model: ECP4404T-4
75 hp, 460 VAC, 3-phase, 60 Hz, 1185 rpm, 405T frame, 1.0 service factor, TEFC, 40 ºC ambient,
continuous duty, oversized F1 mounted main conduit box with 120 VAC space heater terminated
within, 86.9 amps; NEMA Design B, Class F insulation, inverter spike-resistant wire, thermistors
Motor Data: (three total) brought to a single conduit box mounted on the F2 side, a single 100-ohm PT100 RTD
mounted on each bearing (two total) and wired directly to the COP; insulated bearings provided;
provisions are made for mounting three accelerometers and wiring each directly back to the COP;
10:1 constant torque.
Paint: RAL 5011, Andritz dark blue

EASY POND SERVOMOTOR

Manufacturer: Allen-Bradley MP Series Food Grade Motor
Model: MPL-B320P-MJ24AA
3.05 Nm continuous stall torque (1.5 kW), 480 VAC, 3-phase, 60 Hz, 5,000 rpm, IP 66 and IP 67
Motor Data:
rated, 40 ºC ambient, integral 24 VDC brake
Paint: RAL 5011

EASY POND GEAR BOX

Manufacturer: Alpha-Wittenstein Two-Stage Right-Angle Gear Box
Model: SPK075S-MF2-26-1E1
Right-angle design, 25:1 gear ratio, max speed input 6,000 rpm, 94% efficiency at full load, IP 65
Data:
protection class
Paint: RAL 6011

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1.5 CENTRIFUGE INSTALLATION INFORMATION

See Table 1-6 for a summary of centrifuge characteristics.

1.5.1 Anchor Bolts

ANDRITZ supplies all anchor bolts as specified for mounting the centrifuge (refer to the
foundation drawing (F804831-1, rev 6).

1.5.2 Vibration Isolation

The centrifuge is mounted on Solymar isolators rated for the load and impact associated with
normal operation. The centrifuge is provided with vibration monitoring for sensing vibration and
will automatically shut down the centrifuge in the event of excess vibration. The equipment will
not exceed the 0.24 in./s RMS required by the specification under “Dry Shop Testing Conditions.”

1.5.3 Noise

The centrifuge is equipped with sufficient vibration absorption materials so that the average noise
level measured at 3 feet around the periphery of the centrifuge does not exceed 86 dBA when
tested at the factory at nominal speed.

1.5.4 Fasteners

All fasteners are ASTM A320 type 316 stainless steel.

1.5.5 Flexible Joints

ANDRITZ supplies all synthetic rubber flexible joints for the sludge feed, centrate, and solids
discharge connections

TABLE 1-6. EQUIPMENT DATA

SCROLL
Scroll design High performance
Discharge parts Field replaceable
For dismantling purposes:
Total length of scroll with handling hoist and bowl plate 156.0 inches
Corresponding weight to lift 2,933 lb (including lifting beam)

GEARBOX
Type Cyclo reducer
Nominal torque value 228,350 in.- lb

MAIN CENTRIFUGE BEARINGS

Type FAG / SKF
Lubrication Oil

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TABLE 1-6. EQUIPMENT DATA

AFBMA L-10 100,000 hours minimum

POND DEPTH ADJUSTMENT

Type Easy Pond
Drive Servomotor

WEAR PROTECTION
Inner bowl surface Integral cylinder and cone grooving
Scroll Replaceable sintered tungsten carbide tiles
Vickers hardness of the carbide grains 2,500 to 4,000
Scroll feed chamber (distributor) Sintered tungsten carbide nozzles
Bowl discharge (diffuser) Sintered tungsten carbide nozzles
Average life span 16,000 hr /2 years

ANTICORROSION PROTECTION
Frame and parts in cast iron or steel RAL 5011
Standard epoxy paint (dry coat minimum thickness) 12.0 mils
Primer 2.5–3.0 mils
Second coat 4.0 / 6.0 mils
Finish coat 4.0 / 6.0 mils

SEALS

Type BUNA-N
Maximum temperature admissible 175 ºF

NOISE LEVEL
Measured at nominal speed from 3 feet while empty 86 dB (A)

MISCELLANEOUS
Minimum sludge feed pressure 20 psi
Minimum polymer feed pressure 25 psi
440 gpm for 15 minutes at each stop @ 45
Wash water flow rate to 75 psi
Air flow (to vent) 580–885 cfm

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1.6 CENTRIFUGE CONTROL SYSTEM

Each centrifuge is supplied with a centrifuge starter panel, a centrifuge operator panel, and a
servo control panel shared among the five centrifuges supplied by Andritz. All control panels are
UL listed. The centrifuge starter panel (CSP) is located in the electrical room of Thickening
Facility East. The centrifuge operator panel (COP) is located on operating floor of Thickening
Facility West. The Servo Panel is located in the intermediate basement of Thickening Facility
West.

All control panels are completely assembled, prewired, and tested for proper control of the
centrifuge system. All are freestanding units.

For more information about the centrifuge control system, turn to Chapter 3, §3.2. Drawings of the
centrifuge operating panel, centrifuge starter panel, and servomotor control panel are contained in
Chapter 5, §5.6.

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