Decanter Afdal Success

Decanter Operation
MPOB Diploma in Palm Oil Milling

Technology & Management
13th March 2014
Shaik Hassain
Decanter Operation
Application in the Palm Oil Milling Industry
Contents
• Basics
• Main components
• 2-phase and 3-phase operation
• Performance optimisation
Slide 3
Decanter Operation
Basics
Slide 4
Decanter Operation
Basics
Decanter Centrifuges
A decanter centrifuge is a sedimentation centrifuge
for separation of suspended solids from one or two
liquids.
The characteristic which distinguishes a decanter
centrifuge from other type of centrifuges such as
disc stack separators is that it has a cono-cylinder
rotor equiped with a conveyor for continuous
unloading of sedimented solids.
© Alfa Laval Slide 5

Decanter Operation
Basics
Decanter Centrifuges
They are used in a wide range of
application where their ability to achieve
both good clarity and low moisture in the
discharged solids is appreciated.
They are very versatile and can handle
both large and small particles as well as a
wide variety of solids concentrations.

Decanter Operation
Basics
Separation capabilities

Decanter Operation
Basics
Application in a Palm Oil Mill
Replacement of the Nozzle sludge separator

Decanter Operation
Basics
Benefits of using a Decanter
• Reduced solids loading to the effluent ponds

• Fully continuous operation
• Minimal operator supervision
• Lower maintenance cost

Decanter Operation
Main components

Decanter Operation
Main Components
The Bowl or Drum
Big End Hub Cylindrical Part Conical Part Small End Hub
Solids Discharge
Openings

Decanter Operation
Main Components
The Conveyor
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

Decanter Operation
Main Components
The Conveyor
The conveyor rotates slowly in relation to the bowl thus
conveying the sediment towards the solids discharge
openings in the small end of the bowl.
The conveyor is usually single flighted, but some have

double flights.
The conveyor flights and feed outlets are normally

protected against wear by means of an abrasion resistant
material such as hard facing or tungsten carbide tiles.

Decanter Operation
Main Components
Rotating Assembly
Cylindrical part Conical part

Big end hub Small end hub
Spline shaft
Screw Conveyor with bearings and protecting pipe

Decanter Operation
Main Components
Main Bearings
Main Bearing - Gear Box End Main Bearing - Pulley End
(Roller Bearing for axial expansion) (Ball Bearing for axial fixing)

Decanter Operation
MainComponents
Driving the Decanter

Gear Box for Screw Conveyor Drive Pulley for Drive of Bowl
Sunwheel shaft

Decanter Operation
Main Components
Gearbox
The gearbox is fitted to the large end hub of the bowl and
drives the conveyor by means of a spline shaft through
the end hub.
The differential speed is determined by the speed of the

input shaft (sunwheel shaft).
Alfa Laval uses two stage planetary type gearbox for

CPO decanters

Decanter Operation
Main Components
Gearbox - Why do we use it ?

1. Our need in the decanter is to turn the screw conveyor with
2. High torque possibility
3. Low differential speed (2 to max 80 rpm)
4. Decent size of Back Drive System
How to lift a heavy object?
Heavy
stone

Decanter Operation
Main Components
Gearbox - Why do we use it ?

1. Our need in the decanter is to turn the screw conveyor with
2. High torque possibility
3. Low differential speed (2 to max 80 rpm)
4. Decent size of Back Drive System
A heavy stone or a Decanter A man with a crowbar

screw conveyor or Back Drive System
Big force Low force

(high (low torque)
torque) Long way
Short way (high rpm)
(Low rpm)

Decanter Operation
Main Components
Gearbox
Sunwheel shaft Output or Spline shaft
Alfa Laval’s gearbox used in CPO application have a

maximum 2.5 kNm torque with a ratio of 1 :159

Decanter Operation
Main Components - Gearbox
Rotating Assembly with Gearbox

Decanter Operation
Rotating Assembly with Gearbox and main motor

Decanter Operation
Formula for calculation of Differential Speed
n = nb - ns
i
 n : Differential speed (rpm)

 nb : Bowl speed (rpm)
 ns : Sunwheel shaft speed (rpm)
 i : Gearbox ratio

Decanter Operation

Example
n = nb - ns
i
 n : Differential speed
 nb : Bowl speed
 ns : Sunwheel shaft speed

Decanter Operation

Example
n = nb - ns
i
 nb : Bowl speed = 2900 rpm
 ns : Sunwheel shaft speed

Decanter Operation

Example
n = nb - ns
i
 ns : Sunwheel shaft speed = 2105 rpm

Decanter Operation

Example
n = nb - ns
i
 i : Gearbox ratio = 159

Decanter Operation

Example
n = nb - ns
i
 n : Differential speed = 5 rpm


Decanter Operation

Decanter Operation
Formula for calculation of power on the Sunwheel
Ps = Tc x s
i
 Ps : Power on sunwheel shaft (kW)

 Tc : Conveyor torque (kNm)
i : Gearbox ratio
 s : Angular sunwheel speed (rad/s)
( = 2 x sunwheel rpm/60)

Decanter Operation

Example
n = nb - ns
i
 n : Differential speed = 5 rpm


Decanter Operation

Example
Ps = Tc x s
i
 Ps : Power on sunwheel shaft

 Tc : Conveyor torque
i : Gearbox ratio = 159
 s : Angular sunwheel speed

Decanter Operation

Example
Ps = Tc x s
i

 s : Angular sunwheel speed = 220 rad/s
( = 2 x 2105 rpm/60)

Decanter Operation

Example
Ps = Tc x s
i

 Tc : Conveyor torque = 1.0 kNm
( = 2 x 2105 rpm/60)

Decanter Operation

Example
Ps = Tc x s
i
 Ps : Power on sunwheel shaft = 1.39 kW

( = 2 x 2105 rpm/60)

Decanter Operation
1.39 kW required
Normal operating current - 55A

=> 35 kW

Decanter Operation
Can we operate without the Gearbox ?

Decanter Operation

Example
Ps = Tc x s
i

i : Gearbox ratio
 s : Angular sunwheel speed

Decanter Operation
Formula for calculation of power on the Conveyor

Example
Ps = Tc x s
i
 Ps : Power on conveyor shaft

i : Gearbox ratio =1
 s : Angular conveyor speed
( = 2 x conveyor rpm/60)

Decanter Operation

Example
Ps = Tc x s
i
 Ps : Power on conveyor shaft

 s : Angular conveyor speed = 303 rad/s
( = 2 x 2895 rpm/60)

Decanter Operation

Example
Ps = Tc x s
i
 Ps : Power on conveyor shaft = 303 kW

 s : Angular conveyor speed = 303 rad/s
( = 2 x 2895 rpm/60)

Decanter Operation
Rotating Assembly without Gearbox and main motor
303 kW !!

=> 35 kW

Decanter Operation

with a decent Back drive system
1.39 kW required

=> 35 kW

Decanter Operation
Main Components - Back drive system
Eddy Current Brake (ECB)

Decanter Operation
Main Components - Back drive system
Countershaft (CS)

Decanter Operation
2 - phase and 3 - phase operation

Decanter Operation
2 - phase operation
- Liquid / Solids separation
3 - phase operation
- Liquid / Liquid / Solids separation

Decanter Operation
Main Components
The complete Decanter ( 3 - phase operation )

Decanter Operation
2 - phase operation

Decanter Operation
Dam Plates for 3 - phase operation

Decanter Operation
Main Components

Decanter Operation
Main Components

Decanter Operation
Performance Optimisation

Decanter Operation
Requirements
• To recover as much solids as possible.
• To obtain a centrate as free as possible from suspended solids.
• To recover as much liquid as possible in as pure state.
• To obtain as dry solids as possible.
• To obtain as pure as possible the heavy phase from light phase.

Decanter Operation
Nomenclature
Differential speed (  n )
= Bowl rpm - conveyor rpm
Bowl speed
Liquid weirs
Liquid level
(radius)
Feed
Pond depth
Pond Beach

Decanter Operation
Regulating possibilities
According to Decanter design According to Process parameter

Decanter Operation

•Bowl speed

Decanter Operation
Theory of centrifugal separation, Stoke’s Law applied

Vg = d2 ( p - l ) g
18
 Vg : Settling velocity (m/s)

d : Particle diameter (m)
 p : Particle density (kg/m3)
 l : Density of the continuous phase (kg/m3)
 : Viscosity of the continuous phase (kg/m,s)
g : Gravitational acceleration (9.81 m/s2)

Decanter Operation
Centrifugal acceleration
G = 2 rb
g
G : G – force
 : Angular velocity (rad/s)
 rb : Maximum inner radius of bowl (m)

Decanter Operation
Centrifugal acceleration
G = n2 D
1800
G : G – force
n : Bowl speed (rpm)
D : Maximum inner diameter of bowl (m)
 : Angular velocity = 2 x n/60 (rad/s)

Decanter Operation

Vg = d2 ( p - l ) g
18


Decanter Operation

Vg = d2 ( p - l ) G
18

G: Gravitational acceleration (9.81 m/s2)

Decanter Operation
Regulating possibilities , Bowl speed

Centrate clarity
Solids recovery
Solids dryness
High Power
Torque
Wear
Noise
Low
Bowl speed

Decanter Operation

•Bowl speed

Decanter Operation

•Bowl speed
•Differential speed

Decanter Operation
n = nb - ns
i
 n : Differential speed (rpm)

 nb : Bowl speed (rpm)
 ns : Sunwheel shaft speed (rpm)

Decanter Operation
Regulating possibilities , Differential speed
Solids capacity
High
Torque
Low Solids dryness
Differential speed

Decanter Operation

•Bowl speed

Decanter Operation

•Bowl speed
•Pond depth

Decanter Operation
Regulating possibilities, Pond depth

Decanter Operation
Regulating possibilities , Pond depth

Torque
High Solids dryness
Centrate clarity
Low
Short beach Long beach
Deep pond Shallow pond
Decanter Operation

•Bowl speed
•Pond depth

Decanter Operation

•Bowl speed •Feed rate
•Pond depth

Decanter Operation

Vg = d2 ( p - l ) G
18

G: Gravitational acceleration (9.81 m/s2)

Decanter Operation
Regulating possibilities , Feed rate
Solids dryness
High
Low Centrate clarity
Feed rate

Decanter Operation

•Pond depth

Decanter Operation

•Differential speed •Particle size
•Pond depth

Decanter Operation

Vg = d2 ( p - l ) G
18

G: Centrifugal acceleration (9.81 m/s2)

Decanter Operation
Regulating possibilities , Particle size
Solids recovery
High
Solids dryness
Low
Particle size

Decanter Operation

•Differential speed •Particle size
•Pond depth

Decanter Operation

•Differential speed •Particle size (flocculation)
•Pond depth

Decanter Operation

•Pond depth •Viscosity

Decanter Operation

Vg = d2 ( p - l ) G
18

G: Centrifugal acceleration (9.81 m/s2)

Decanter Operation
Regulating possibilities , Viscosity
High
Separation efficiency
Low
Viscosity

Decanter Operation

•Pond depth •Viscosity

Decanter Operation

•Pond depth •Viscosity (heating)

Decanter Operation
Guaranteed Performance
Decanter Cake Heavy Phase

Moisture <78% NOS 6-7%
Oil on dry basis 12-14% Oil on dry basis <14%

Alfa Laval’s advantage

Decanter Operation
Challenges of a Decanter in a POM
•High amount of abrasive material in the feed, mostly Sand

•Hot operating conditions, ambient and feed temperature
•Long operating hours
•Low skill operators

Decanter Operation
Main Components

Tungsten Carbide welded Tiles
Guaranteed for 20,000 hours!
No protection Low grade High grade Tungsten

hardfacing hardfacing carbide tiles

Erosion Protection - 2 Port Feedzone
• Optimal introduction on sludge
• Heavy duty materials
• All parts exchangeable
• Less maintenance & downtime

Decanter Operation
Actual conveyor after 20,000 hours

Decanter Operation

•Lowly skilled operators

Decanter Operation
Central greasing system

Decanter Operation


Decanter Operation


Decanter Operation


Decanter Operation
Fool-proof Control Panel

• Automatic Bowl Flushing during
- Start up
- Shut down
- While in operation
• All alarm with visual and audible
warning
• Differential speed push buttons
controls

Decanter Operation
C.I.P valves for bowl flushing

Decanter Operation
C.I.P valves for bowl flushing

Decanter Operation


Decanter Operation


Decanter Operation


Decanter Operation

•L/D ratio

Decanter Operation
Standardized family of Decanters
PANX 200
PANX 934
PANX 500
PANX 600

Decanter Operation

•L/D ratio

Decanter Operation

•L/D ratio , > 5.00

Decanter Operation

•L/D ratio , > 5.00
•Patented Baffle Disc design

Decanter Operation
Regulating possibilities, Pond depth

Decanter Operation

•L/D ratio , > 5.00
•Patented Baffle Disc design

Decanter Operation

•L/D ratio , > 5.00
•Patented Active Baffle Disc design

238 PANX’s Reference Installations in
• Indonesia
• Malaysia
• Thailand
• PNG

Coffee Break !!!

Decanter Afdal Success

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Decanter Operation

MPOB Diploma in Palm Oil Milling

© Alfa Laval Slide 5

© Alfa Laval Slide 11

© Alfa Laval Slide 12

Application in a Palm Oil Mill

Replacement of the Nozzle sludge separator

© Alfa Laval Slide 13

Benefits of using a Decanter

• Reduced solids loading to the effluent ponds

© Alfa Laval Slide 16

© Alfa Laval Slide 17

The Bowl or Drum

© Alfa Laval Slide 18

Screw conveyor with fine pitch

© Alfa Laval Slide 19

The conveyor is usually single flighted, but some have

The conveyor flights and feed outlets are normally

© Alfa Laval Slide 20

Cylindrical part Conical part

Screw Conveyor with bearings and protecting pipe

© Alfa Laval Slide 21

© Alfa Laval Slide 22

Driving the Decanter

© Alfa Laval Slide 23

The differential speed is determined by the speed of the

Alfa Laval uses two stage planetary type gearbox for

© Alfa Laval Slide 24

Gearbox - Why do we use it ?

How to lift a heavy object?

© Alfa Laval Slide 25

Gearbox - Why do we use it ?

A heavy stone or a Decanter A man with a crowbar

Big force Low force

© Alfa Laval Slide 26

Sunwheel shaft Output or Spline shaft

Alfa Laval’s gearbox used in CPO application have a

© Alfa Laval Slide 27

Rotating Assembly with Gearbox

© Alfa Laval Slide 28

Rotating Assembly with Gearbox and main motor

© Alfa Laval Slide 29

Formula for calculation of Differential Speed

 n : Differential speed (rpm)

© Alfa Laval Slide 30

Formula for calculation of Differential Speed

© Alfa Laval Slide 31

Formula for calculation of Differential Speed

© Alfa Laval Slide 32

Formula for calculation of Differential Speed

© Alfa Laval Slide 33

Formula for calculation of Differential Speed

© Alfa Laval Slide 34

Formula for calculation of Differential Speed

 n : Differential speed = 5 rpm

© Alfa Laval Slide 35

Rotating Assembly with Gearbox and main motor

© Alfa Laval Slide 36

Formula for calculation of power on the Sunwheel

 Ps : Power on sunwheel shaft (kW)

© Alfa Laval Slide 37

Formula for calculation of Differential Speed

 n : Differential speed = 5 rpm

© Alfa Laval Slide 38