Westfalia Separator

Food Tec GmbH

Mechanical Separation
Division

Oils and Fats Processing

Technical Details of RSE-Separators

 Westfalia Separator
Food Tec GmbH
Oils and Fats Processing
Mechanical Separation
Division
Theoretical background of separation

Basics for separation of 2- or 3-phase systems:

In solid suspensions ( clarification) :

• density difference between liquid and solids

In liquid / liquid mixtures ( separation ):

• liquids are insoluble in each other

• density difference between the liquids

 Westfalia Separator
Oils and Fats Processing
Food Tec GmbH
Mechanical Separation
Division
Theoretical background of separation

Factors influencing separation velocity:

• particle size

• density difference

• viscosity

• gravitational force

Factors influencing separation efficiency:

• flow rate and retention time

• tendency to emulsification
 Westfalia Separator Oils and Fats Processing
Mechanical Separation
Food Tec GmbH Theoretical background of separation
Division

Calculation of the throughput capacity

Legend:

D = particel size
∆ρ = density difference
η = dynamic viscosity

ω = angle velocity
tgζ= disc angle
g = gravitational force
z = number of discs
D * ∆ρ
2
2π r1 = outer disc radius
Q = ---------- * g * ---- * ω2 * tgζ * z ( r13 - r23 ) r2 = inner disc radius
18 * η 3g

product related machine related

 Westfalia Separator Oils and Fats Processing
Food Tec GmbH
Mechanical Separation
Division
RSE-Separators

• Requirements of the industry on modern centrifugal

separators:

• lower noise level

• reliable bowl discharge system
• ability to discharge viscous gums or soaps
• optimum separating efficiency
• higher flexibility
• higher throughput capacities
 Westfalia Separator Oils and Fats Processing
Food Tec GmbH
Mechanical Separation
Division
RSE-Separators – Noise Level

double
shell hood
• < 80 dB(A) meets the
requirements in Europe and USA

• only in exceptional cases lower

levels are expected

• heat insulation comes along

with noise insulation !!!

• high internal temperature when Double shell

sludge catcher
the machine runs without
product feed !!!
 Westfalia Separator Oils and Fats Processing
Food Tec GmbH
Mechanical Separation
Division
RSE-Separators – Noise Level

Noise level of different separators

90

RSA 150
85
RSE 150
80
RSE 250
sound pressure in dB

75

70

65

60

55

50
62,5 125 250 500 1000 2000 4000 8000 16000
frequency in Hz

Average sound pressure: RSA 150 - 86 dB(A) – no noise reducing measures

RSE 150 - 80 dB/A) – gear drive, double shell hood
RSE 300 - 78 dB(A) – belt drive, double shell hood
 Westfalia Separator Oils and Fats Processing
Food Tec GmbH
Mechanical Separation
Division
RSE-Separators – Desludging Mechanism

• Requirements:

– Exact and fast opening

– Wide opening gap
– No tilting of sliding piston
(even opening gap)
– Wear protection

• Realisation:

– Fully hydraulic system

– Opening water injection by
piston valve
– Two piston valves
– Wear liners in discharge ports
 Westfalia Separator Oils and Fats Processing
Food Tec GmbH
Mechanical Separation
Division
RSE-Separators – Desludging Mechanism

Advantages of the
metering piston :
• accurate discharge volume
• independent from PLC cycle times
• independent from operating
water pressure

Closing water

Opening water
 Westfalia Separator Oils and Fats Processing
Food Tec GmbH
Mechanical Separation
Division
RSE-Separators – Desludging Mechanism

1. Metering device
2. Valve for compressed air
3. Opening-water valve
4. Opening-water-filler valve
5. 5- Non-return valve
6. Closing-water valve
7. Injection chamber for closing-water
8. Injection chamber for opening–water
9. Closing-chamber
10. Sliding piston
11. Piston valve
12. Drain hole for closing water

Metering Piston
 Westfalia Separator Oils and Fats Processing
Food Tec GmbH
Mechanical Separation
Division
RSE-Separators – Desludging Mechanism

Piston valve in closed position Piston valve in open

position

Closing water

Opening water
 Westfalia Separator Oils and Fats Processing
Food Tec GmbH
Mechanical Separation
Division
RSE-Separators – Desludging Mechanism

Piston valve:
new design with combination gaskets

Outer ring :
Teflon

Inner ring:
FKM
 Westfalia Separator Oils and Fats Processing
Food Tec GmbH
Mechanical Separation
Division
RSE-Separators – Desludging Mechanism

Desludging diagram

10

0
RSA 150
0
0,05
0,1
0,15

0,2

0,25

RSE 150
0,3

0,35

0,4

0,45

0,5

0,55
bow l opening tim e

type of disludging: partial

discharged volume: 5 l
 Westfalia Separator Oils and Fats Processing
Food Tec GmbH
Mechanical Separation
Division
RSE-Separators – Desludging Mechanism

Operating water quality:

hardness: < 12° dH up to 55 °C separating temperature

< 6° dH above 55 °C separating temperature

chlorine ions: < 100 mg/l

pH-value: 6,5 - 7,5
sediment content: max. 10 mg/l
particle size: max. 50 µm
pressure: 2,0 - 2,5 bar
Water supply: 3.000 l/h

Cooling water limitation for most of the machines :

max. 1 bar pressure
 Westfalia Separator
Food Tec GmbH Oils and Fats Processing
Mechanical Separation
Division RSE-Separators – Desludging Mechanism
New protection for
sliding piston RSE 300:

„fused“
surface
 Westfalia Separator Oils and Fats Processing
Food Tec GmbH
Mechanical Separation
Division
RSE-Separators – Desludging Mechanism

Protection for discharge ports RSE :

„Wear liners“
 Westfalia Separator Oils and Fats Processing
Food Tec GmbH
Mechanical Separation
Division
RSE-Separators – Separating Efficiency

• Requirements:

– Low oil losses

– Low soap content on oil
– Ability to discharge viscous
gums or soaps

• Realisation:

– Sealed feeding chamber

– Smooth handling the liquid in
the feed
– Various disc stack designs
– Bowl flush
 Westfalia Separator Oils and Fats Processing
Food Tec GmbH
Mechanical Separation
Division
RSE-Separators – Separating Efficiency

Hydrohermetic Vapor Seal

• barrier to prevent vapors

from rising out of the
feeding chamber into the
lower centripetal pump
chamber

• positive effect in case of

higher separating
temperatures (> 90°C),
washing, miscella refining
 Westfalia Separator Oils and Fats Processing
Food Tec GmbH
Mechanical Separation
Division
RSE-Separators – Separating Efficiency

Hydrohermetic Feed

• lower soap content

< 500 ppm after neutralisation
(150 - 300 ppm achieved)
< 50 ppm after one washing

• feed pressure 1 - 2,0 bar

necessary

• range of throughput has to be

defined
 Westfalia Separator Oils and Fats Processing
Food Tec GmbH
Mechanical Separation
Division
RSE-Separators – Separating Efficiency

Feed,
product
Discharge
light product
Discharge phase
heavy product
phase

Separation-
zone
 Westfalia Separator Oils and Fats Processing
Food Tec GmbH
Mechanical Separation
Division
RSE-Separators – Separating Efficiency

feed
bar
Discharge
bar light product
Discharge phase
heavy product
phase Pressure increasing at discharge
Pressure in feed increase

Separation- Filling level increase

zone
 Westfalia Separator Oils and Fats Processing
Food Tec GmbH
Mechanical Separation
Division
RSE-Separators – Separating Efficiency

Comparison of a standard to a hydrohermetic feed

900

800
700
soap content in ppm

600

500 RSA 200

400 RSE 200

300

200
100

0
1. / 2. / 3. / 4. / 5. / 6. / 7. / 8./ 9. / 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29.
S S S R R R R R R /R /R /S /S /R /R /R /R /R /R /R /R /R /R /S /S /S /R /R /R
test day / kind of oil (R - rapeseed, S - soyabean)

Average reduction of soap content by the hydrohermetic feed: 20 %

 Westfalia Separator
Food Tec GmbH
Oils and Fats Processing
Mechanical Separation
Division
RSE-Separators – Separating Efficiency

Disc stack designs

oil phase
oil phase
gap 0,7 - 1,5 mm gap 0,7 - 1,5 mm

Soap/water phase gum phase

gap 0,7 - 1,5 mm gap 2 - 3,5 mm

Disc stack ( long discs only ) Disc stack ( alternating long / short discs )
Application : neutralisation
Application : acid degumming
washing
water degumming
winterisation
 Westfalia Separator Oils and Fats Processing
Food Tec GmbH
Mechanical Separation
Division
RSE-Separators – Separating Efficiency

Bowl Flush

• useful for dilution of

soaps and gums

or

• to flush out excess

caustic soda
 Westfalia Separator Oils and Fats Processing
Food Tec GmbH
Mechanical Separation
Division
RSE-Separators – Flexibility

• Requirements:

– Use of the machine for

different feed stocks and
processes without alterations

• Realisation:

– Fine Tuner:
• Adjustable upper
centripetal pump
 Westfalia Separator Oils and Fats Processing
Food Tec GmbH
Mechanical Separation
Division
RSE-Separators – Flexibility

Fine Tuner

• optimal adjustment of the

separating zone during
operation

• easier handling during start-up

(no break-overs)

• no break-overs after
desludgings (lower losses)

• lower power consumption

• high flexibility (miscella

refining and winterisation
without exchange of parts)
 Westfalia Separator Oils and Fats Processing
Food Tec GmbH
Mechanical Separation
Division
RSE-Separators – Flexibility

Zulauf

Discharge
light product
Ablauf phase
schwere Phase

Fine Tuner
Trennzone
Separation-
zone
 Westfalia Separator Oils and Fats Processing
Food Tec GmbH
Mechanical Separation
Division
RSE-Separators – Flexibility

Zulauf

Opening of the Discharge

light product
Fine
AblaufTuner phase
schwere Phase

Fine tuner

Trennzone
Separation zone
Separation moves outside
zone
→ clean oil phase
 Westfalia Separator Oils and Fats Processing
Food Tec GmbH
Mechanical Separation
Division
RSE-Separators – Flexibility

Zulauf
Closing of the
Discharge
Fine Tuner light product
Ablauf phase
schwere Phase

Fine tuner

Trennzone
Separation zone
Separation-
moves inside
zone → cleaner
heavy phase
 Westfalia Separator Oils and Fats Processing
Food Tec GmbH
Mechanical Separation
Division
RSE-Separators – Flexibility

Fine Tuner Drive

Positioner

Pneumatic drive

Gear box
 Westfalia Separator Oils and Fats Processing
Food Tec GmbH
Mechanical Separation
Division
RSE-Separators – Flexibility

Setting Range of the Fine Tuner

• Assumptions: separating zone unchanged

specific weight of heavy phase
1g/cm³

• min. specific weight of light phase:

0,74 g/cm³

• max. specific weight of light phase:

0,94 g/cm³
 Westfalia Separator Oils and Fats Processing
Food Tec GmbH
Mechanical Separation
Division
RSE-Separators – Drive Systems

• Gear Drive

– With fluid clutch and direct

starting of motor
or
– With rigid coupling and
frequency converter for the
motor (requirement for
ATEX)

– Available in gastight design

for inert gas blanketing
Gastight
(miscella refining, Biodiesel) frame

– Limited motor size 45 kW

Worm
wheel
drive
 Westfalia Separator Oils and Fats Processing
Food Tec GmbH
Mechanical Separation
Division
RSE-Separators – Drive Systems

Oil Cooling Unit for gear

driven separators

• bigger oil volume for

longer service intervals

• longer lifetime of the gears

due to lower oil
temperature

• less wear off due to a

continuous filtration of the
lubricating oil

• in combination with
synthetic oils oil change
intervals of >2000 hours
 Westfalia Separator Oils and Fats Processing
Food Tec GmbH
Mechanical Separation
Division
RSE-Separators – Drive Systems

technical data: gear oil cooler

oil temperature in / out °C 125 / 80

oil flow rate l/min 2
flow rate cooling water l/h 900
cooling water temp. In/out °C 20 - 48
filter um 30
tank volume ltr. 12
motor power kW 0,37

external gear oil

cooling/filtering aggregate

in combination with synthetic

oils extension of the oil change
cycle to > 2000 hours
 Westfalia Separator Oils and Fats Processing
Food Tec GmbH
Mechanical Separation
Division
RSE-Separators – Drive Systems
Lubricating oils for separators with gear drive: Alternatives to
CLP 220
Food grade 1) Mineral oil based Synthetic oils
Supplier
Aral Degol BG 220 Degol PAS 220
Avia Syntogear EP 220
BP Energol GR-XP 220 Enersyn HTX 220
Castrol Alpha SP 220 Alphasyn HG 220
DEA Intor HCLP 220
Esso Gear Oil FM 220 Spartan EP 220 Spartan Synthetic EP 220

Total Fina Elf Lubriplate SFGO-220 Giran P 220

Fuchs Renolin Unisyn CLP 220

Klüber Klübersynth GEM 4-220

Mobil DTE FM 220 Mobilgear 630 SHC 630
Shell Cassida GL 220 Omala Oil 220 Omala Oil HD 220
Texaco Meropa 220 Syngear 220

Remarks: 1) approval acc. to USDA H1

 Westfalia Separator Oils and Fats Processing
Food Tec GmbH
Mechanical Separation
Division
RSE-Separators – Drive Systems

Inert Gas to ventilation system

Blanketing N2

Nitrogen Control Unit

N2

Operating water
 Westfalia Separator Oils and Fats Processing
Food Tec GmbH
Mechanical Separation
Division
RSE-Separators – Drive Systems

Hood chamber blanketing

and flushing

Gear box blanketing and

flushing

Sealing chamber blanketing

Inert Gas
Blanketing Unit
 Westfalia Separator Oils and Fats Processing
Food Tec GmbH
Mechanical Separation
Division
RSE-Separators – Drive Systems

• Flat Belt Drive

– No clutch, no coupling

– Standard motor with

frequency converter

– Spindle cartridge for

easier maintenance

– Drive can be blanketed

with inert gas

– Nevertheless no approval
for NFPA 36 regulations
!!!
 Westfalia Separator Oils and Fats Processing
Food Tec GmbH
Mechanical Separation
Division
RSE-Separators – Drive Systems

• New design with Direct Drive

– no gears
– no belt

• Standard motor
– speed equal to bowl speed
– in case of RSA 300: 4800 rpm

• Bowl and upper housing

identical to RSE 300 belt driven

• Ideal construction for ex-proof

environments and/or miscella
refining
– nitrogen blanketing possible
 Westfalia Separator
Oils and Fats Processing
Food Tec GmbH
Mechanical Separation RSE-Separators – Drive Systems
Division

• Requirements for ATEX regulations ( Status ??)

– Direct coupling without clutch shoes requires frequency

controlled motor for gear driven machines

– Two independent speed measurements required

– Double vibration monitoring

– ATEX approval for Turbo clutch has passed !