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GEA Mechanical Equipment / GEA Westfalia Separator
ExtractionComponents, systems and installationsfrom GEA Westfalia Separator
Liquids to Value
2
GEA Westfalia Separator
3
GEA Westfalia Separator
Contents 4 1. Introduction
4 1.1 Fundamentalaspectsofextraction
6 2. ExtractionTypes
6 2.1 Antibiotics
Directextraction–totalyieldupto98%
7 2.2 Statins
Directextractionforhi-techdrugs
8 2.3 Steroids/hormones
Obtainingestrogenandsimilarsubstances
9 2.4 Plantextracts
Gentleextractionforsensitiveactive
ingredients
10 2.5 Polycarbonate
Polymerextraction/washingprocesses
11 2.6 Pectin
Fromcitrusfruitstosettingagent
13 3. CentrifugalExtraction
13 3.1 Mixers
14 3.1.1 Centrifugalmixer
14 3.1.2 Integratedmixerinthebowlhead
15 3.2 Centrifuges
16 3.3 Liquid-liquidextraction
16 3.3.1 Separatorwithsolid-wall
disc-typebowl
17 3.3.2 Separatorwithself-cleaning
disc-typebowl
18 3.3.3 Driveconceptsforseparators
19 3.4 Solid-liquid-liquidextraction
19 3.4.1 Extractiondecanters
20 3.5 Solid-liquidextraction
20 3.5.1 Clarifyingdecanters
20 3.5.2 Clarifyingseparators
21 3.5.2 WestfaliaSeparator®varipond®–
reliablemasteringphaseseparation
21 3.5.3 Innovativedriveconcepts
fordecanters
23 3.6 Alternativeprocesses:
Filtrateextractionordirectextraction
23 3.6.1 Filtrateextraction:
Antibiotics
24 3.6.2 Directextraction
25 4. Explosion-ProtectedCentrifuges
27 5. CeramicMembraneFiltration–
Ultra-andMicro-FineClarification
28 6. AutomationSystems–PlugandPlay
29 7. SpecialMaterials
30 8. CentralProcessEngineering–
theReliableBasisforDecision-Making
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GEA Westfalia Separator
Theterm“extraction”isderivedfromtheLatinword“extrahere.” “Ex”specifies thedirection,i.e.,outof,and“trahere”describestheaction,namely drawing or removing. Extraction isdefinedastheprocessofremovingasubstanceorseveralsubstances fromanother substance.Theprocess isextremely important inawiderange of technical applications, for instancebiotechnology, the pharmaceutical and foodindustriesaswellasenvironmentalprotection.Extractionisaseparatingprocesswhichhastheadvantageoflowenergyconsumption.
Overall, particularly gentle processes arecharacteristicofthese“lifesciences”methods.Inbiotechnologyproductioninstallations, theprocessof separating thevaluablesubstancesfrom the biosuspension and the subsequentpurificationofsuchsubstanceswiththeaidofextractionarekeyaspects.Sensitivesubstancesarefrequentlyprocessedinbioprocesses.Theirstructure and biological activity require verylowtolerances,particularlywithregardtotheprocessingstageofextraction.Thishas tobeadjustedtobebroughtintolinewiththeambientconditions.ThevitalprocessparametersinthisrespectarethepHvalue,thesaltconcentrationandthetemperature,aswellasthestructureofthevaluablesubstance.
Innumerousareasofapplication,extractionisthemoreefficient,moreselectiveandlessexpensivealternativecomparedwithcompetingseparatingmethodssuchasdistillation,evaporationandmembranetechnology.Extractionhasbecomeestablished inconjunctionwiththefollowingprocessconditions:
Minorboilingpointdifferencesofthe componentstobeseparatedoraceotropic separation,e.g.,separationofisomers, aromaticsubstancesoraliphates
Heat-sensitiveorunstablesubstances,e.g., antibiotics
Non-volatilesubstances,recoveryand purificationofcatalystsorheavymetals
Mixtureswithinorganiccomponentswhichwouldresultinencrustationofevaporator
surfacesinconjunctionwiththethermal separatingprocess
Separationoflowmasscontentsofa componentwhichisnotreadilyvolatile
Introduction
The tasksofextractioncoverawiderangeofapplications. In the field of hydrometallurgy,extractionmethodsareusedforprocessingore,recoveringmetalsfromwastesludgesandforpurification.
Environmental protection is an area ofapplication for extraction which is becomingmoreandmoreimportant.
1.1 Fundamental aspects of extractionThe extraction agent or solvent is extremelyimportant for carrying out an extractionprocess,asthevaluablesubstance(theextractE), is released with the aid of an extractionagent. The nature of the phases which areinvolved characterize the extraction processas solid-liquid extraction or liquid-liquidextraction.
Liquid-liquidextractionisusedforseparatingvitaminmixtures.Anewmethod isalsousedforpurifyingphosphoricacid.Theprincipleofliquid-liquidextractionisillustratedinFigure1.
A fundamental criterion for liquid-liquidextractionisthattheextractionagentandtheliquid in which the extract is dissolved [thecarriermedium(T)]arenotperfectlymiscible.Inexcessofacertainconcentration,twophasesformwithaclearlydefinedboundary.Afamiliarexample is themixingbehaviorofwater andbutylacetate.
The two phases are known as the extract (E)phaseandtheraffinate(R)phase.Theextractphase is the phase into which the extract istransferredfromthecarriermedium.Ideally,itconsistsexclusivelyoftheextractionagentandtheextract,whereastheraffinatephaseconsistsonlyofthecarriermedium.Apartfrombeingless than perfectly miscible with the carriermedium,theextractionagenthastomeetfurtherrequirements.
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GEA Westfalia Separator
Thesecriteriaincludethefollowing: Capacitytoabsorbalargeamountof
extract(highcapacity) Highdegreeofselectivity Minimumcostforprocessingtheextract Highavailabilityandlowprice Lowlevelofcorrosion Lowor,ifpossible,notoxicity
Of the above-mentioned requirements,capacityandselectivityareofprimaryinterest.However, the corrosion properties as well asthetoxicitylevelsarealsobecomingmoreandmoresignificant,particularlywhenextractionmethodsareusedinthefoodanddrugfield(lifesciences)withrespecttoGMPguidelines.
Capacityisameasureofquantity,i.e.,itspecifiestheamountofextractwhichcanbeabsorbedbytheextractionagent.Selectivityisameasureofquality.Itexpressestheefficiencywithwhichthesolventdistributesthevaluablesubstancesover the various phases within a separatingstage.
Thehigherthecapacity,thegreatertheefficiencywithwhichthevolumestreamscanbeadjusted.Assuming that volume streams remainunchanged, a solvent with a high capacity isabletoabsorbmoreextractthanasolventwithalowercapacity.
Thehighertheselectivity,thelowerthenumberof separating stages. This means that theinstallationor the separatingdevicebecomessmaller.When the choice of solvent is beingconsidered,ithastobekeptinmindthatthereis frequentlyan inverse relationshipbetweencapacity and selectivity. In other words, highcapacity is frequently accompanied by lowselectivity,andviceversa.Thechoiceofsolventisfrequentlyanoptimizationprocessinwhichacompromisehastobefoundbetweenselectivityandcapacity.
Fig. 1 Example of liquid-liquid extraction
Before extraction
Solvent (LM)
Liquid mixture(X + Y)
Carrier liquid Y(raffinate phase)
Extraction solution LM + X(extract phase)
Mixing
After extraction andseparation
Fig. 2 Various extraction agent / carrier substance mixtures
2.1 AntibioticsDirect extraction – total yield up to 98%Antibiotics form the most important groupof drugs in the fight against infectiousdiseases. Representing around 13% of totalpharmaceutical consumption, they have thehighest market share of any pharmaceuticalproduct.Thepharmaceuticalindustryextractsantibioticsfromfermentationbroths.
GEAWestfaliaSeparatorsupportsthisprocesswith special decanters resulting in efficientdirectextractionwhichissimultaneouslykindtotheenvironment.Extractionalwaysconsistsofmixingandseparating,processeswhichcanbeviewedascomplex.ThisiswhyGEAWestfaliaSeparator developed a patented extractiondecanterforextractingactiveingredientswhichcombines the two process steps, mixing andseparating,inasinglemachine.
Thisdecanterallowssuspensionswithahighsolids content to be processed.This propertymakes it suitable for direct extraction ofantibioticsfromtheculturesolution,whichhasahighmyceliumcontent.Filtration,whichusedtobeessential,istherebyrenderedobsolete,andthecontinuousprocessavoidslossofvaluablematerial,aproblemassociatedwithfiltration.
Thisincreasestotalyieldtoupto98%.Comparedto conventional counter-current extraction,directextractionissignificantlylessexpensivebecausefilteraidsarenolongerrequired.Thefermentationbrothisnotdilutedbyfilterwashwater,reducingtherequirementforsolventandtheriskofinfection.Asafinalconsequence,thenewmethodalsoreduceswastewaterpollutionandthevolumeofwastewaterproduced.
Fig. 3 Extraction of antibiotics
Filtration
Counter-currentliquid-liquid extraction
Continuous directextraction using decanter
Precipitation
CentrifugationWashingCentrifugation
Drying
Raw salt
Liquid-liquidextractors
FermentationMold fungus
Mycelium and contamination
Nutrient solution
Counter-currentextraction decanter
or
2. Extraction Types
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GEA Westfalia Separator
2.2 StatinsDirect extraction for hi-tech drugsDirect extraction with decanters from GEAWestfalia Separator plays an important rolein pharmaceuticals other than antibiotics.Hi-tech drugs such as statins are alsoobtained by this method. In pharmacology,a statin is a drug belonging to the class ofsubstances known as HMG-CoA reductaseinhibitors.AsHMG-CoAisanintermediateofhuman cholesterol synthesis, statins such asLovastatin are used primarily as cholesterol-lowering agents (CSE inhibitors). In additionto fat metabolism disorders, statins are alsosuccessfully used to treat diseases of ourmodernsocietysuchasdiabetes (Pravastatin)or fungal infections (Nystatin).GEAWestfaliaSeparator has developed extraction decantersand polishing separators which can be usedto obtain these statins economically throughdirectextraction.
Lovastatinwaslicensedasacholesterol-loweringagentin1987andsincethenhasbeenoneofthemostimportantdrugsofthiskind.TheflowchartshowsthecomplexprocessinvolvedinthedirectextractionofLovastatinfromthefermentationbroth. Extraction decanters operated on thecounter-current principle are used in fourconsecutive stages. A polishing separatorobtainstheenrichedextract.Themachinesaredesigned to be gas-tight in accordance withcurrentexplosionprotectionguidelines,withtheresultthattheysatisfyallsafetyspecifications.ThisversatileprocesscanbeusedinasimilarwaytoobtainPravastatinandNystatin.
Fig. 4 Lovastatin extraction
1st stageextraction decanter
Fermentation brothButyl acetateWetting agent
First-stage extract
Alkali water
Extracted broth
Sulfuric acidButyl acetateWetting agent
Butyl acetateWetting agent
Butyl acetateWetting agent
2nd stageextraction decanter
Polishing separator Enriched extract
4th stageextraction decanter
3rd stageextraction decanter
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GEA Westfalia Separator
2.3 Steroids / hormonesObtaining estrogen and similar substancesSteroidsareendogenoushormonesasare thesex hormones estrogen and testosterone andthe hormones of the adrenal cortex, cortisoland aldosterone. They are used for hormonetherapyaswellasinantirheumatic,antiarthriticand muscle-building preparations. EfficientproductionisprovidedbyextractiondecantersfromGEAWestfaliaSeparator.
In order to produce steroid hormones forpharmaceuticalapplicationsoutsidethebody,weusedirectextractionfromspecialnutrientsolutions.IncontinuousdirectextractionfromGEAWestfaliaSeparator,thefermentednutrientsolution is treated by liquid-liquid extractionor in a counter-current process. Followingprecipitation,concentration,crystallizationanddryingoftheextract,thesteroidhormonesareavailableintheformofarawsaltandcanbeprocessedbythepharmaceuticalindustry.
Fig. 5 Obtaining steroids
Filtration or
Counter-currentliquid-liquid extraction
Continuous directextraction using decanter
Precipitation
Crystallizedproduct
Concentration /precipitation
Drying
Raw salt
Liquid-liquidextraction
FermentationMold fungus
Mycelium and foreign substances
Nutrient solution
Counter-currentextraction decanter
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GEA Westfalia Separator
2.4 Plant extractsGentle extraction for sensitive active ingredientsThere are approximately 500,000 species ofhigher plants around the world, of whicharound70,000serveasabasisforplant-baseddrugs. Ingredients are extremely sensitivesubstanceswhichhavetobetreatedgentlybythebiotechnicalprocessused toobtain them.Extractiondecantersandpolishingseparatorsfrom GEA Westfalia Separator are perfectlydesignedforthispurpose.
The structure and biological activity of thesubstances mean that very specific mediumconditions have to be used. The extractionprocessisparticularlysuitableforthis,buthastobepreciselyadaptedtosuitprocessparameterssuchaspH,temperature,concentrationandthedelicatestructureofthevaluablesubstances.
Theefficacyofaphytopharmaceuticalproductalsodependsonadequateandconsistentdosageoftheplantextract,soindustrialstandardizationis important. Plant extracts are defined asconcentrated preparations of liquid, solid orviscousconsistency.Asarule,theyareobtained
bymaceration(extractiontoequilibriumwithwateroralcohol)orpercolation(extractiontoexhaustionwithwateroralcohol).Akeyfactorin production is selection of the extractionagent.Water-soluble(hydrophilic)constituentscanbeextractedwithwater,while fat-soluble(lipophilic) constituents are extracted froma particular part of the plant with alcohol orothersolvents.
Compared to competing separationprocessessuchasdistillation,concentrationandmembranetechnology,extractionhasprovedmoreefficientintermsofprocesstechnologyandmoreselectiveandcheaperinnumerousapplications.Itisnotonlyextremelygentle,butisalsocharacterizedby a low energy requirement. The extractiondecantersandpolishingseparators fromGEAWestfaliaSeparatorusedinthepharmaceuticalindustry cover all processes and modes ofoperation. Liquid-liquid extraction can berealized, as can liquid-liquid-solid and liquid-solidextractions.Figure6showsatypicalplantextractionprocess.
Fig. 6 Plant extraction
Phase mixing
Extract
Solid
Extract
Solid for recovering solvent
Solvent
Medium fromfermentation Solvent
1st separatingdecanter
2nd separatingdecanter
Phase mixing
Polishing separator
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GEA Westfalia Separator
2.5 PolycarbonatePolymer extraction / washing processesWhenthecompactdiscwasinvented25yearsago,itchangedstereosystems,recordshopsandturnedpolycarbonateintoaworldstar.Today,polycarbonatesare someof themostpopularplasticsasaresultoftheirexcellenttransparencyand impact resistant properties. They can befoundinnumerousapplicationssuchaselectro-technology, equipment construction, the carmakingindustryorformakingeyeglasslenses.
Separators are used in the phase boundarymethodintheproductionofpolycarbonateinwhichthepolycarbonate,afterthereaction,isdissolvedinanorganicsolvent.Asecondwaterphase contains dissolved salts and unwantedadditives. Pure polycarbonate is obtained bydistilling off the solvent after being washedelectrolyte-free.
Thewashingprocessiscarriedoutinamulti-stageprocesswithacidandcompletelydesalinatedwater.Separatorswithasolid-wallbowlareusedforseparatingthepolymersolutionandwashingliquidintheindividualwashingstages.
Stand-alonemachinesandcompletelinesTheaimistoachievenotonlyextremepuritybutalsominimumresidualwatercontentintheorganicphasetomeetthemarket’sincreasinglystringentproductqualityrequirements.Theseproductrequirementsaremetbyusingseparatortechnologyathighspeeds.Solid-wall,disc-typeseparatorsoftypeXTAandXTCareusedattheacidstage.Allproduct-contactingcomponentsaremadeofhighcorrosionresistantmaterials.Inadditiontothesestandalonemachines,GEAWestfalia Separator also supplies completeprocesslinesforwashing.
Fig. 7 Production of polycarbonate
Reactor
Caustic sodasolution
Catalyst acid
Outgoing air
Wastewater
Polycarbonatesolution
Demineral-ized water
HCl
NaOH
Bisphonel A, methylene chloride,phosgene and additives
Separator I
Separator III
Separator II
Separator IV
Separator V
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GEA Westfalia Separator
2.6 PectinFrom citrus fruits to setting agentPectin (from theGreek “pektos”=gel) occursin all higher plants. Citrus fruits occupy aspecialposition,astheyhaveanunusuallyhighconcentrationofpectinsubstancesintheflavedoandalbedo(about25%ofthemoistmassofthewholecitrusfruit).Thepectinobtainedfromthecitruspeelisusedmainlyasasettingagentinthefoodindustry,butalsoforpharmaceuticaland cosmetic products. Global production ofpurepectinisestimatedatabout35,000tonsofwhich70%comesfromcitruspeel.ThepectinprocessfromGEAWestfaliaSeparatorprovidestoday’s producers with an extraction processwhichisasgentleontheproductasitisefficient.
Followinganinitialtreatmentofthefreshpeelandstorageinmechanizedsilos,thedriedpeelismilledandfedintotheextractionprocess.
Thepectinsareextractedbyavarietyofacidswith a pH-value of 1 to 3, at a temperaturebetween65°Cand85°Candforanextractionperiodof0.5to6hours.Extractiondeliversarawextractwith0.3to1%pectin.Separatingthisviscoussolutionfromtheheavilyswollenand in somecasesdisintegratedpomacecakeis the key technical problem in the pectinindustry. In the pectin process from GEAWestfaliaSeparatorshowninFigure8,thistaskismanagedbycombininganumberofdecantersandafilterpress.Theextractthenrunsthroughtheseparatorandprecoatfiltrationbeforethepectin is precipitated using isopropanol. Theexcessprecipitant is then separatedbyagas-tightdecanteruntilonlydrypurecitruspectinwithgoodstoragepropertiesremains.
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GEA Westfalia Separator
Fig. 8 Obtaining pectin
Reaction tankpH = 1.5 – 3
Separator
TankpH = 2.2 T~ 65 ºC
Adsorber toremove color
Decanter,gas-tight
Screens
Filter press
Precoat filtration
Isopropanolprecipitation
Isopropanol
Isopropanol(recovery)
Precipitated pectin gel
Pectin fibers
Dryer
Decanter IIDecanter I Decanter III
Dried pectinRaw materialH2OHNO3
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GEA Westfalia Separator
Centrifugal extraction is the link betweenthermal andmechanicalprocess engineering.Thechoiceofsolventisbasedonthermodynamic
3. Centrifugal Extraction
andchemical/physicalprinciples,whereasthedesign of the centrifuge and the separatingprocessarebasedonmechanicalprinciples.
3.1 MixersAn extraction stage always consists of amixingunitandacentrifugeunit.Inthecaseof the mixing unit, there are two equipmentalternatives. First, the centrifugal mixer andsecond,theintegratedmixerinthebowlheadtheofseparators.
and higher overall yield qualities
to a large extent, avoid valuable substance decayShort contact time
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GEA Westfalia Separator
Advantages of centrifugal extraction fromGEA Westfalia Separator... ...so that you...
3.1.1 Centrifugal mixer (Figure 9)In the case of the centrifugal mixer, the twophases to be mixed are pumped jointly intoa rotating mixing drum (2), where they areacceleratedtothecircumferentialvelocityofthebowl.Thecentripetalpump(3)dischargestheliquidmixturefromthemixingdrum.Thetwophasesaremixedintensivelyinthechannelsofthecentripetalpump.Themixedliquidisthendischargedfromthemixerattheoutlet(4).Thepressureinthedischargelineisadjustedwiththe aid of a throttling valve. This affects thesuspensioninsuchawaythatthechannelsofthecentripetalpumpareimmersedunderthesurfaceofthesuspensionandpreventanyairintake. The hermetic version is the standardversionforgas-tightapplications.Aslideringpacking ensures a hermetic seal between thedrum and the hood. The slide ring packingconsistsofastainlesssteelhousingslideringandacounter-ringmadeofhardcarbon.
The output of the 3-phase AC motor istransferred directly from the horizontalmotor shaft to the mixer drum. The variablespeedmixerwithafrequencyconverterdriveis a further development of the original ZAmixer. In thissolution,a frequencyconvertercan be used for infinite electric adjustmentof phase mixing. The mixing characteristicscan be adjusted individually, which is ofgreat importance particularly in the case of“multipurpose”applications.Thedropsizeandthe required turbulencevaryasa functionofthe speed. The frequency converter enablestheperformanceofthemixertobeadjustedatanytime.
3.1.2 Integrated mixer in the bowl head (Figure 10)Besides the mixers installed upstream of thecentrifuges,itisalsopossibletohaveafacilityformixingtheextractphaseandraffinatephasetobe installed inside theactual separators.Amixture tobeseparated is fed in throughthefeed(1).Theextractphaseofthenextstageorthefreshextractionagent(4)ismixedwiththeheavyphaseseparatedintheseparator(theraffinate)inthecentripetalpump(5).Themixedphaseisdischargedfromtheseparatorattheoutlet(3).Theclarifiedextractphaseleavestheseparatorthroughthelightphasedischarge(2).Apartfromthefacilityformixinginthecentripetalpumpchamber, it is alsopossible for theextractionagent (4) tobeaddedto theraffinatedirectlybeforeitenterstheseparator.Theactualprocesswherebythetwophasesaremixedtakesplaceinthedistributorchamberofthebowl(6)undertheactionofcentrifugalforce.
1
2
4
5
6
3
Fig. 10 Section through the bowl of a solid-wallseparator with mixing device in the bowl head
Fig. 9 Drum of a centrifugal mixer in hermetic design, type ZA 40-67-905
1
1
4 3 2
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GEA Westfalia Separator
3.2 CentrifugesThere are various options available forthe extraction process, whereby theappropriate variant and the centrifuge tobe used is determined by the nature ofthephases.
Extraction
Liquid-liquid-solid
Extraction decanter
Multi-stage
Counter-current
Single-stage
Direct current
Liquid-solid
Clarifying decantercentrifugal clarifier
Liquid-liquid
Disc separator
Fig. 11 Overview of centrifugal extraction processes and equipment from GEA Westfalia Separator
Fig. 12 Overview: Solid content as a selection criterion for centrifugal extractors Suitable for light solvents Suitable for heavy solvents
Extraction process
Liquid-liquid Liquid-liquid-solid Liquid-solid
< 0.1 ÷ 7 ÷ 15 ÷ 60 ÷ 7 ÷ 60
Separator with solid-wall bowl
Self-cleaning separator
Self-cleaning clarifier
Nozzle-type separator
Clarifying decanter
Extraction decanter
Phases Solids content in % (by vol.) Centrifugal extractors
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GEA Westfalia Separator
3.3 Liquid-liquid extractionDisc-typeseparatorswithsolid-wallbowlsandself-cleaningdisc-typebowlsareusedforliquid-liquidextractionprocesses.
3.3.1 Separator with solid-wall disc-type bowl (Figure 13)Theseparatorisequippedwithasolid-wallbowl.Theproductflowsthroughthehydrohermeticfeed,whichminimizestheshearingforcesforsensitiveproducts,andisbrokendownintoalightphaseandaheavyphaseinthediscstack.The separated components are dischargedunderpressurebymeansofthecorrespondingcentripetalpumpsthroughoutlets.Theuseofadiscstackincreasestheequivalentclarificationarea ∑ of the separator many times overcomparedwithacentrifugewiththesamevolumewhichconsistsofasinglechamber.Dependingon the particular product characteristics, thebowl can be equipped with discharge boreholessothatthesuspensioncanbedrainedformaintenancepurposesfromthebowlwhenthemachinehascometoastandstill.Theadvantageof this arrangement is that the maintenancepersonneldonothavetocomeintoexcessivecontact with the process media. At the sametime, CIP (cleaning-in-place) is also possiblewithout thebowlbeingopened.The selectedpair of centripetal pumps also enables theseparatingzonetobeadjustedinanoptimummanner even when there is a major densitydifferencebetweentheproducts.Theseparatingzonecanbeadjusteddependingonthevolumeoftheproductsinvolved.Theseparatingzoneis adjusted by adapting the regulating rings.Theseregulatingringsalsoguaranteeextremelyefficientseparationevenwhentherearemajorfluctuationsinthecompositionofthephases.
Inthegas-tightversion,whichisalwaysessentialwhenhandlingsolvents,theseparatorisequippedwithexplosion-protectedcomponents,andthebrake chamber is in a flame-proof enclosure.Theframechamber,sealingchamberandgearchamberareequippedwithconnectionsforinertgasblanketing.Anexternalcontrolunitregulatesandmonitorsthepressureandtheflowstothecorresponding chambers for all operationsoftheseparator.Thesolid-walldisc-typeseparatorisusedprimarilyforseparatingliquidmixtureswithnooronlyminimalsolidcontents(lessthan<0.1%byvol.).Otherwise,itwouldbenecessaryfor operation to be interrupted frequentlyin order to remove the separated solidsfrom the separator either manually or usingflushingprograms.
Fig. 13 Section through a bowl of a separatorwith solid-wall bowl
Feed
Heavy phase discharge
Light phase discharge
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GEA Westfalia Separator
3.3.2 Separator with self-cleaningdisc-type bowl (Figure 14)Unlikethesituationwiththesolid-walldisc-typeseparator, self-cleaning separators are able todischargetheseparatedsolidsatfullbowlspeed.Thismeans that theyarealsoable tooperatewithproductswithasolidscontentofupto7%(byvol.).However,ithastobekeptinmindthatseparatorsareliquid-orientedmachinesandarenotusedprimarilyforremovingsolids.
Fig. 14 Section through the bowl of a separator with a self-cleaning disc-type bowl
Fig. 15 Installation with type XSC 35 separators
Feed
Heavy phase discharge
Light phase discharge
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GEA Westfalia Separator
3.3.3 Drive concepts for separatorsDifferentdriveconceptsarealsoavailablefortheseparators.Twodriveconceptsareavailable:flat-beltanddirectdrive.
Flat-beltdriveInthissolution,themotorpoweristransferredtothespindlebymeansofanantistaticflat-belt.Oilcirculationlubricationensuresthatbearingsarecontinuously lubricated.Compared to thegeardrive,whichisstillusedinoldermodels,themotorpoweristransferredwithupto10%lesspowerloss.Thebeltitselfcanbereplacedquicklyandinaservicefriendlymannerwithoutthe bowl or motor having to be dismantledbeforehand.
DirectdrivesystemThe direct drive is an example of intelligentsimplification in separating technology.Wherever the upper limit for gear loads hasbeenreachedorbeltdrivesareundesirable,ourseparators with direct drive permit virtuallyloss-free power transmission. This boost inperformance simultaneously reduces thecostsofenergy,wear,maintenanceandspace.Therequiredpower is transmitteddirectly tothebowlspindlebya3-phaseACmotorwithfrequency converter control via a torsionallyelasticclutch.Thespindleassemblyissupportedbyrubber-metalcushions.Thismakespossiblelow-vibrationrunningathighbowlspeeds.
Ataglance: Extremelyspace-savingdesign Avoidanceofhousingdeformation Highperformanceinput Lowmaintenancerequirement Lessparts Reducednoice
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GEA Westfalia Separator
3.4 Solid-liquid-liquid extraction
3.4.1 Extraction decantersDecantersareaveryefficientmeansofcarryingout liquid-liquidextractionwithahighsolidscontent.GEAWestfaliaSeparatorhasdevelopedacontinuouscounter-currentdecanterspecificallyfor such applications. The counter-currentextractiondecanter is ahorizontal scroll-typecentrifugewithacylindrical/conicalsolid-wallbowl.Ascrolladaptedtothebowlwallrotateswithadifferentialspeedinsidethebowl.
Thesedecantersareabletoextractvaluablesub-stancesdirectlyoutofthesuspensions.Atypicalarea of application for these machines is theextraction of antibiotics from fermentationsolutions.Thesuspensiontobeextracted,e.g.,fermentationbroth,flowsthroughtheexternalcentrallyarrangedinlettubeandisfedintothemachineviadistributorslotsinthescrollofthebowl.Thesuspensionthenentersthecounter-current extractionzoneof thebowl,where it
flows to the conical end of the bowl via theseparating disc against the flow direction ofthe extraction agent (counter-current effect).The extracted suspension (raffinate) is thendischargedundergravity.Thesedimentedsolidsare conveyed by the scroll which rotates at adifferentialspeedinrelationtothebowl,andaredischargedundergravitytogetherwiththeraffinate.Theextractionagent (solvent) flowsthroughtheinternalcentrallyarrangedinlettubeintothedistributor,whereitentersthecounter-currentextractionzonethroughapertures.Theextraction agent flows to the cylindrical endof the bowl against the flow direction of thesuspensiontobeextracted.Itisthendischargedunderpressureviathecentripetalpump.Bothphases,namelytheextractandtheraffinate,arefirstmixedandthenflowthroughtheclarifyingzones.Thisenablesthephasestobeseparatedefficiently.Inordertopermitsafeoperationinexplosivesurroundings,thedecanterhasbeenprovidedwithagas-tightdesignandcanalsobeblanketedwithinertgas.
Fig. 16 Section through an extraction decanter
Extract Extractionagent
Suspension
Raffinate
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GEA Westfalia Separator
3.5 Solid-liquid extraction
3.5.1 Clarifying decantersBefore entering the decanter, the extractionproduct, which has previously beencomminuted,brokendownorgrounddown,ismixedintensivelywiththeextractionagentinaseparatemixer.Theinletthroughwhichthesuspensionflowsintothedecanterisarrangedaxiallyinrelationtotherotatingbowl.Thesolid-wallbowlhasacylindricalsectionforefficientclarificationoftheliquidandaconicalsectionfor dewatering the solids. The scroll, whichrotateswithaslightdifferentialspeedrelativetothebowl,conveysthesolids(extractionresidue)to the solids discharge at the conical end ofthebowl.
Theextract isconveyedtothecylindricalendof the bowl where it is discharged via acentripetalpump.
3.5.2 Clarifying separatorsInthecaseofsolid-liquidextractionprocesseswithalowsolidscontent(uptoapprox.7%byvol.), clarifiers with a self-cleaning disc-typebowl can be used as an alternative solution.Becauseof theirhigher speedsandclarifyingarea,thesemachinesprovideahigherclarifyingperformancethanisthecasewithdecanters.
Fig. 17 Section through a clarifying decanter
Suspension
Solids discharge
Light phase discharge
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GEA Westfalia Separator
3.5.2 Westfalia Separator® varipond® – reliable mastering phase separation
Theponddepthinthedecanterisanimportantparameter with which the separating zonebetween the light and heavy phase can beinfluenced.TheWestfaliaSeparatorvaripondsystem gives the user the opportunity toalter the pond depth to adapt to specificconditions during ongoing operation. AWestfalia Separator varipond disc dips intothe clarified light phase directly in front oftheregulatingring.Thisdiscformsahermeticchamber (“Westfalia Separator varipond”chamber) together with the centripetalpump, to which pressure can be appliedthrough a hole in the feed tube. Since theliquid level between the Westfalia Separatorvariponddiscandtheregulatingringisdefinedbytheoverflowdiameter,overpressureintheWestfaliaSeparatorvaripondchamberhastheeffectofenlargingtheponddepthinthedecanterbowl in accordance with the principle of thecommunicatingtubes.Asaresult,theseparatingzone between the light and heavy phase isdisplacedoutwards.Theprocessoperatorhasa tool that permits precise adjustment of thepurity of the heavy and light phases. This isindispensable for efficient and cost-savingdecanteroperation,particularlyinthecaseofchangingfeedconditions.In the case of gastight decanters, theWestfalia Separator varipond system has theadvantage that it requires no mechanicallyadjustable parts such as rotary leadthroughs.Therefore,itprovidesahighlevelofprotectionagainstdischargingharmfulgases.
3.5.3 Innovative drive concepts for decanters
Flexibleprocessmanagementwithsimultaneousmaximumavailabilityareessentialrequirementsformoderndriveconcepts.Thevarietyofprocessengineering applications in which decantersfromGEAWestfaliaSeparatorareusedrequiresdifferentdriveconcepts.Thisistheonlywaytomeetthecorrespondingproductrequirementsin an optimum manner. The product linetherefore includes drive systems with andwithoutthepossibilityofsimpleregulationofthedifferentialspeed.Therequirementsforthemachineandprocess,aswellascustomerwishesdeterminewhattypeofdriveisused.Inthecaseof decanters which are used in the chemicalindustry,flexibleandpreciseregulationofthedifferential speed is particularly important.Thisistheonlywaytoachieveextremelyhighsolidconcentrationsandthushighseparatingefficiency.The2-geardriveandthedifferentialgeardrivehavebecomeestablishedinpractice.
2-geardriveThe advantage of the 2-gear drive whichhas been developed and patented byGEA Westfalia Separator is the facility forregulatingthescrolldrive.Thedifferentialspeedisadaptedautomaticallyandextremelypreciselyasafunctionofthescrolltorque–andthusasa function of the solids content in the bowl.Thesolidsaredischargedfromthebowlwithaconstantconcentrationand inanextremelydrystate.The2-geardrivesareusedwheneverthevolumeofsolidsisnotconstant,whenthesolidsaredifficulttoconveyandwhenveryhighrequirementsareapplicablewithregardtotheresidualwatercontentofthesolids.
Fig. 18 Westfalia Separator® varipond®
Fig. 19 2-gear drive
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GEA Westfalia Separator
DifferentialgeardriveThe differential gear drive is recommendedwhenever it is necessary to automaticallyregulatethescrollspeedinadditiontoregulatingthebowlspeed.Thiscanbeachievedbymeansof twogears.Thesecondarymotordrives thecentralinputshaftandgeneratesthedifferentialspeedproportionallytoitsownspeed.Asecondinputshaftwithoutanyspeedisconnectedtothehousing.Thismeansthatthedifferentialspeedisnotdependentonthebowlspeed.Differentialgeardrivesareusedprimarilyinthelowerrangeofthedifferentialspeeds.
Fig. 20 Differential gear drive
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GEA Westfalia Separator
Fig. 21 2-stage extraction, direct current process
Nutrient solution
Aeration
Spore emulsion
Starterfermenter
1. Discseparator
Buffer tank
Basket centrifuge
Penicillin raw salt
Effluent
Fresh solvent
Biomass
Wash water
Vacuum drum filter
2. Discseparator
Acid or caustic
Demulsifier
3.6 Alternative processes: Filtrate extraction or direct extractionBoth processes are suitable for extractingantibiotics (e.g., scraps) from a fermentationsolution.Thefiltrateextractionprocessmakes
use of disc-type separators with an upstreamfiltrationsystem.Thedirectextractionprocess,alsoknownas“wholebrothextraction,”makesuseofdirectextractiondecanters.
3.6.1 Filtrate extraction: AntibioticsIn the first step, the aqueous biomass whichcontainsthefungalmyceliumischannelledviaavacuumbowlfilterandseparated.Thefiltercakewhichformsonthebowliswashedwithwaterinordertoachieveamaximumyieldofpenicillin.Subsequently,sulfuricacidisaddedinordertochangethepHvalueinsuchawaythattheconditionsformasstransferareoptimized.Theadditionofawettingagentensureshigherseparating efficiency during the extractionprocess.Theaqueousfermentationsolutionfromwhichmostofthesolidshavebeenremovedisthenconveyed to the firstdisc-typeseparatorinthe2-stagecounter-currentextractionstage.Here,itismixedwiththesolventfromthesecondseparator which already contains penicillin.Thesolventwhichisdischargedfromthefirstseparator is subsequently precipitated andprocessed incentrifugesuntil theprovisional
end product – penicillin raw salt – isobtained in the purity required by themanufacturer. The maximum efficiencyof the two separators is equivalent to thatof two theoretical stages, and is 94 – 96%measuredagainstthefeedtothefirstseparator.However, the filtration stageupstreamof theextractionstagemeansthatthismethodsuffersseveraldisadvantagescomparedwiththedirectextractionprocess:
Increasedriskofcontaminationduetouseofwashwater
Increaseduseofsolventresultinginhigherenergycostsforrecoveringvaluablesubstancefromtheextractionsolution(morewashwater moreraffinate moresolvent highercosts)
Lossofvaluablesubstance(>5%) Onlyfilterablemyceliumstructuresfrom
fermentationcanbeprocessed.
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GEA Westfalia Separator
3.6.2 Direct extractionThe use of extraction decanters offers majoradvantages. The decanter is able to extractsuspensionswithasolidscontentofupto60%(byvol.),whichmeansthatonlyasinglestageisnecessaryforseparatingthesolids(thefungalmycelium) from the fermentation solutionandforextractingthevaluablesubstance(theantibiotic). This means that the prefiltrationstagecanbeeliminatedandthattheextractionstagecanbeinstalleddirectlydownstreamofthefermentationstage.Sulfuricacidandawettingagentareaddedto the fermentationsolution,whichisthenprocessedinthe2-stagecounter-currentprocess.
Theyieldoftwoextractiondecantersoperatedin a counter-current arrangement is 95 –96%. Laboratory trials have demonstratedthat, depending on the particular substancesystem, a theoretical stage coefficient of upto 1.7 per extraction decanter is possible. Inordertoseparateveryfinesolidparticles, thesolvent(extract)whichisdischargedfromthefirst extractiondecanter canbepolished inadownstreamdisc-type separator.This enablesextremelypureextracttobeobtained.
Fig. 22 2-stage direct extraction with extraction decanters
Nutrient solution
Aeration
Spore emulsion
Fresh solvent
Acid or caustic
1. Extractiondecanter
2. Extractiondecanter
Demulsifier
Enrichedsolvent
Disc separatorExtract polishing
Buffer tank Basket centrifuge
Effluent
Biomass
Penicillin raw salt
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GEA Westfalia Separator
Centrifuges are used in the chemical industryfor clarifying and separating flammablepharmaceutical liquids. Theoretically, suchapplicationscanresultincriticalconcentrationsofsolventvaporsandoxygeninsidethecentrifugethatcancauseexplosionsorfires.However,thevaporsmustalsobepreventedfromescapingsoasnottoposearisktothehealthoftheoperators.Boththeseriskscanbepreventedbyusinggas-tightcentrifugesfromGEAWestfaliaSeparator.
No sparks, no static charges, no hot bearings–thetestcriteriaofthestrictEuropeanATEXstandardswhich are implemented in allGEAWestfalia Separator explosion-protectedcentrifuges. In addition, before the start ofoperation,thecentrifugeisfloodedwithinertgasandblanketedwithaslightexcesspressuresothatnofurtheroxygenisabletopenetrate.This is because fire is not possible withoutoxygen.Whenprocessingsensitiveliquids,thenecessaryinertgasatmosphereintheseparatoris automatically monitored throughout theentireoperation.
NothingisabletopenetratethisbarrierAn essential design feature of the gas-tightseparatorsfromGEAWestfaliaSeparatoristheneck bearing bridge that separates the drivewiththemotorandgearboxfromtheproductchamber.Thisbridgeisblanketedwithinertgas,and the connecting spindle is protected withdynamicspecialseals.
Theneckbearingbridgereliablypreventsthesolventfrompassingfromtheproductchambertothedrivechamberorintothesurroundings.Thisisbeneficialnotonlyfromthepointofviewof fireandhealthprotection, it alsomakes itpossibleforthesolventtodilutetheoil,whichwoulddiminish its lubricatingefficiencyandthusposearisktothedriveunit.
4. Explosion-Protected Centrifuges
Thesameisalsotrueinreverse:nooilisabletopenetratetheproductchamberandthushaveanegativeimpactonthequalityofthevaluableproduct.
ATEX95(directive94/9EC)AdirectiveformachinesoperatinginhazardoussurroundingshasbeeninforceinEuropesinceJuly1,2003.Thisaffectsnumerousapplicationsinthechemicalandpharmaceuticalindustries,particularlywheregas-tightmachinesareused.Accordingtothedirective,thefirststepistocarryoutariskassessmentoftherelevantmachinestoidentifyanypresentorpotentialrisks.
The measures are documented and thedocumentation is submitted to an EntitledBody. In specific terms, this means that GEAWestfaliaSeparatordecantersarenowequippedwithfail-safevibrationmonitoringequipment,atemperaturemeasurementfacilityaswellasaninertgasfacility.
All electrical equipment must have beenawardedanATEXcertificateoramanufacturerdeclaration.Thisdirectiveisonlyapplicabletonewmachines.AseparatedirectiveATEX137(directive1999/92EC)isapplicableforoperatorsofinstallationsinhazardousareas.Becauseofthis,operatorshavealsobeenobligedtocarryoutriskassessmentsforexistinginstallations.
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GEA Westfalia Separator
Machines and installations must have beenassessed by no later than January 1, 2006.GEAWestfaliaSeparatoroffers its customerssupport for assessing and, where reasonable,convertingthesecentrifuges.
GEAWestfaliaSeparatorimprovesinertgasconceptRequirementswithregardtosafetyandreliabilityarebecomingmorestringentforseparatorsanddecantersusedinzoneswithariskofexplosion.The existing inert gas concept is constantlyimprovedtomeettheserequirements.ThelatestEuropeanstandards,aswellasGEAWestfaliaSeparator’spracticaloperatingexperience,havebeen incorporated.Ashasbeenthecasewithmostexistingconcepts,theatmosphereintheseparatorisdisplacedwithinertgasbeforeeverystart-upandtheexcesspressureismaintainedduringoperationtomeettherequirementforminimuminertgasconsumption.
Thefittingsandmeasuringdevicesusedhavebeensubjecttoanextensivetestandhavealsobeenoptimizedasfaras investmentcostsareconcerned. The new inert gas supply facilitycomplies not only with the familiar directive94/9 EC (ATEX) but also with the TA Luft,i.e.,productleakagesfromtheequipmentarereduced to a minimum using state-of-the-arttechnology.
GEAWestfaliaSeparatorplacesgreatemphasison complete and easy-to-understand operatordocumentationaswellasacarefullyperformedconformityassessmentprocedure(CEsymbol).The company also provides informationconcerningthecorrectinstallationofseparatorsanddecantersinzonesthatareexposedtotheriskofexplosion.
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GEA Westfalia Separator
GEAWestfalia Separator has achieved a newdimension of ultra-fine clarification withsolutions comprisinga centrifugal separationsystemandfiltrationtechnology.
Inaddition tocentrifugalseparationsystems,GEA Westfalia Separator also has an expertcommand of membrane filtration withceramic elements for ultra-fine clarificationof particles with a size of up to one nano-meter. Because of this, our company is ableto significantly expand product clarificationwithin a process line. The combination ofcentrifugation and membrane filtrationimprovestheefficiencyoftheoverallinstallation.
IndividualspecificationsThe ceramic membrane installationscontinuously supply a clear filtrate with thespecifieddegreeofclarificationandthedesiredperformance.Theceramicmembraneformsamechanicalbarrierwithadefinedporesize.
GEAWestfaliaSeparatorprovidesawiderangeofceramicmembranemodulesintheporesizerangeofultra-andmicro-filtration.
5. Ceramic Membrane Filtration – Ultra- and Micro-Fine Clarification
The modules are mainly standardized, withvariable channel diameters, element lengthsand pore sizes. This membrane installationdownstreamoftheseparatorpermitsextremelyfineclarificationofparticleswithadiameterof<1micrometer.
Ataglance: GEAWestfaliaSeparatorofferssolutions
comprisingcentrifugationandmembranefiltration
Allcomponentsfromasinglesource Intelligentharmonizingofallcomponents
enhancesprocessefficiency Widerangeofceramicmembranemodules Individualconfigurationaccordingto
specificrequirements
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GEA Westfalia Separator
Everything from a single source.
GEA Westfalia Separator has extensiveexperienceinthedriveandcontroltechnologyof separation systems. Customer-specificautomation of centrifuges and membranefiltration means that their operation issimple, reliable and safe.Solutions fromGEAWestfalia Separator combine tried-and-testedprocess and machine technology with thelatest drive and control technology. Theautomationconceptsarecustomizedtomeettheindividualrequirements.Fromadviceprovidedbyexperiencedengineeringspecialists,compactcontrolunitsforindividualmachinesandpowerfulPC-based installation controls right through tocomprehensiveoriginalmanufacturerservice.
HighcompatibilityIn addition to our company‘s own compactcontrol units, the S7 control units fromSiemensconstitutethecoreitemofinstallationautomation. However, components fromAllen Bradley, Group Schneider, Mitsubishi,Modicon or Telemechanique can also be usedandcombinedwitheachotherasrequired.Thevisualization options always ensure optimumuser-friendliness.WinCCorIntouchcanbeusedforuptofivevisualizationfacilitiesintheprocessline,andcanalsobecombinedwitheachother.Whetherasimplenotificationsignaloracomplexprocessdataexchangearrangementisrequired,theconnectiontoexistinginstallationsorprocessesviasoftwareisnowadaysalmostobligatory.
6. Automation Systems – Plug and Play
Our specialists from GEA Westfalia Separatoruse the best-known systems such as ProfibusDP/PAorIndustrialEthernetaswellasadditionalconnections such as DeviceNet, ControlNet orModbusforthispurpose.Fullyautomaticoperationoftheinstallationcanalsobesupportedbyremotedata transfer by means of Internet, modem orGPRS.WithWestfaliaSeparator®wewatch®,anindependentandcomprehensiveserviceconceptisavailableforremotediagnosis.
Ataglance: Strongcompetenceindriveandcontrol
technology Individualautomationconcepts Adviceprovidedbyengineeringspecialists Compactcontrolunitfromawiderangeof
manufacturers Uptofivevisualizationsintheprocessline Comprehensivecontrolpossibilitiesfrom
asimplereportingsignalrightthroughtocomplexprocessdatainterchange
ConnectionviasoftwarewithProfibusDP/PA,IndustrialEthernetorothersystems
Supportforremotetransmissionanddiagnosis(WestfaliaSeparator®wewatch®)
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GEA Westfalia Separator
Itisimportanttoselectthecorrectmaterialsforcomponentsthatcomeintocontactwithproduct,suchasthebowl,scrollordiscstack.Strength,corrosionresistanceandhygienicspecificationsareimportantcriteriainthisrespect.Ingeneral,the quality of the material must increase astherequirementsbecomemorestringent.Thestandard material is stainless duplex steel,whichhashighstrengthandexcellentcorrosionresistance. On the other hand, super duplexsteelisthepreferredmaterialformorecomplexapplications.Forparticularly“hard”applications,GEA Westfalia Separator uses special alloyssuchasIncoloy“Titanium”825orHastelloyC4.Theload-bearingparts(bowlbottomandbowltop) can also be of complete 1.4501 superduplexmaterial.
AgenuineGEAWestfaliaSeparatorspecialityisthe lining of solid-wall bowls with HastelloyC4oreventitaniumpalladium.Inthisprocess,sheetsof theappropriate specialmaterial areincorporatedinthebowltopandbowlbottomtoensurelongcorrosionprotection.Theload-bearingbowlpartshowevercontinuetobemadewith standard materials to permit high bowlspeeds.Thisprocedurehasspecificadvantages.First, ifnecessary, the liningcanbe replaced.Second,theuseofexpensivespecialmaterialisreducedtoanabsoluteminimum.
7. Special Materials
1. Inserting the lining in the bowl bottom
2. Dye penetration test after welding the lining
3. Bowl bottom with lining in place
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GEA Westfalia Separator
Customer-specific testing in Central ProcessEngineeringprovidesareliablebasisfordecision-making for all investments in mechanicalseparationtechnology.Noseparationisidenticalwith another. In many cases, it is necessarytoperformaseriesof testsbeforethecorrectdecisioncanbemadeforaspecificinstallation.GEAWestfaliaSeparatorhassetuptheCentralProcessEngineeringdepartmentforthispurpose.Depending on the specific task involved, testseriescanberunwiththecustomer‘soriginalproduct in a mobile pilot installation on siteorinthelaboratoryatGEAWestfaliaSeparator.Thespecificationof thecustomer,alongwithoperating temperature, throughput capacity,clarifying or separating efficiency and otherfactors, constitute the information necessaryto complete a reliable analysis. After everytest series, the customer receives informativedocumentation in which the technical andeconomicdataaredetailed.
FocusoninvestmentprotectionTheresults fromCentralProcessEngineeringcanbeusedtopreciselyidentifywhatmachinetype and what model from GEA WestfaliaSeparatoraremostsuitableforthespecifictask.Thecustomerachievesareliablebasisonwhichhecanmakethecorrectinvestmentdecision.
Scale-upforextractionapplicationsThe scale-up of extraction applications isoftenbasedonpracticaltrialscarriedoutwithtest centrifuges. If extraction is chemicallydeterminedandifthesolvent,thetemperaturesetting and the pH value are defined, a pilotscale operation can be tested. The mixingcharacteristics togetherwith themixing timeanddropsizeaswellassubsequentcentrifugalseparation have to be adjusted individuallyfor the specific substance system. The phaseratiobetween the raffinate and the extract isoptimizedinordertotakefulladvantageofthegivencapacityofthesolvent.
8. Central Process Engineering –the Reliable Basis for Decision-Making
Ataglance: Seriesoftestswiththecustomer‘soriginal
products InthelaboratoryofGEAWestfalia
Separatororinpilotinstallationsonsite Detailedtestdocumentation Specificmachinerecommendation Detailedmassbalance Totalcostanalysis
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GEA Westfalia Separator
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GEA Westfalia Separator
Our Westfalia Separator® capitalcare service commitment
As an EN ISO 9001 company we stand behind the quality of both our products and our service. Our continuing commitment is to provide customers with the support they need to maximize productivity and minimize downtime. You can count on us for round-the-clock assistance in all service areas.
Original manufacturer’s spare parts –We house a large inventory of partsthroughoutour6officenetwork.Thesearereadytobeshippedoutwitha24-hourturn-around. Only genuine GEA WestfaliaSeparatorpartsaremanufacturedunderthesame strictquality control andusing thesame specifications and materials as ouroriginalequipment.
Factory-AuthorizedRepairs–Weoffertwofull-servicerepairfacilities,oneontheWestCoast(Patterson,CA)andoneontheEastCoast(Northvale,NJ).Thishelpstospeeduprepairtimesandkeeptransportationcostsdown.Both facilitiesare factory-certifiedandarestaffedwithexperiencedtechnicianswhohaveundergoneextensivetraining.Ifneeded,weofferover100rentalscrollsorbowlassembliestokeepcustomersupandrunningwhilerepairsareunderway.
FieldService–Wehaveanextensivefieldservice team to perform routine andpreventivemaintenanceandtohandleanyemergencies that may come up. Locatedthroughout NorthAmerica, these servicetechniciansarestrategicallypositioned inareas where their industry and process-specificknowledge ismostvaluable.Ourserviceengineersareoncall24/7.
Maximum availability
Absolute budget reliability
Permanent efficiency
Westfalia, Westfalia Separator, varipond® and wewatch® are registered trademarks of GEA Westfalia Separator GmbH.
GEA Mechanical Equipment US, Inc.GEA Westfalia Separator Division
Headquarters:100 Fairway CourtNorthvale, NJ 07647201-767-3900
Midwest:725 Tollgate Road, Suite BElgin, IL 60123630-503-4700
South:4725 Lakeland Commerce Parkway, Suite 4 Lakeland, FL 33805863-603-8900
Southwest:2408 Timberloch Place, Suite C-4 The Woodlands, TX 77380281-465-7900
West Coast:Western Region Customer Support Center555 Baldwin RoadPatterson, CA 95363209-895-6300
GEA Mechanical Equipment Canada, Inc.GEA Westfalia Separator Canada Division835 Harrington CourtBurlington, ON L7N 3P3289-288-5500
Toll-Free: 800-722-662224-Hour Technical Help: 800-509-9299www.wsus.com
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