CF-Decanter Centrifuge Series - Take the best of 50 years decanter design

GEA Westfalia Separator Group GmbH

Overview

New CF-Decanter generation: motivation design features Scale-Up to entire decanter family

efficiency in food and energy processes.

Overview

New CF-Decanter generation: motivation design features Scale-Up to entire decanter family

efficiency in food and energy processes.

Invention of new gear: Summationdrive - Breakthrough in DriveConcept for Decanter

Features of new gear drive: - planetary differential gear => high torque => only power input, no back drive => high efficiency - high differential speed range from 1 rpm up to 70 rpm (Westfalia patent) => high flexibilty in operation of decanter

efficiency in food and energy processes.

New Summationdrive - constant torque and higher differential speed

efficiency in food and energy processes.

summationdrive - configuration for low differential speeds

Power: 15kW

Power: 15kW

Differential speed 1-25 rpm selectable Secondary motor feeds power into the system for solid transport Main motor delivers pumping power liquid phase and noload power Motors supply only the power that is needed. No energy circulation.

efficiency in food and energy processes.

summationdrive - configuration for high differential speeds

power main motor: 15kW Power: 15kW Power: 30kW

Higher differential speeds (e.g. 30-50 rpm or 50-70 rpm) selectable. Full torque capacity at higher differential speeds Both secondary and main motor drive the scroll. Additional required power is added by the second belt drive. No power circulation within the belt drives. All belts feed power to the gearbox.
efficiency in food and energy processes.

Development history SummationDrive - over 100 installations have proven the design
PGA364 gearbox:

- 6400 Nm torque -1-70 rpm differential speed

Time Schedule SummationDrive:

- Development started in year 2005 (Westfalia design, own patent) - Detailed design and manufacturing of PGA364 gear in year 2006 - First gear tested in 2007 ; Own gear test rig for full torque and full speed - First field test started in 2007, series release in 2008 - installation of over 100 gearboxes PGA364 in the field until end 2010 - series release of next gearbox PGA342 (4200Nm torque) in 2009 - series release of gearbox PGA368 (6800Nm torque) in 2010

efficiency in food and energy processes.

Overview

New CF-Decanter generation: motivation design features Scale-Up to entire decanter family

efficiency in food and energy processes.

Design features new decanter series

leading Performance: => deep pool design => new gear drive => high bowl speed => low energy consumption high Flexibility => new gear drive => add-on-system design

efficiency in food and energy processes.

Matrix of bowl options for one decanter bowl size

Deep pond bowl (400 mm decanter) bowl length L/D=4.0 15 cone angle dfa = 185 mm bowl length L/D=4.8

8 cone angle dfa = 195 mm

efficiency in food and energy processes.

Design features new decanter series

leading Performance: => deep pool design => new gear drive => high bowl speed => low energy consumption high Flexibility => new gear drive => add-on-system design best in class Serviceability => outboard gear drive design => pillow block design => good access to all parts high Robustness => proven technology => high quality standards regarding material and manufacturing
efficiency in food and energy processes.

Design process new decanter series - Using latest available design tools

3D-CAD system Assembly check

FE-analysis Mechanical stresses and eigenfrequencies

Testing Performance tests Mechanical tests Testbed gear drive

CFD-analysis Distributor design, scroll design

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efficiency in food and energy processes.

Overall dimensions of CF405 decanter

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efficiency in food and energy processes.

Overview

New CF-Decanter generation: motivation design features Scale-Up to entire decanter family

efficiency in food and energy processes.

CF-Decanter family - 8 models planned

Starting point for new decanter family is the 400 mm decanter

Scaling factor for geometry: 1.17 Scaling factor for capacity by clarification area: 1.17 (with same velocity) Scaling factor for capacity by g-volume: 1.37 (1.17^2 with same velocity)
CF 20x G * Surface G * Volume 62% 39% CF 27x 73% 53% CF 34x 85% 73% CF 40x 100% 100% CF 47x 117% 137% CF 55x 137% 187% CF 64x 160% 257% CF 75x 187% 351%

Series of decanters:

CF20x

CF27x

CF34x

CF40x

CF47x

CF55x

CF64x

CF75x

efficiency in food and energy processes.

Gearbox sizes Summationdrive for CF-decanter

Notes: * = decanter model currently not planned ** = two motor drive instead of new WS differential drive ***= no new decanter planned, current CA1035 decanter torque for all gears need to be reduced by 5% for bowl speed u=105m/s

efficiency in food and energy processes.

Future Product Line Westfalia Decanter - 2 models of CF-Series ready for sales
CF750 CF640 CF550 CF470 CF400 CF340 CA1035 CF270 CF200

efficiency in food and energy processes.

Thank you very much.

efficiency in food and energy processes.