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Separators Digest

1 | 2007 The Magazine of Westfalia Separator AG

Turnkey Project
Complete dairy
installed in Iran

Must Clarification
Winemaking operations
benefit from decanter
technology

Crud Processing
Hydrometal recovery
by liquid extraction
Contents

Turnkey Project | 10 The Oscar of Shipping | 26

Preface Mineraloil Systems


3 Changing One's Perception 23 Nothing More in the Air
26 The Oscar of Shipping
Separators News
4 Topical Umwelttechnik
30 PET Recycling
Food Tec 33 Separators Reduce the
10 Turnkey Project Strain on SBR Reactor
14 Must Clarification and 36 It Makes Twice the
Must Trub Clarification Sense to Reduce Speed
18 Control is Better
Lifestyle
Industry 38 Crucial Question
20 Crud Processing

Imprint
Publisher: Photography:
Westfalia Separator AG Michael Dannemann, Tim Luhmann,
Project management: Peter Arens Heinz-Gnter Spasic,
archive Westfalia Separator AG
Editors:
Peter Arens, Dr. Jrg Bckle, Conception and Layout:
Manfred Kaiser Kabutz Kommunikation GmbH The information contained in this brochure merely serves as a non-binding description
Feldstrae 5 59423 Unna of our products and is without guarantee. Binding information, in particular relating to
info@kabutz.de www.kabutz.de capacity data and suitability for specific applications, can only be provided within the
framework of concrete inquiries.

2 Contents
Separators Digest 1 | 2007
Preface

Changing One's Perception


A good drop of wine must of course come from a
bottle with a genuine natural cork or so experts have
believed for centuries. Nothing else was acceptable; screw
caps were vilified. How times change! More and more
alternatives to the cork are becoming available as a means
of stopping wine bottles. In particular, the unloved screw
top is much better than its reputation and offers numerous
advantages. More and more premium wine growers in Stefan Rehnert
Australia and New Zealand are therefore using screw tops (right) and
for their bottles of high-quality wines. This provides them Werner Kohlstette

with obvious advantages: it is an undisputed fact that


approximately ten percent of all wines have their flavour
tainted by the cork (corked). The screw top avoids this as
the wine is also no longer able to oxidise. The wine does
not need a natural cork even to breathe or to develop. For
good wines, a screw top is therefore a major alternative for
undisturbed enjoyment of wine.

In certain cases, many years and decades are necessary


before received opinions, such as those concerning the
natural cork, can be revised. The newly presented CE 345 decanter is also a very
attractive product for SME operations. The decanter can
At Westfalia Separator, this process of revision, namely be used as a multi-function machine for clarifying must,
that of considering an already successful solution from processing tank bottoms or removing tartrate.
another point of view, is an established standard. We
for instance consistently pursue a policy of combining a Are you interested in breaking new ground, do you have an
centrifuge and membrane filtration as an extension of open mind for innovative solutions, then please visit us at
mechanical separation technology. Westfalia Separator is the INTERVITIS INTERFRUCTA in Stuttgart.
now presenting such hybrid solutions for sustainable
optimisation of the winemaking process at the INTERVITIS
INTERFRUCTA.

The separator GSC 25 is a further excellent example of


the strategy of always offering the best and most modern
solution. The hydrohermetic seal protects a product
that is sensitive to shearing, and avoids the absorption of Stefan Rehnert Werner Kohlstette
oxygen from the air. The tried-and-tested Westfalia Chief Executive Officer Chief Operating Officer
Separator HydroStop system ensures that the trub is also
particularly dry when it is discharged from the machine.
The benefit for winemaking operations is maximum yield.

Preface 3
Separators Digest 1 | 2007
Separators News

Sold Out and Well


Attended: INTERVITIS
INTERFRUCTA 2007
It is by far the most international than 1000 wine, fruit and fruit juice
technology exhibition for wine, fruit experts from all over the world have
and fruit juice: the Deutsche registered to attend the high quality
Weinbauverband and Messe Stuttgart supporting programme of the
expect to receive around 600 exhibition.
exhibitors and 40,000 visitors from
all continents at the INTERVITIS
INTERFRUCTA 2007 between 22 26
April 2007. As with previous events,
the exhibition grounds Killesberg will
also be completely sold out. The
INTERVITIS INTERFRUCTA 2007 does
not need to fear any reduction in the
number of exhibitors or overall area.
On the contrary, it is somewhat above Westfalia Separator Food Tec
budget compared with the previous is traditionally represented with
event in 2004. For the first time more a stand in hall 4.0, stand 114

Decanter CE 345 The new CE 345 decanter was


presented at the INTERVITIS INTER-
The CE 345 is equipped with the
"Delta power T" drive for automatic
New Multi-Function Machine FRUCTA by Westfalia Separator Food torque measurement and differential

for Winemaking Operations Tec. The new machine has a capacity


of up to 5000 l/h and excellent
speed regulation. This drive differs
from conventional gear drives in that
value-for-money making it ideal for an additional secondary gear and
SME operations. The decanter can be a secondary motor are used. This
used as a multi-function machine for construction allows infinitely-variable,
must clarification, tank bottom torque-dependent differential speed
processing or must trub processing. regulation. The high regulating
The optimised bowl design of the accuracy permits extremely small
decanter ensures a large clarifying differential speeds giving optimum
area to give maximum separating dewatering of the solids. This, for
performance in every area of instance, always provides maximum
application. yields in tank lees processing and
excellent quality of the recovered
wine.

Further characteristic features of


the CE 345 are excellent efficiency,
low space requirement,
low maintenance and an
environmentally sound method
of operation.

4 Separators News
Separators Digest 1 | 2007
Separators News

Hybrid Solutions Optimise the Winemaking Process Optimum Wine


Through the concept of modern solids and Must
management, Westfalia Separator
Food Tec recognises that solid/liquid
Clarification
separation is increasingly determining
the quality of the end product and The GSC 25 separator shown at the
the cost-effectiveness of the entire INTERVITIS INTERFRUCTA has been
process chain. To achieve this, optimised by Westfalia Separator Food
Westfalia Separator is consistently Tec particularly for must and wine
pursuing a policy of combining the clarification in SME operations. The
centrifuge and membrane filtration as Westfalia Separator HyDRY separator,
an extension of mechanical separation developed in accordance with the new
technology. Westfalia Separator is standardisation concept, can be used
presenting this hybrid technology in the performance range 1000 l/h
for sustainable optimising of the wine- to 3000 l/h for must clarification
making process at the INTERVITIS and 3000 l/h to 7000 l/h for wine
INTERFRUCTA. clarification. It can also be used for
polishing wine upstream of filtration
The purposeful combination of centrifuge and membrane filtration
The intelligently combined technologies or recovering wine from lees.
extends mechanical separation technology.
of centrifugation and cross-flow
filtration with ceramic elements and
the related customised design for red
wine, white wine and ros wine also
increase the wine yield, availability
and the cost-effectiveness of the
entire process chain.

The GSC 25 is a further excellent


example of the Westfalia Separator
strategy of offering the latest
centrifuge technology in all market-
relevant performance classes. This
includes the hydrohermetic seal to
prevent the inclusion of oxygen from
the ambient air; and the tried-and-
tested Westfalia Separator HydroStop
system to ensure that the separated
trub is particularly dry when it is
discharged from the machine. Despite
these advanced engineering features,
the GSC 25 offers the customer
excellent value for money.

Separators News 5
Separators Digest 1 | 2007
Separators News

Service
Expanding in New Managing
Hamburg Director in Denmark
The service division (Customer Support Boy Konstmann became the managing director of Westfalia Separator A/S,
Centre) of Westfalia Separator Denmark on 1 October 2006. Following technical training, Mr. Konstmann
Mineraloil Systems has expanded so studied management, specialising in sales and marketing. He has been
strongly in recent years that the working in various positions at Emerson Process Management since 1988,
premises in Hamburg-Bergedorf were most recently as sales director for Denmark.
no longer sufficient. For this purpose,
a new building is now being
constructed, and the Customer
Support Centre will move in starting
mid-2007. In December 2006, the Authorized Workshop Ireland
foundation stone was laid in
Hamburg for the new building in the
Neulnder Business Park in Hamburg- Westfalia Separator Ireland Ltd.
Harburg. opened its authorized workshop
at the end of October 2006. Safety for
To meet increasing customer require- employees and customers are some
ments and to be in a good position of the fundamental objectives of
to meet future developments, the Westfalia Separator Ireland Ltd.
division will also be expanded. A so it is focusing on preventive main-
total area of 5441 m2 will see the tenance services.
creation of 1316 m2 of office space,
a 590 m2 repair workshop and a The company has supplied a large
860 m2 warehouse as well as service number of decanters for environmental
and outdoor areas. and industrial applications with Werner Kohlstette, Chief Operating
new activities including routine Officer, Westfalia Separator, Michael
Hosford, Safety Officer Westfalia
replacement as well as overhauling of
Separator Ireland, Vincenzo Spitaleri,
gearboxes as a preventive measure.
Chairman Westfalia Separator
Ireland, Con OBrien, Managing
Director Westfalia Separator Ireland.

Authorized Workshop
in Belgium

At the end of 2006, Westfalia repairs for the marine sector allowing
Separator Belgium was recognised it to provide support services to the
as an authorized workshop. This Port of Antwerp.
means that it is now able to offer
the enhanced range of professional
services and overhaul replacement
parts such as spindles and clutches.
In the subsequent phase, Westfalia
Separator Belgium will include

The authorized workshop


in Antwerp

6 Separators News
Separators Digest 1 | 2007
Separators News

Crude Oil Processing Installation for a Power Station in Riyadh


In 2006, Westfalia Separator Mineraloil
Systems received an order for a crude
oil processing installation for the
PP9 power station in Riyadh, Saudi
Arabia. This power station, with a
capacity of 2100 MW in the final design
stage, is responsible for assuring
energy supplies in the capital city of
Riyadh. It is responsible for cleaning
the crude oil and dewatering and
desalinating the fuel. This guarantees
the continuous and trouble-free
operation of the gas turbine power
station.

The order volume consists of the fuel


processing facility with 32 OSD 60
separators, various feeder pump
stations for crude oil, and feeder
installations. The scope of supply also
comprises a complete monitoring
installation with redundant control and
motor starters.

32 type OSD 60 separators will in future be operating in Riyadh.

Rapid Success: 100th CD 53 Decanter

The 100 th CD 53 decanter was The still young decanter has been
delivered from the Westfalia Separator very well received by the market
Niederahr works at the end of 2006. not only as a result of its high
The anniversary machine was sent performance but also as a result of
to Spain to recover olive oil. The the intelligent overall concept. The
decanter is the middle-class model machine has a very compact design,
of the new CDforce generation of a footprint of only 4 m 2; and
Westfalia Separator and was only numerous new developments for
released for the market two years individual components to ensure that
ago. One of the major reasons behind the decanter can be maintained
this success is that the decanter is quickly and easily.
one of the most powerful in its size
class. The CD 53 has also been able
to compete with much larger
machines from competitors.

Separators News 7
Separators Digest 1 | 2007
A Crocodile for the Wattenmeer

The Oldenburgisch-Ostfriesische Was- the mainland, where the sludge


serverband (OOWV) has modernised is disposed of in a sewage sludge
the sludge dewatering facility at the incinerating facility.
waste water treatment plant on
Spiekeroog. At the Eastern end of the Spiekeroog has about 800 inhabitants,
village on the North Sea Island, a and also reports in the region of
strainer belt press has now been 500,000 overnight stays of tourists.
replaced by a new decanter from This results in major seasonal
Westfalia Separator. fluctuations in effluent. With the
UCD 305 decanter known as the
crocodile a machine has been
Disposal costs installed that can reliably process the
reduced by more quantity of sludge at peak times.
than 20 per cent

As a result of the increase in the


dewatering efficiency from 18 to
more than 23 percent, the disposal
costs per tonne of dewatered
sludge have declined by more than
20 percent. In addition, there are also
savings in terms of transportation
The North Sea island of Spiekeroog
costs, because only approximately remains a popular tourist
25 containers instead of 35 containers destination also thanks to the
have to be transported by ship to decanter type UCD 305.

Remote Maintenance System


for On-Board Separator
Installations

The increase in global trade is being Employees of Westfalia Separator


accompanied by a constant increase Mineraloil Systems can carry out
in world-wide ship traffic. Time is changes to the process control world-
becoming more and more important. wide via an Internet connection. In
The process of controlling large trans- addition, a facility is to be provided
port vessels is being increasingly for ordering original spare parts
automated. However, on board, there via the remote maintenance system
are no suitably qualified personnel to guarantee optimised customer-
for carrying out changes to the oriented service. The Internet remote
installation control directly on site. maintenance system was presented
However, to ensure that a quick and in Hamburg as a new service product
efficient service programme is at the exhibition SMM Ship,
available, process problems in future Machine, Marine Technology in
are to be remedied by the remote 2006.
maintenance system.

8 Separators News
Separators Digest 1 | 2007
Separators News

Controls for Separators with Simatic C7

Westfalia Separator Mineraloil The increased short-circuit resistance


Systems uses Simatic C7 controls of analogue outputs, the redesign
from Siemens for controlling the of the printed circuit boards to
BilgeMaster-D 3000
separating processes in the engine permit better heat dissipation and
with Siemens
rooms of ships. Operating conditions the integrated PT-100 input are
control unit C7-635 (D20)
on board are anything but simple, examples of Westfalia Separator
in particular, constantly high recommendations that have been
temperatures of 45 C and more implemented. The handling of
mean that technology has to face software has also become more
severe challenges. simple for exchanging devices or
handling updates: The new Micro
Ulrich Dahlkemper, Head of Memory Card (MMC) and the
Automation and Drive Technology Compact Flash-Card (CF) for the HMI
said, We have incorporated our part of the C7-635 can be handled by
comprehensive field experience in a fitter or marine engineer without
the development of the latest any specialist knowledge. For
C7-generation. This feedback Westfalia Separator, the worldwide
from practical applications has availability of spare parts and, if
demonstrated its worth and has necessary, support provided by the
resulted in further improvements in manufacturer are major factors
terms of reliability, operability, service for using Siemens automation
life and software concept of the technology.
current machines.

Mobile
Installation
Mobile waste water treatment
plants from Westfalia Separator
Umwelttechnik have two key func-
tions within the waste water sector:
to enable trials to be carried out with
original sewage sludge on site at
waste water treatment plants; and to
provide cover during shut down when
operators convert to new technology.
For instance, the Abwasserzweck-
verband Holtemme has ordered
a type UCD 536 decanter in
addition to the existing type UCA 505
machine from Westfalia Separator
The participants of the expert training, in front of the mobile installation
Umwelttechnik to expand the capacity
with decanter type UCD 536.
of the waste water treatment plant in
Silstedt. Until the new decanter was
installed, the waste water treatment
plant used the mobile installation as
a temporary solution for sludge
dewatering.

Separators News 9
Separators Digest 1 | 2007
Turnkey Project
Complete dairy installed in Iran

At the end of last year, Westfalia Separator Food Tec,


Business Unit Dairy Technology, completed an entire fully
automated dairy as an exclusive order and turnkey project
for Iran Dairy Industries Company (IDIC) in Isfahan.
Westfalia Separator Food Tec was responsible for planning,
delivering and installing the entire process engineering with the
latest automation technology and high hygienic standards,
from the point at which milk is received right through to the
cooling room with the exception of locally manufactured
tanks. The exemplary project with a milk acceptance capacity of
200,000 l/day was also the largest individual order for Westfalia
Separator Food Tec.

Positive experience Separator Food Tec. Both installations are


from the past still running to the complete satisfaction of
the operator, and without any problems,
Westfalia Separator Food Tec, Business Unit several years after initial commissioning.
Dairy Technology, had already worked very These positive experiences, and mutual
successfully on two occasions in recent trust, were a major reason why Iran Dairy
years for the semi-state-run Iranian dairy Industries Company again engaged the
group IDIC. In Teheran, Westfalia Separator services of Westfalia Separator Food Tec for
Food Tec had installed a turnkey production a turnkey order. However, the project in
installation for double cream cheese seven Isfahan was much more extensive. Isfahan
years before. This was followed by a turnkey is the capital of the province of the
installation for the production of labneh, a same name in Iran with around 2.5 million
typical product similar to quark in the inhabitants.
countries of the Middle East, in Zanjan,
approximately 500 km to the North of
Teheran, under the leadership of Westfalia

10 Food Tec
Separators Digest 1 | 2007
Food Tec 11
Separators Digest 1 | 2007
Food Tec

Milk process and double cream cheese


IDIC also operates one of its many dairies in Isfahan. A 'dairy in
the dairy' has now been integrated in this large dairy with a wide
range of products; this offers a facility of taking 200,000 l of
whole milk per day and making 50,000 l of standardised milk
for the production of double cream cheese and processing
the remaining 150,000 l milk into milk powder. The dairy itself
installed the plant for making milk powder.

Alternatively, pasteurised and standardised Three tanks, each with a capacity of


milk as well as pasteurised cream can be 75,000 l, receive the cooled whole milk
taken for further application to the other from two reception areas; the whole milk is
production facilities located about 300 separated with a separator MSD 170.
metres away. Vice versa, the new process Bacteria are removed with a separator
plant can receive additional cream from the CNE 215; the whole milk is standardised
older dairy or from external suppliers via with a Westfalia Separator STANDOMAT
a cream reception facility to produce a and pasteurised with a plate heat exchanger.
higher quantity of double cream cheese and The cream is pasteurised separately via a
consequently less milk powder if required. cream pasteuriser, cooled and then stored in
This is because the minimum fat content in a tank facility of 2 x 20,000 l. Four 50,000 l
the milk for producing double cream cheese tanks blanketed with sterile air are available
is 8 per cent. These various options enable for the skim milk and standardised milk. The
plant management to respond to the standardised milk is subject to heat treatment
supply of whole milk/cream and the market and is homogenised in two stages using a
requirements very flexibly. homogeniser from Niro Soavi, a company of

12 Food Tec
Separators Digest 1 | 2007
GEA Group. For the culture necessary
for the subsequent fermentation of
the milk (lactic acid bacteria), Westfalia
Separator Food Tec has installed a
virtually fully automated culture
station. On the basis of concentrated
freeze-dried or deep frozen lactic acid
bacteria (culture), this arrangement
produces a large volume of so-called
liquid 'bulk starter' (starter culture) The new dairy in the dairy processes up to 200,000 litres
which is supplied to the fermentation of whole milk per day.
tanks via a feed pump.

Unique process technology

After the fermented milk has lating facility, i.e. inductive flow meter Dairy Industries Company in Isfahan
attained the desired pH value, after and regulating valve in the feed and in for double cream cheese and milk
the temperature of the milk has been the whey discharge. From the separator, powder after a one-year construction
raised to 80 C, and after a reaction the viscous cheese is pumped into two period. This advanced installation is
time of 20 minutes in a reaction tank, mixing tanks. Salt is added beforehand a further reference installation of
the heat-treated milk is supplied to the to the cheese through a metering device. Westfalia Separator Food Tec for
separator KSA 20. The double cream It is also possible for ingredients to be the entire Middle East. Following this
cheese is discharged as the light phase added to the contents of the mixing successful project, IDIC will continue
almost completely under gravity as a tanks, for instance, garlic, onions or to work together with Westfalia
result of the high fat content and thus herbs. In the mixing tanks, the finished Separator Food Tec and there are
the low specific weight, whereas the product is constantly agitated; it is already plans for a subsequent order
whey (the heavy phase) with a higher then conveyed to a packaging machine for a new labneh production line,
specific weight is discharged under (still at a temperature of 80 C) and identical to the line already installed in
pressure via a so-called centripetal packed, then stacked on palettes, cooled Zanjan. An impressive confirmation of
pump at the periphery of the bowl. to a temperature of 15 C by passing satisfaction.
through a 16 metre long cooling tunnel
For the mechanical separating process and stored in a cooling room. The double
of double cream cheese recovery, cream cheese is now ready to be sold.
Westfalia Separator Food Tec has
traditionally enjoyed a unique position The hygiene requirements have
equivalent to that of a monopoly been satisfied by Westfalia Separator
in the dairy world thanks to its Food Tec by means of sterile air
advanced technology. Because the blanketing of process tanks as well as
KSA 20 separator is designed for a the installation of a large CIP system
cheese output of 2500 kg/h with a with four circuits for more than 30 CIP
corresponding feed of 7500 l milk/h, routes. A concentrate feed installation,
Klaus-Michael Dukatz
150,000 l whole milk per day can, if including a tank for dissolving soda
required, be processed into double pellets, adds the acid and lye Business Unit Dairy Technology
Westfalia Separator
cream cheese in a 20 hour operation. concentrate to the corresponding CIP
Food Tec, Oelde
buffer tanks fully automatically.
Tel. +49 2522 77-2832
A constant dry matter of the product dukatz.klaus-michael@
is attained irrespective of the feed November 2006 saw the commissioning gea-westfalia.de
quantity through a dry matter regu- of the new 'dairy in a dairy' at Iran

Food Tec 13
Separators Digest 1 | 2007
Food Tec

Must Clarification and


Must Trub Clarification
Winemaking operations benefit
from decanter technology

The way is defined. Winemaking


operations wish to produce without
the use of kieselguhr in the medium
term for must and fine clarification. As
an alternative to kieselguhr filtration with
vacuum rotary filters, it is possible to
clarify must with decanters. Decanter
technology not only prevents the must
trub coming into contact with kieselguhr;
it also allows more gentle operation
than vacuum rotary filters, they are less
expensive because they do not use
consumables, and they require less labour
for preparation and cleaning.

14 Food Tec
Separators Digest 1 | 2007
Food Tec

This is all achieved with identical or even


better separating efficiency and higher
quality. And because the product remains in
the rotary filter for longer the oxygen
consumption is also higher. A further factor
is that a decanter is a multi-purpose machine
in a winemaking operation which, in
addition to seasonal must clarification, can
also be used for must trub treatment, lees
processing and for tartrate separation.
Various practical installations have taken
this step and prove that the decanter
process is flexible, less labour-intensive and
more cost-effective.

Pre-clarification necessary

Scroll-type presses and pneumatic tank


presses are frequently still to be found in
winemaking operations to press the must
with a high solid rate. The solid content
is too high to enable the product to go
immediately to the fermentation stage.
Pre-clarification is therefore necessary
upstream of fermentation. This is a task for
a decanter, although the machines are in
principle solids-oriented.

Food Tec 15
Separators Digest 1 | 2007
Food Tec

A question of philosophy: must


clarification or trub concentration?

The procedure tends to be a question of


winemaking operation philosophy. Either the
decanter reduces the solids content directly
from the pressed or freely discharging must, or
the must is initially sedimented in a settling
tank, the clear phase is drawn off from the top
of the tank to the fermentation stage and the
must sediment, namely the trub, is routed via
the decanter.

In the case of must from scroll-type presses, the


decanter is responsible for reducing the solid
content from approximately 10 percent to
around 1 percent (by volume) or (depending
on the specific requirement) even to 0.5 to
0.6 percent (by volume) with a corresponding
reduction in capacity. With pneumatic tank
presses, the initial solids content is around
2 to 4 percent; this can then be reduced to the
same low values in the decanter.

If sedimentation takes place as a pre-clarification


process, the decanter is responsible for separating
the remaining must from the must trub. The
must trub has much higher solid contents of
around 20 percent (by volume) or more.
However, the decanter is ideally suited for this
task. The trub still contains approximately
80 percent must. The decanter then separates
the trub from the remaining must and recovers
a minimum of around 16 percent of top
quality must, in relation to the total quantity.
Pre-clarification removes the trub with micro- The must is of a much higher quality than
organisms and other residues on the grape that produced in a pure settling process
using, for example, a vacuum rotary filter. The
skins, avoids unwanted initial fermentation as a capacity of the decanter is lower because
result of bacteria reduction, ensures fewer wine the solid load in the sediment is naturally much
faults such as unwanted factors of taste and higher than in the must. For certain qualities
and types, some winemaking operations
nose and overall allows the fermentation process
use both methods. However, sedimentation
to be monitored more easily to produce good requires large tank capacities and additional
wine quality. cooling.

16 Food Tec
Separators Digest 1 | 2007
Food Tec

Comparison between must losses due to the kieselguhr. there is the CA 501 machine with a
vacuum rotary filter and Vacuum rotary filters are more difficult capacity of 15,000 to 17,000 l/h for
decanter to clean, and therefore involve high must clarification and 3500 l/h for trub
water and personnel costs. This is not concentration. At the upper end
A direct comparison between a vacuum the case with the decanter. In addition, of the performance range, there is the
rotary filter and a decanter used for decanters operate continuously and CA 755 with a capacity of 35,000 to
processing must trub demonstrates automatically, whereas vacuum rotary 40,000 l/h for must clarification and
the advantages and weaknesses of the filters, with their semi-continuous 10,000 l/h for trub concentration. All
two systems. Whereas the investment method of operation, require monitor- types can also be used as a multi-
costs of a decanter are initially slightly ing. Personnel, cleaning and filter aid function machine for processing tank
higher than a vacuum rotary filter, the costs are the main economic factors in bottoms and removing tartrate. The
decanter's financial benefits are to be favour of the decanter. They are easy decanter method is the technological

The decanter method is the technical


and economic alternative for must
clarification and trub concentration.

seen in the running costs. For example, to handle, automation costs are low, and economic alternative for must
a vacuum rotary filter with a filter area and the practice-performance ratio is clarification and trub concentration.
of 20 m and a CD 305 decanter are
2
favourable. The decanter also enables This is also the reason why decanters
each to reduce 5000 l/h must trub a flotation facility to be connected in have been increasingly installed in
downstream of the floatation tank to the discharge; after a settling period in many quality winemaking operations
a solid content of less than 0.5 percent the flotation tank downstream of for several years.
(by volume). For 10 to 11 hours process the decanter, the must can then be
time, the vacuum rotary filter requires pumped to the fermentation stage
approximately 300 400 kg kieselguhr. with a residual solid content of less
For preparation and cleaning time, than 0.5 percent (by volume).
the vacuum rotary filter requires
approximately 2.5 hours, whereas the Wide range of products
decanter needs half an hour.
Frank Schauz
For clarifying must and/or treating
This example demonstrates the diffe- must trub, Westfalia Separator offers a Product Manager Wine/Juice
Business Unit Beverage Technology
rences between the technologies. If wide range of decanters, starting with
Westfalia Separator
a decanter is used, there are no the smallest version of the CD 305.
Food Tec, Oelde
operating costs attributable to filter Its capacity is 5000 to 8000 l/h for Tel. +49 2522 77-2938
aids such as kieselguhr, and there are must clarification and 2000 l/h for trub schauz.frank@gea-westfalia.de
also no disposal costs. There are also no concentration. In the medium range,

Food Tec 17
Separators Digest 1 | 2007
Food Tec

Control
is Better
Preventing unwanted
down times with Westfalia
Separator WEWATCH

It would be good to know the status of a separator or decanter in ongoing


operation, thought Westfalia Separator. It would then be possible to identify
damage to bearings or bowl imbalance far in advance, to replace parts at a planned
date and not have to make an ad hoc response to unforeseen problems. So Westfalia
Separator has developed the WEWATCH system.

18 Food Tec
Separators Digest 1 | 2007
Food Tec

This condition monitoring aroused the interest of operators such an early stage that unwanted
downtimes are avoided. On the contrary,
right from the very beginning, and since being launched it is either possible for timely action to
on the market around one year ago, has established a be taken or for planned repairs to be
very good presence in the food and beverage segment. carried out with due consideration
being given to ongoing production.
Maximum process reliability increase in the signals, the on-call team Pro-active control is simply better.
established contact with the operator Westfalia Separator WEWATCH has
By permanently monitoring a machine and described the situation. Because already demonstrated its worth in
in production mode, the condition the machine was initially running the dairy industry, the vegetable oil
monitoring facility prevents unwanted well, the customer did not take the industry and the brewing industry of
downtimes. Sensors are applied to information seriously at first. However, Europe.
defined measuring points of the after approximately two months, the
separator or decanter; these measure machine had to be shut down as a
and record the vibrations and the result of imbalance, and it had to be
speed. In this way, the measuring overhauled. The reason: as a result of
facility records the total vibration in a the change to the CIP programme, the
defined frequency range as well as cleaning process was incomplete, and
specific bearing data. If certain preset product had accumulated in the bowl;
limit values are exceeded, the system this resulted in bowl imbalance. Now
initially triggers a preliminary alarm,
and a main alarm follows if even higher
values are recorded. The system then
generates a message which is sent
to the Westfalia Separator WEWATCH
server at the headquarters in Oelde Besides vibration
and also with an SMS message to the measurement,
on-call mobile of the Westfalia other process data
Separator WEWATCH team. This team
can be read out
and transmitted.
is on call 24-hours a day, and responds
immediately. Outside normal office
hours, the team is able to log onto the
server at any time and retrieve the
machine data if required. This solution
provides maximum process reliability
for the operator. In critical situations, that the discs have been replaced, the
the on-call engineer also notifies machine is running perfectly again. An
the local subsidiary of Westfalia immediate response however would
Separator, which in turn contacts the have permitted a planned procedure.
operator, who is then able to initiate The company then retrofitted the
any necessary action. Westfalia Separator WEWATCH system
in all separators in the company.
Thomas Fritz
Bowl imbalance recognised
Service International
Pro-active control
Westfalia Separator
The capability of this system was
Food Tec, Oelde
established by an operator shortly The primary objective of condition
Tel. +49 2522 77-5038
after his machine had been installed. monitoring is to recognise any signs of fritz.thomas@gea-westfalia.de
After the system had recognised an damage to a separator or decanter at

Food Tec 19
Separators Digest 1 | 2007
Industry

Crud Processing
Elegant process of hydrometal
recovery by liquid extraction

Raw materials are the driving force behind the world economy.
Liquid extraction with acid has become established globally as a
method of recovering valuable hydrometals such as copper,
nickel, zinc, cobalt and uranium.

During the reaction in settling tanks, an Acid washing, extraction and


emulsion layer known as crud forms. electro-cathode recovery
This relatively stable emulsion can have
a significantly negative impact on the The liquid extraction procedure is relatively
effectiveness of extraction because there is simple. The decomposed hydrometals are
hardly any contact between the aqueous first broken down and then subjected to
metal solution and the organic acid. The organic acid washing, generally using
crud therefore has to be constantly treated, sulphuric acid. This is followed by extraction
and there is nothing better than a 3-phase in several stages connected in series in
decanter for this task. These specially- settling tanks. The final stage of the process
developed centrifugal systems from is to recover copper electrically from the
Westfalia Separator are ideal for this copper electrolytes on cathodes.
application. They primarily ensure a reliable
and continuous extraction process, and also In the settling tanks, the extraction liquid
recover valuable acids from the crud. with the dissolved copper breaks down in
three phases, with ideally five to ten percent
The method involving liquid extraction of solid copper about 30 percent organic
" hydrometals" has become established phase and about 60 percent aqueous
throughout the world because it has phase. Unfortunately, an emulsion, or the
a relatively low energy consumption. The crud, forms between the organic and
liquid extraction method is preferred not the aqueous phase; this hinders further
only for copper, but also for molybdenum, extraction because it reduces the phase
rhenium, calcium, zinc, cobalt, nickel, surface between the aqueous and organic
magnesium, uranium and rare earths. phase.

20 Industry
Separators Digest 1 | 2007
The method involving
liquid extraction of
hydrometals has become
established throughout
the world because it has
a relatively low energy
consumption.

Industry 21
Separators Digest 1 | 2007
Industry

3-phase decanter ensures constant efficiency

This is where the 3-phase decanter technology


from Westfalia Separator comes into play.
The emulsion is drawn up from the tank and
pumped into the decanter. The 3-phase
decanter separates the crud into three
phases of solids, aqueous solution and
organic phase. The organic material is
recycled into the first stage of extraction
where it is used again as solvent. Solids
and aqueous phase are discharged by the
decanter.

Westfalia Separator can guarantee that the


organic phase recovered from the crud is
more than 97 percent and that not more
than two percent of organic components Duplex steel is available for the decanters CE 205 and
are contained in the discarded aqueous CE 305; this year it has also been available for CE 345
phase. These extremely high values ensure
that, over a period of time, a balance is
and CE 450 and thus for the complete family of
achieved between emulsion formation and 3-phase decanters. This range of models is designed
emulsion breakdown to allow uniform to cope with processing capacities of 600 to 23,000 l
extraction with a constant efficiency.
crud per hour to cover all sizes of industrial operation.
The clean and fully automatic method of
operation of the 3-phase decanters has also If the phase conditions of the emulsion, the crud, change as a result of

demonstrated its value when compared external factors such as dust, it may be necessary for the pond depth of the
with open and labour-intensive filter decanter to be changed. This can be achieved with the VariPond system for
presses.
the Westfalia Separator decanters while the installation is still running.

Specifically adapted to meet Westfalia Separator has thought of everything.


the process needs
Tore Hartmann
Westfalia Separator has designed decanters
Product Manager
specifically for these process needs. The low Westfalia Separator
pH value of the process (pH 2) in conjunction Industry, Oelde
with a range of chloride concentrations Tel. +49 2522 77-1630

results in pitting. The only remedy is to hartmann.tore@gea-westfalia.de

use very high-quality material. For all


components that come into contact with
Ralf Schestak
product, Westfalia Separator Industry uses
duplex steel that is resistant to pitting and is Product Manager
Westfalia Separator
more resistant to abrasion/erosion than
Industry, Oelde
normal steel.
Tel. +49 2522 77-2869
schestak.ralf@gea-westfalia.de

22 Industry
Separators Digest 1 | 2007
Nothing More
in the Air
Indian automotive supplier uses
OTC 2 separator to increase the
operating life of its cooling lubricants
Mineraloil Systems

Good lubrication is a well known requirement for good


travel, not only on the road but also in the production of
automotive components. Drilling, milling, grinding, stamping
and pressing operations are used in this industry and cooling
lubricants are used to ensure that everything runs properly.
However, cooling lubricants have a major enemy: impurities
from the processing process that cut off the air to this complex
emulsion.

The result: microbial decomposition of the


emulsifiers, acid formation and discoloration.
This is not an acceptable situation for a
quality-oriented company operating in
accordance with Kaizen principles, such as
the Indian automotive supplier Delphi-TVS.
The solution: continuous cooling lubricant
treatment with a separator type OTC 2 from
Westfalia Separator.

The latest diesel technology


made in India

Delphi-TVS is a joint venture between the


US Delphi Automotive Systems and the
Indian T.V. Sundaram Iyengar & Sons.
Delphi-TVS is India's largest producer of
automotive components such as injection
systems and filters. The company has
established a profile particularly in the field
of diesel technology. Accordingly, in 1991,
Delphi-TVS launched the first modern direct
injection system for car diesel engines on
the Indian market. This is to be followed
soon by an extremely modern common rail
injection system.

24 Mineraloil Systems
Separators Digest 1 | 2007
Mineraloil Systems

To produce these injection systems and shutting down and making up new cooling
all the other automotive components, lubricants as well the high cost of staff
Delphi-TVS (in the same way as any absence.
other manufacturer who processes metal)
requires cooling lubricating emulsions. Kaizen project
These reduce friction and convert energy
which is generated during metal cutting; The aim of a Kaizen project at Delphi-TVS
they assist the process of dissipating heat was to close this gap in terms of quality.
and also flush away the swarf from the The solution of 'how to prevent the
tool face. formation of bacteria' was quickly found.
The solids and tramp oils that entered the
Water-soluble cooling lubricating emulsions emulsions had to be separated as quickly as
consist of various components such as possible and as effectively as possible.
emulsifiers, stabilisers or corrosion-protection Delphi-TVS, therefore, decided to install a
additives and mineral oil constituents. Their type OTC 2 separator that fulfils both tasks
main enemy is contamination from foreign simultaneously. Extremely fine solids and
substances such as tramp oils or solids. Solids tramp oil are continuously separated in a
introduced into an emulsion either rise to single process.
the top or fall to the bottom. A third part is
suspended in the emulsion and is constantly From more than 100,000 CFU
rinsed onto the work pieces. to less than 1000 CFU

Micro-organisms The installation was commissioned in


feel at home August 2004, and has since been operating
to everybody's complete satisfaction. The
Together with the tramp oils, the solids that major evaluation criterion for Delphi-TVS
rise to the surface form a thick floating was the bacteria load before and after the
layer. These hinder the process of oxygen installation of the OTC 2 separator. The
interchange or mean that the process is result is clear: the bacteria count was
completely impossible. In parallel with this reduced by the separator from an initial
process, the solids which fall through load of more than 100,000 CFU (CFU = Cell
the emulsion collect at the bottom of the Forming Units) to less than 1000. The
machine. Both factors together produce odour problem is correspondingly low,
ideal living conditions for certain types of whereby this was the primary Kaizen
micro-organisms, which start to expand objective of Delphi-TVS - because pleasant
almost like an explosion at temperatures in work conditions mean better motivated
excess of 22 C. staff. The continuous treatment of cooling
lubricating emulsions using the separator
These micro-organisms lower the pH value also contributes to a considerable direct
of the cooling lubricating emulsions very reduction of costs.
quickly, and the cooling and lubricating
characteristics deteriorate significantly. This
Rajesh Chhabra
results in shorter and uncalculable tool
operating lives, longer setup times, quality Project Coordinator
Westfalia Separator India Pvt. Ltd.
problems and strong odours as well as a
New Delhi
major hazard potential for employees. In
Tel. +91 1128520538
the metal processing industry, this results rajesh@westfalia-india.com
in high costs for replacing, disposing of,

Mineraloil Systems 25
Separators Digest 1 | 2007
SeaProtect Solutions, the system for processing bilgewater
and sludge at sea, which was launched on the market only
a few years ago, is making headlines.

The Oscar
of Shipping
SeaProtect Solutions receive the
Seatrade Dubai International Maritime Award
The BilgeMaster treatment system from
the SeaProtect Solutions programme of
Westfalia Separator Mineraloil Systems,
Oelde, has received the most coveted
award of international shipping, which is
considered to be the 'Shipping Oscar'. At
the end of 2006 at the Seatrade Middle
East Maritime Exhibition, the Business Unit
Marine received the Seatrade Dubai
International Maritime Award which is
recognised worldwide for environmental
protection. SeaProtect Solutions have
accordingly received the highest public
recognition.
Mineraloil Systems

And the winner is

More than 150 applicants took part in the competition


which was held in a total of 11 categories. Westfalia
Separator Mineraloil Systems was put on the shortlist in the
environmental protection category right from the very beginning.
The official award ceremony was held on the occasion of the
Seatrade Middle East Maritime Exhibition.

A jury of experts selected the best of the And the winner is The Area Sales
best: the jury panel included the Secretary Manager of Westfalia Separator Mineraloil
General of the International Maritime Systems Business Unit Marine, Richard
Organisation (IMO), a sub-organisation of Holthaus, had the honour of receiving
the UN, Efthimios Mitropoulos, as well as the award on the evening of 4 December
Captain Duncan McKelvie, Chairman of the 2006, in front of an audience of around
Nautical Institute of the United Arab 800 guests, from the hands of the Managing
Emirates, Captain Jitendra Misra, Chairman Director of the National Iranian Tanker
of the Institute of Chartered Shipbrokers as Company (NITC), Mohammad Souri.
well as Anthony Muncer, Chairman of the
Institute of Marine Engineering, Science and
Technology, in the United Arab Emirates.
The environmental protection award was
sponsored by the renowned classification
society American Bureau of Shipping (ABS).

Kurt Poprawa

Head of Business Unit Marine


Westfalia Separator
Mineraloil Systems, Oelde
Tel. +49 2522 77-2539
poprawa.kurt@gea-westfalia.de

28 Mineraloil Systems
Separators Digest 1 | 2007
Mineraloil Systems

Extremely reliable

The unbeatable advantage of the BilgeMaster There was a correspondingly strong response
system, which the jury also recognised with at the Dubai Seatrade Middle East Maritime
its decision, is its extremely high reliability. Exhibition after the award ceremony.
Centrifugal systems have been used in Not only ship operators but also various
shipping for 85 years, and are known to the classification societies were very interested
ship's crew, for instance also in fuel and lube in this reliable technology of the future.
oil systems. The ship's crew is the operator
of the system, and does not require any
additional training; the separators are In the Business Unit Marine of Westfalia Separator
relatively easy to handle. This ease of
handling and reliable operation means
Mineraloil Systems, SeaProtect Solutions has
that the crew does not have to bypass tripled revenues and volume sales of the systems
bilge processing and discharge effluent
containing oil into the ocean, as has during the past two years, and the trend is still
frequently been the case in the past with rising. Many shipping companies are retrofitting the
malfunctioning static de-oiling systems. A
further advantage is that the BilgeMaster BilgeMaster, SludgeMaster or CombiMaster systems
system is a purely mechanical centrifugal
to existing fleets or are equipping new vessels with
system that works simply without any
chemicals or other consumables. the systems right from the very beginning.

Richard Holthaus (left),


Area Sales Manager
Westfalia Separator
Mineraloil Systems, Business
Unit Marine, was extremely
proud of the Seatrade
Dubai International
Maritime Award in the
field of environmental
protection, which he
received from the hands of
Chairman and Managing
Director of the National
Iranian Tanker Company,
Mohammad Souri (centre),
and Andrew Callaghan,
Sales Director of Seatrade.

Mineraloil Systems 29
Separators Digest 1 | 2007
Umwelttechnik

PET Recycling
Decanters used for cleaning
washing lye and water circuit
with high efficiency

Recycling

In the recycling process, old PET products are


cut up into smaller pieces. This PET recyclate
can then be melted down and subsequently
extruded to make new products. There are
a wide range of applications for recycled
PET: (deep-drawn) film, tyre belts as a
substitute for metal belts, fibres e.g. as
fleece for functional clothing or as a cushion
filling, right through to 'bottle-to-bottle'
recycling (B2B), which requires very extensive
cleaning of the used PET. Extremely hygienic
PET regranulate suitable for use with food is
obtained to be made into new PET beverage
bottles. PET recycling is carried out in a
series of several separating and cleaning
stages. Cleaning with wash lye is particularly
important and intense to produce high
quality PET flakes.

30 Umwelttechnik
Separators Digest 1 | 2007
Umwelttechnik

They are light, they are 'indestructible', they are suitable for use
with food, and they are recyclable. Everybody knows them,
everybody uses them: PET beverage bottles are on the advance
throughout the world for soft drinks, mineral water, and now
also for beer. PET is made from crude oil making it a valuable raw
material that can be recycled profitably. Westfalia Separator supports this
requirement with centrifugal technology. Decanter technology is used in two ways for

the recycling of PET. It makes sense to use such technology for washing lye and also for

removing solids from the water circuit. This is because water consumption in PET recycling is

high and is a considerable cost factor. For both purposes, several decanters from Westfalia

Separator have already been installed in practical recycling applications.

Umwelttechnik 31
Separators Digest 1 | 2007
Umwelttechnik

Decanters used for cleaning Decanters for treating decanter. This processes up to 10 m3/h
the water circuit washing lyes of washing lye with a temperature of
90 C fully automatically and with little
The water from the various washing The UCD 345 decanter at Texplast manual labour.
stages is collected for water recycling, GmbH in Wolfen is used for another
and initially pre-clarified using an purpose. This company processes The advantages of decanter technology
inclined clarifier. The pre-concentrated PET plastics, and commissioned an in the PET recycling process are also
effluent sludge, the sump of the inclined additional process installation with a recognised outside Germany. Sulo,
clarifier, is passed conventionally capacity of 25,000 tonnes p.a. of PET formerly Cleanaway, one of the largest
through a decanter. The company in October 2006; this installation disposal companies on the European
MultiPet uses a UCD 305 decanter for increased the total capacity of the market, has been using two UCD 305
this purpose. At its Bernburg location plant to 45,000 tonnes. Texplast decanters since the year 2005, one for
in Saxony-Anhalt, MultiPet Gesellschaft supplies its parent company Fromm lye washing and also one for the
fr PET-Recycling mbH recycles almost Plastics in Thuringia with flakes. water circuit in Norrkpping, Sweden.
20,000 tonnes of PET bottle waste Texplast is also able to further process In Austria, various beverage manufac-
every year, and uses this to make high flakes and make regranulate for use in turers, including Coca Cola Beverages
quality PET flakes for use in the plastics food packaging at the Wolfen site. Austria, have acquired an equity
industry. In this application, 5 m3/h interest in PET to PET Recycling GmbH.
effluent sludge with a concentration of Lye washing is extremely important for In 2007, this company is also installing
approximately 8 percent (by volume) is this process. An alternative solution for two UCD 305 decanters, one for lye
fed from the inclined clarifier to the recovering the soda lye used would be washing and one for the water circuit
UCD 305; the sludge is then separated to employ a depth filter, as indeed was in the Mllendorf plant. The demand
into a clarified phase and solids with a the case in the existing old installation for PET recycling material continues to
dry matter content of up to 50 percent at Texplast. However, depth filters rise.
(by weight). In this case, the decanter require frequent backflushing and
pays for itself quickly as a result of the thus involve a lot of manual labour.
lower fresh water requirement and the This problem is solved in a much
lower effluent costs. more elegant manner by the UCD 345

Recycling
In the recycling process, old PET products
are cut up into smaller pieces. This
PET recyclate can then be melted down
and subsequently extruded to make new
products.

Martin Neugebauer

Sales Industry
Westfalia Separator
Deutschland, Edderitz
Tel. +49 34976 38-552
neugebauer.martin@gea-westfalia.de

32 Umwelttechnik
Separators Digest 1 | 2007
Umwelttechnik

Separators Reduce the


Strain on SBR Reactor
Premiere at WMG in the Netherlands
Reduction of effluent costs

Using highly innovative separators,


Westfalia Separator Umwelttechnik has
enabled the waste water treatment plant
WMG to remedy a quality problem affecting
its effluent before the expiry of an
official deadline. WMG ['Waterzuivering
Milieuboulevard Groningen' (waste water
treatment plant in the Milieuboulevard
Business Park, Groningen/NL)] is a subsidiary
of the Grontmij Group, a major European
consulting and engineering company with
3500 employees. The company is responsible
for the pre-treatment of waste water of
the member companies of the Milieu-
boulevard, and in particular three industrial
waste landfill sites and a fermentation
installation for domestic waste. The latter
received numerous separators at the end of
2005 - the first for WMG in the Netherlands.

Umwelttechnik 33
Separators Digest 1 | 2007
Umwelttechnik

Threshold values exceeded by 500 percent

As with many other installations, the waste water at WMG is pre-


treated with the aid of an SBR reactor, a biological clarification
system. The pre-treated water is then forwarded to the municipal
treatment plants of the regional water works. However, this water is
not sufficiently clean to meet the local water quality standards. This is due
to a problem frequently encountered in SBR reactors, where the processes of
nitrification, denitrification and sedimentation take place in a single reactor.
The problem arises as a result of the formation of light sludge when
the reactor is running under extreme loads and adequate sedimentation
therefore does not take place.

"The quantity of solids to be disposed not contain sufficient solids. Three Separators: tremendous
of in the water has to be less than alternative possibilities were considered: results, considerably lower
100 mg per litre of water, says Tiemen filter/strainer technologies, relaxation than the limit values
Romkes, who is responsible for the flotation and separator technology. In
financial as well as the technical side of principle, all three technologies would WMG also considered using centrifuges.
the project as the works manager have been suitable for this task. Tiemen Romkes explains, Initially, we
at WMG. So far, the limit values carried out a laboratory trial with
have consistently been exceeded However, the sludge in Groningen Westfalia Separator Nederland, to
by 500 percent. In such cases, it proved to be insufficiently stable for the establish whether such a solution
would have been possible to throttle filter/strainer technology. The sludge would function at all. The laboratory
production; however, this would not simply passed through the strainer, tests were successful, and were there-
have been a meaningful solution. We said Romkes. The idea of the relaxation fore followed by a pilot programme
did not consider the use of chemicals, flotation installation was also abandoned at the headquarters of Westfalia
as these are precisely the substances shortly afterwards. Although the pro- Separator in Oelde.
we are required to remove from the cedure worked, it was not possible to
water. do without the addition of chemicals. The results were simply tremendous,
In addition, this system would have says Romkes. We were able to separate
Search for alternatives made us extremely dependent on the more than 12 kg of sludge per cubic
human factor: because of the different metre of water! We achieved well
Accordingly, WMG started to search composition of the effluent encountered, below 50 mg per litre: considerably
for technical alternatives. It was not we would have had to employ highly lower than the limit values defined
possible for decanters to be used in this qualified specialists to constantly moni- by the municipal water authority. In
application, because the water did tor the corresponding water quality. addition, the procedure resulted in a

34 Umwelttechnik
Separators Digest 1 | 2007
Umwelttechnik

considerable decline in disposal costs, which of labour and chemicals. In addition, the
are determined by the quantity of 'Kjeldahl separators operate much more reliably than
nitrogen'. We were also able to reduce the the relaxation/flotation installation. We will
settling period and thus the time spent in certainly never regret this step.
the SBR reactor".

The 25 m3 of effluent produced every


Omnipresent problem
hour by the reactor are now split over two
separators type OSD 60, each of which has WMG is now operating the first waste water
treatment plant in the Netherlands that uses
an hourly capacity of 15 m . At the end
3

a separator. Tiemen Romkes is of the opinion


of 2005, they were connected to the SBR
that many more will follow. The problem
installation. It was not a minute too soon, with flotation sludge is omnipresent. We
because the municipal water authority had have been courageous enough to take off
given WMG time until 1 January 2006 to our blinkers and we have been successful!
solve this problem. With hindsight, I have to ask myself why we
did not consider this solution before.

Payback period of two years

For Romkes, this was an excellent investment.


Joost Barneveld
In the final analysis, everything is merely a
matter of costs and benefits: we were Sales Engineer
Westfalia Separator Nederland B.V.
indeed able to amortise our entire investment
Cuijk, Netherlands
within two years simply on the basis of the
Tel. +31 485319358
disposal costs. And this calculation does not joost.barneveld@westfalia.nl
even take into account the savings in terms

Umwelttechnik 35
Separators Digest 1 | 2007
It Makes Twice the
Sense to Reduce Speed
Energy optimizer for Westfalia Separator
VariPond decanter reduces electricity costs

It is possible to drive a car at various speeds: with high engine


speed and high energy consumption; or to step up a gear,
reduce engine revs and, ultimately, the consumption of energy.

This is roughly the way in which the new plants. These should be filled with a defined
energy optimizer from Westfalia Separator concentration to achieve a gas yield which is
for VariPond decanters works. The bowl

as high as possible and also to permit the
speed the engine speed is automatically necessary circulation. This optimum solids
reduced, if this is possible by process concentration is regulated by Westfalia
engineering means. Nevertheless, Westfalia Separator VariPond even when feed
Separator VariPond the gear ensures conditions fluctuate significantly. The energy
that the discharge concentration (the speed) optimizer now also dictates the bowl speed.
is maintained constant. And because the
output is related to the square of the bowl Westfalia Separator VariPond is a weir
speed, reducing bowl speed makes twice which can be adjusted during operation. If
the sense. Indeed, when the reduction in for instance the solids concentration is too
labour-intensive conversion work is factored high, the weir increases the liquid level in the
in, three-times the reduction in cost can be decanter, and the solids are diluted back to
achieved. the desired concentration. The same effect is
achieved if the decanter thickens the solids to
Westfalia Separator a lesser extent in this case, Westfalia
VariPond gives the signal Separator VariPond has to decrease the
level of dilution. And this is precisely the
Westfalia Separator VariPond decanters point at which the energy optimizer is used.
from Westfalia Separator can be found With the sensors of the Westfalia Separator
wherever the downstream process requires a VariPond it recognises the need to dilute the
constant feed concentration. One example is product and generates the command for the
in digesting towers in waste water treatment bowl speed to be reduced.
Umwelttechnik

Only ever the required


acceleration energy

However, is it possible for the nominal speed


to be reduced from the point of view of
process engineering? Certainly not always,
but very often it is. New decanters are, for
instance, set to their maximum performance
on commissioning. In practice, however, they
are frequently operated with lower outputs
because the operator wishes to maintain a
performance reserve. Daily fluctuations are
also encountered in the feed; this means that
the throughput capacity which is required
under real conditions can thus be reduced
further. In both cases, the bowl speed can be
reduced without any problem. If there is any
change in the throughput capacity or the
consistency of the product, the speed is auto-
matically increased again. With the energy
optimizer, only the acceleration energy
required for the process is ever used. In the
waste water treatment plant Oldenburg,
three decanters of the type UCA 501 were
equipped with an energy optimizer at the
beginning of 2005. For more than one year
now, they have been working to the full
satisfaction of the operator. And rightly so:
the bowl speed has been reduced by up to
25 percent, corresponding to an energy saving
of 50 percent. This technology is also attractive
for customers already operating a Westfalia
Separator VariPond decanter because the
energy optimizer can be retrofitted.

Bernd Lking

Head of Business Unit


Westfalia Separator
Umwelttechnik, Oelde
Tel. +49 2522 77-2002
lueking.bernd@gea-westfalia.de

Martin Lentrup

Decanter Research and Development


Westfalia Separator
Industry, Oelde
Tel. +49 2522 77-1603
lentrup.martin@gea-westfalia.de
Lifestyle

Crucial Question
More and more technologies are becoming
available to the wine grower but is it
also in the interests of the consumer?

How much technology can wine take? This And fruity white wines with clear tones and
question has always been the subject of a considerable amount of CO2 are in
passionate discussions, as wine is perceived demand at present. Stainless-steel tanks
to be the counterpart to the soulless for white wines are for this reason just as
industrial product. The debate has been accepted today as cooled fermentation.
fuelled further as a result of oak chips being These are only a few examples indicating
approved in the EU; these provide a less that the consumer in principle is not
expensive alternative, which can also be absolutely opposed to technology. The
more easily controlled by technical means, crucial question is: what technology?
for adjusting the oak-matured label
(Barrique) which is very much in demand. A nag is not a thoroughbred
However, these new possibilities of
winemaking technology are increasingly If we look at the relevant expert media and
dividing the wine world. On the one hand, internet chat rooms, its obvious that most
the producers argue that the product has to people prefer traditional technology to
be adjusted to meet the global taste of trying to convert a nag into an expensive
consumers with all permissible technological thoroughbred: the process of breaking
means. On the other, traditionalists argue down and subsequently recomposing the
that wine is only wine if it is subject to a wine with a spinning cone column, the
minimum of treatment in the winemaking addition of wood chips, water, tannins and
operation. Somewhere between these two special aroma yeasts, the production of ice
extremes are wine growers who use selected wine with the aid of cryo extraction. For
winemaking techniques and succeed in consumers, this is too much technology for
achieving a modern interpretation of wines nature, and the fascination of what is wine
which are rooted in the traditions of a wine- degenerates into an artificial product.
growing area. But what does the consumer
think of these discussions between experts? On the other hand, the wine drinker accepts
all technologies that enable the special
In the past, wine was often only ready for features of the particular grape, such as
drinking after many years of maturing. terroir and the signature of the wine-
Thanks to winemaking technology, this long grower, to be developed in such a way that
storage period is no longer necessary. The they meet the consumers' preferences. The
customer welcomes this development. Who worldwide renaissance of modern German
wants to look at his red wine for five years Riesling is a good example in this respect.
and more before he can open it? However, the fact that the consumer

38 Lifestyle
Separators Digest 1 | 2007
Lifestyle

approves the technology is only half the


battle. The technology must also permit
cost-effective wine production, because
wine is increasingly coming under price
pressure. In this context, centrifugal
technology is becoming more and more
important in the winemaking process. For
many consumers, it is a positive development,
as it only accelerates the traditional process of
clarifying wine by means of sedimentation
entirely without chemicals or high-tech tricks.

Olives and grapes

At the same time, with their fully continuous


method of operation without any auxiliary
substances, they provide the wine grower
with benefits in terms of quality and cost-
There are many indications that centri-
effectiveness throughout all stages of wine fuges will introduce major changes in
clarification and also during juicing and
must clarification compared with kieselguhr winemaking techniques. This has already
filtration or presses. A further factor is that become reality with another food which
decanters and separators are multi-purpose
machines in a winemaking operation. arouses at least as many emotions as wine
For instance, the decanter used for must
among consumers: most top quality olive
processing can also be used for processing
tank yeast for the rest of the year. oils are now extracted by centrifugal force.
A Good Wine
Unfolds its Message
in the Glass

absolutely clear: colour, bouquet, clarity, subtlety,


aroma, taste nothing should cloud the pleasure of the
producer and the consumer.

The VINEX process from Westfalia Separator, which uses


decanters to juice the grapes, improves the winemaking
results, is gentle on the grapes and minimises costs.

The pigments are extracted from the grape skins in a


continuous process, releasing the valuable substances from
the pulp. The seeds and stems remain intact, so no bitter
substances develop.

With VINEX the vintner no longer has an issue with long


mash standing times, large and expensive mash tanks,
inhomogeneous must quality and undesirable oxidation.

VINEX ensures constantly high quality and good yields.

Take the Best Separate the Rest

Westfalia Separator
Food Tec
Werner-Habig-Strae 1
www.kabutz.de

59302 Oelde (Germany)


Phone +49 2522 77-0
Fax +49 2522 77-2089
foodtec@gea-westfalia.de
2100.537

www.westfalia-separator.com

9997-1302-000/0407 EN Printed in Germany Printed on chlorine-free, bleached paper