TorqueRequirementfor High-Solids

CentrifugalSludgeDewatering
Wallace W.-F. Leung
Baker Process,1 00 Neponset St., S. Walpole, Mass 02071-9103, USA. Tel: +l 508 668
0400; Fax: +l 508 668 6855; E-mail: wallace.leung@bakerhughes.com

In dewatering of compactible sludges to high dryness, the solid-bowl decanter centrifuge is operated
with the annular volume between the conveyor hub and the bowl wall packed almost completely with cake
solids.The torque required to maintain the conveyor rotating at differential speed with respect to the bowl
can be determined for a given type of sludge from the “effective frictional coefficient”, which for munici-
pal and industrial sludges, is typically in the range between 0.5 and lS.The back-drive torque, which sus-
tains the conveyor under a small differential speed with respect to the rotating bowl, is used to convey the
cake. Concurrently applying a churning action on the cake allows the moisture in the interstitial voids of
the cake to be expressed out to the cake surface away from the bowl wall. Higher torque is a consequence
of either, or a combination of, higher operating centrifugal gravity, higher solids throughput, thicker cake
from lower differential speed, longer transport distance from a large length-to-diameter decanter, and
drier cake. The decanter can be operated either under torque control, differential-speed control, or a
hybrid algorithm involving both variables. A high-solids decanter mimics a rheometer with continuous
inflow and outflow of test fluid material wherein the rheological properties are determined from the
torque-speed measurements.

decanter centrifuge’. 2. 3 consists of a bowl and a conveyor, the conveyor hub and the bowi wall. This is illustrated in Figure 1 a.

A both of which are rotating at high speed. The bowl has a

cylindrical section followed by a conical beach. The screw
conveyor conforms to the same profile as the bowl. Despite the
As the heavier feed solids gravitate to the bowl wall, the cake con-
solidates in the cylindrical clarifier and in the conical beach under
high compressive stress which is proportional to the product of
fact that both are rotating, there is a small difference in speed the centrifugal gravity G and the cake height h,The Gh for a high-
(hereafter referred to as the differential speed) between the two solids decanter is normally 5-7 times that of a conventional
components so that the settled solids can be conveyed from the decanter’ due to the higher 13 and thicker cake pile especially
cylindrical clarifier to the conical beach toward discharge. Liquid is
discharged through the weirs at the opposite end of the cylinder.
A special type of decanter, the high-solids decanterle5, has
been commonly used to dewater waste sludges (municipal
sewage and industrial sludges) to high dryness. Typically, cake
solids can be about 5-10% higher compared to those obtained
from conventional dewatering decanters depending on the sludge
and the operating condition of the centrifuge.
Unlike conventional decanters, the cake in a high-solids
decanteri,4,5 fills almost completely the annular space between

Conveyor Blade+ at Differential Speed

23 24 25 26 27 :8

%Ca ke Solids
Liquid I Figure 2a: Specific Power Consumption versus Cake Solids

Figure la: High-Solids Decanter :.4

(I bar = 281 in-lb,)

1.2

0-c : : : : : : : : : I : iN
I
%w- 25 26 27 28 29 3L3’1& 3131
I 20 21 22 23 24 25 26 27 28 29 30 31 321

% Cake Solids %Cake Solids

Figure 2b: Effective Frictional Coefficient for Raw Mixed Sludge in Plant
Figure 1 b: Torque versus Cake Solids A (460mm diameter decanter)
 The rate of “mechanical work” or “power” required to convey
the solids over an effective length Leff against Coulomb’s friction-
al force is mssGCfLetf where mSS is the cake solids rate(dry
1 basis), and C, is the frictional coefficient between the cake and
the conveyor blades. L,rrcan be taken say as 213 of the total
length of the decanter along the axis. (Note: the rate of work to
lift the cake solids against the G-field is m,,G(R,-R,), where R,
and R, are respectively the bowl radius of the cylinder and the
discharge radius at the conical beach. Given (Rb-Rd)<< CfLef,,
therefore the second cake transport resistance can be neglected
as discussed above.)
On the other hand, the power input to maintain the differential
speed A from a hydraulic or electric backdrive at a sustained
.2 - Plant A torque T is simply TA. Balancing the two,
23III 26III 29Ill 32I
'22 24 25 27 28 3@ 31 33
I
L. %Cake Solids
Figure 3: Effective Frictional Coefficient for Anaerobically Digested
1
2
“L
= c, CL‘,,

(1)
Sludge in Plant 6, and Comparison with Raw Mixed Sludge in Plant A (6.8-9.1 cum/h)
(46lJmm diameter Decanter) 1
0.9
when the machine is operated under lower differential speed. .
0.8
Liquid from the cake interstitial spaces percolates upward against 0.7 . .
G-force to the cake surface. The “expression” of liquid depends on 0.6 - .
the G-force, time and the cake permeability(inverse of the cake I
resistance), which can be further reduced when the cake is under
compaction and consolidation.
In transporting a cake undergoing continuous compaction in a
pool of liquid, the torque to maintain the conveyor at a differential
speed with respect to the bowl can still be very demanding, despite
some relief from the buoyancy of the liquid pool. The cake solid
increases by compaction and expression as it is being transported 25 30 35 40 45

toward the conical beach. The cake follows a complicated cork- % Cake Solids
screw motion as it is transported along the helical channel formed
by adjacent blades from the cylinder to the conical beach, see Figure 4a: 460mm Diameter Decanter, Plant C
Figure 1a. The primary resistance to the cake transport is Coulomb
friction between the cake and the face of the conveyor blades. (6.8-9.1 cum/h)
1
Another resistance is the longitudinal component of the G-force
with which the cake has to overcome as it moves from the large 0.9 . n )

diameter at the cylindrical clarifier to the smaller diameter conical 0

~ 0.8 B . . I
beach toward cake discharge. An order of magnitude estimate
0.7
reveals that the second resistance is much less as compared to
the first. Also, the latter is further alleviated by the hydraulic force 0.6
when a dip weir’, or a baffle, is used providing a U-tube effect with Y 0.5
a differential liquid head across the two legs formed across the 0.4
weir/baffle. In this paper, the focus will be on the first resistance
0.3
that is by far the dominating cake transport resistance.
It is important to be able to determine the conveyance torque 0.2
that provides a good indication of the cake dryness. Figure 1 b, 0.1
reproduced from Reference 1, shows a plot of torque versus cake
solids confirming a strong correlation between these two vari- I O 25 26 27 28 29 30 31 32 33 34 35 36 37
ables. Consequently, high-solids decanters operate with higher
torque and drier cake. % Cake Solids

MODEL Figure 4b: 425mm Diameter Decanter, Plant C

A coaxial cylinder viscometer or rheometer is commonly used to

measure the viscosity of a liquid. Liquid sample is placed in an
annulus formed between the stationary outer cup and the inner
rotating cylinder. The rotor can be set at a prescribed rotation
speed while the rotor torque is measured upon reaching equilibri-
um. Based on the geometry, torque and speed values, the viscos-
ity of a Newtonian liquid, or the rheological properties of a
.
nonNewtonian fluid, can be determined. Interestingly, a high- .

solids decanter mimics a large rheometer for measuring the rheo- . /

logical behavior of concentrated fluid cake where continuous

inflow and outflow of cake material is maintained. The differential
speed is analogous to the RPM of the inner rotor of the rheometer, I
o~,“,l”“;‘,“l”‘,I’,“I
and the recorded torque provides a measure of the rheology of 1 25 27 29 31 33 35
the concentrated material under the centrifugal field. Due to the
complexity, it is difficult to analyze and interpret the cake rheolog- % Cake Solids
ical measurement; despite this, a simplified approach is adopted Figure 4c: Comparing Performance of Two Different Size Machines for
herein so as to get some additional insights to the problem. Plant 0
I 1.4
4a, I is almost constant for a wide range of cake solids between
1.2 1 25% and 40%. Other tests at different Gs are also conducted,
one set at IOOOg and the other at 15669. The I value did not
1 -1 change significantly with G confirming that T is proportional to
the G-force. In Figure 4b, the results are shown for a slightly
0.8 -y smaller, different-design, high-solids decanter with a 425-mm
c
0.6 --
bowl diameter operating at 2600g. The data are more scattered
as compared to those shown in Figure 4a on the same sludge.
0.4 -: Generally, I is also higher.
Finally, in Figure 4c test results from the pilot (460 mm diame-
0.2 -- ter) as well as production (914 mm diameter) size high-solids
c
decanters are compared for Plant D. The I values determined for
o~,“‘l’,‘,l”“l”,,l”,‘:““r the same sludge from the two different size machines are in
IO 12 14 16 18 20 22
accord with each other confirming the validity and consistency of
%Cake Solids the approach.
From the foregoing examples, it is evident that the effective
Figure 5: Plant E, Aerobically Digested Waste Activated Sludge frictional coefficient I as defined by Equation 3 is relatively con-
stant. However for some sludges, it increases gradually with
increasing cake solids, while for others it could increase rapidly
Note: The term Ta/m,, is the specific power consumption per unit after reaching a critical cake solids consistency. This scenario is
cake mass transported. Because the cake is predominantly sub- best illustrated by Figure 5 where the high solids decanter is used
merged inside a pool, buoyancy helps to relieve the weight under to dewater an aerobically digested sludge to a maximum of 21%
centrifugal force and consequently the frictional torque. Equation cake solids and where I rises from the base level of 0.4-0.6 to 1.4
1 should be properly modified to account for the pool buoyancy between 18-21%. In general. the behaviour of I with cake solids
effect as follows: depends on a given sludge.
Based on the foregoing discussion, it can be concluded that
riz-P,-- CL the conveyance torque generally increases with:

* higher cake solids rate;

Typical range of specific power consumption is about 50 OOO-
200 000 f&s* or 5 000-20 000 m2/s2. It is more appropriate to
define the effective coefficient of friction I as:
TA
l higher G;
* lower differential speed, which implies thicker cake;
l longer cake transport distance for a large length-to-diameter
ratio design;
* reduced liquid buoyancy when the decanter is operated at a
shallower pool; and
l drier cake solids for certain sludges.

T-A STATES
where Ap=p,-pL with ps the cake density and pL the liquid den-
sity. For bio-solids sludge, the former is about 1010-l 100 kg/m3, Figure 6 shows a plot of T versus A for Plant F delineating the
whereas the latter which is predominantly water is at 1000 kg/m3 possible operating “conditions” or “states” for a dewatering
decanter. The plot demonstrates an inverse relationship
between T and A, in accord with the foregoing discussion and
TESTS
the functional relationships predicted by Equation 3. For a given
A series of tests were conducted at a sewage plant, Plant A, cake solids rate, the cake height increases at lower differential
over a 3-month period on a raw mixed sludge with 48% primary speed yielding high conveyance torque; while the cake height
and 52% waste activated sludge using a 460.mm pilot high- decreases at higher differential conveyance speed resulting in
solids decanter operating under three different pools - Pools l- low torque. The results Figures 2a, 2b, 3, 4a-c, 5 can all be re-
3; a range of feed rates between 30-70 gpm (6.8-16 mzih); and plotted in form of T versus A, validating this inverse relationship.
operating G-force at 2500 and 30009, respectively. Two convey- However, by plotting the results as a product of T and A, or bet-
or geometries (S and X conveyors) were tested with no appre- ter still I where the rheological property can be determined,
ciable difference between the two based on the measured fric- torque can be predicted for a given differential speed, G and
tional coefficient. The specific power consumption and the decanter geometry.
effective frictional coefficient are both plotted in Figures 2a and
2b, respectively. Both the specific power consumption and the
effective frictional coefficient I both increase with cake solids. 1
increases only moderately from 0.4 at 24% to 0.6 at 30+%. After El50 1
the cake solid has reached 30-32%, it rises sharply from 0.6 to i%
-140 -
1.2. It is also perceivable that for certain cakes, I rises very w
steeply by several folds after a critical cake dryness is reached 5130 -
corresponding to a dramatic change of the cake physical rheo- 3120 -
logical behaviour. It is more appropriate to use the effective fric-
El10 -
tional coefficient given that it is normalized using both G and the 11 4 cum/h
TS-5 0%
length scale. 595 kg/h
In sewage Plant B, the test was carried out with anaerobic 290
digested sludge with some fines being re-circulated back to the g BO-
headwork. The pilot machine that has the S-conveyor design was
used in the tests. As shown in Figure 3, the I value varies from 0.6 G* 70 -
TS=5 3%
to 1 .I while the cake solid increases from 24% to 28%. Obviously, 378 kg/h
the anaerobic digested sludge is a more difficult to dewater sludge I I I I I I I 1 I
as the coarse materials have broken down to finer materials dur- ;r 0 12 3 4 5 6 7 8 9 10
ing digestion.
In sewage Plant C, a 460-mm diameter high-solids decanter DIFFERENTIAL SPEED, RPM
was tested with average 1 recorded at 0.44. As shown in Figure Figure 6: Plant F, Torque versus Differential Speed
 tion time to ensure a dry cake. However, for precautionary purpos-
es, the maximum torque level should be set such that when the
machine reaches this level, a by-pass of feed. for example, should
be activated. In Figure 7, with the differential control mode
deployed the operating equilibrium is point 6 on curve 1; and this
equilibrium shifts to point B’ on curve 2 at higher G and/or solids
rate. In all cases, the resultant torque value needs to be below the
safe torque limit.

Linear T-A Relationship(T = k,+ k,A):

Assuming a linear trend after the torque threshold T>T,,,<,,,is
I /
(1) 6, mssl exceeded, this is given by,
t I
T=li, +k,A
(6)
, Differential Speed, RPM
The equilibrium is determined by solving Equations 3 and 6, thus
Figure 7: Torque versus Differential Speed, RPM (Reproduced from
Reference 1).
A=
T-A CONTROL MODES ~
(7)
From an operation standpoint, a back-drive motor is used to main-
tain the differential speed of the conveyor with respect to the bowl The A value calculated from Equation 7 can be substituted back to
in response to the monitored torque. There are three commonly Equation 3, or more conveniently Equation 6 to obtain the corre-
operating control modes: sponding torque. In Figure 7, the equilibrium point is shown by
1. Torque control mode (i.e.T=T, = constant, or a horizontal line in point C on curve 1 under lower G and solids rate, and point C’ on
T-A plot) curve 2 at higher G and/or solids rate. It is apparent that the hybrid
2. Differential control mode (i.e. A=A, = constant, or a vertical line mode is in between the constant torque and constant differential
in T-A plot), or mode; but unlike these two modes both torque and differential
3. Hybrid control mode, (e.g. after a critical torque is reached, speed are allowed to increase in response to increase in mechan-
A=function(T) when T>T,,,,+ in the T-A plot) ical loading.

Under equilibrium, or more appropriately quasi-equilibrium (the Example

machine may never reach true equilibrium as the process includ- Calculate the equilibrium torque and differential speed for the fol-
ing feed keeps changing at a slow time scale), the torque and dif- lowing high-solids decanter using the following parameters:
ferential speed values as prescribed by the operating control
mode have to agree with those as dictated by the centrifuge D=460-mm bowl
dynamics and process, i.e. Equations 2 and 3. Mathematically this L/D=3
implies that equilibrium requires a solution to exist by solving Leff=(2/3)L=36 in (915 mm)
simultaneously the two algebraic equations, one for the control mss=l 175 Ibm/h or 534 kg/h (dry basis)
mode and the other for the T-A equation. If both equations are G=2500g
delineated on the T-versus-A plot as two independent curves, g=32.2 ftIs2 (9.8 ft’s2)
equilibrium requires an intersection of these two curves. This is l=O.5
illustrated in Figure 7 that is discussed in details below for each k,=80 bar (pressure of hydraulic backdrive)
operating mode. k, = 5.3 barirpm
281 in-lbf = 1 bar (hydraulic backdrive)
(i) Torque Control ( T=To): g,=32.2 ft-lb/lb-s’

I%,, ‘Tl \ s
,
A=-F- //
(4) A=\/IIJ2K5.3).
-!- I +L5.3175. 3600)(2500)(36)(0.5)(1 ‘2X1)(30
m)- lJ!?L
(2N5.3) I
= 4.75RPM
-__
Torque is an indirect measure of the solids thickness in the
decanter. Higher torque assures higher compaction stress Gh act-
ing on the cake.. The resulting differential speed can be predicted T = k, + /+:A = 80+(5.3)(4.75)= 105h
from Equation 4. The torque control mode provides a reliable
means of assuring dry cake without torquing-out the machine
when the operating torque is set reasonably below the maximum For this example, the hydraulic backdrive is such that 1 bar = 281
allowable limit. In Figure 7, this is illustrated by point A on operat- in-lb,, the torque is 29,554 in-lb, or 3,340 N-m.
ing curve 1 corresponding to given G and solids rate, or by point
A’ on curve 2 under higher G, and/or higher solids rate. It is evi- CONCLUSIONS
dent that for the same operating set torque, when G or solids rate
increases the A needs to be increased as well so as to maintain In conclusion, a high-solids decanter can be modeled as a large
torque constant. rheometer. Based on this, the behavior of conveyance torque with
respect to the other operating variables can be determined.
(ii) Differential Control (A=Ao) Specifically, the effective frictional coefficient, determined for the
model for numerous waste sludges using different size high-solids
CL,,,, 111>< decanters of various designs and different geometric sizes, falls in
T=-- the nominal range of 0.5-l .5. By stipulating a torque-differential
A,, (5) speed control mode, both quantities can be determined under
quasi-equilibrium once the machine T-A operating curve, or the I
Differential control is used when the torque fluctuates erratically value together with the appropriate operating conditions, are
with the consequence of unstable operation with periodical dis- known. Conversely, torque can be predicted for a given differential
charge of wet cake. Under such conditions, the differential control speed, G, and solids throughput provided the I value is known for
mode is adopted to prolong and simultaneously control the reten- a given sludge.
 NOMENCLATURE: SPECIAL SYMBOL:

cf = Coulomb’s frictional coefficient I = effective frictional coefficient

D = bowl diameter, m (or mm)
9 =9.81 m/s’, (32.2 ft/s*)
REFERENCES
90 = constant (32.2 ft-lb,/lb,-sz)
G = centrifugal gravity, m/s* 1. W.W.-F. Leung, industrial Cenfrifugation Technology, published by
k,, k, = constants McGraw-Hill, New York, March 1998.
L = length, m (or mm) 2. W.W.-F. Leung, “Centrifuges” in Perry and Greens (eds.), Chemical
L efl = effective length, m Engineers’ Handbook, 7th ed., McGraw-Hill, New York, 1997.
mss = solids rate (dry basis), kg/h (Ib,/h) 3. W.W.-F. Leung, “Centrifugation” in Schweitzer (ed.),_Handbook of
% = bowl radius, m Separation Techniques for Chemical Engineers, 3rd ed., McGraw-
4 = discharge radius, m Hill, New York, 1997.
T = conveyance torque, N-m (in-lb, and bar) 4. W. W.-F. Leung, “High Solids Decanter Centrifuge”, Fluid-fakle
Separation J., vol 5, March 1992.
GREEK SYMBOLS: 5. K. Miyano, K. Nishida, and W.W.-F. Leung, “Advanced Centrifuge
Application on Biological Sludge Treatment in Japan”, in Proc. AFS
= differential speed, rpm Conference, Chicago, IL, May :3-S. 1993.
= density difference
= cake density
= liquid density

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