Professional Documents
Culture Documents
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Business Line Environmental Technology
GEA Westfalia Separator s the world’s leading company for mechanical separation
technology. The comprehensive expertise in the Business Line Environmental Technology
enables us to offer our customers process solutions which set a worldwide standard in
terms of economy, efficiency and sustainable environmental protection in drinking
water recovery as well as in the treatment of water and waste water.
Whether recovering drinking water or treating munici- Drinking water recovery /waste water treatment
pal or industrial waste water – plant operators always • Dewatering of sewage sludge
focus on how these jobs can be managed efficiently • Thickening of sewage sludge
and with minimum impact on the environment • Treatment of municipal and industrial
for the least possible cost. waste water
• Treatment of process water
The Business Line Environmental Technology at • Recovery of valuable materials from production
GEA Westfalia Separator Group responds to these streams and sewage sludge
challenges with high-performance separators and • Treatment of drinking water
decanters, convincing machines in both economic and
ecological terms. Focus – cost efficiency
Treatment systems from GEA Westfalia Separator
Resource-saving treatment systems demand Group are designed to achieve maximum separa-
made-to-measure solutions tion performances for minimum footprint and
With the experience gleaned from over 3500 systems energy requirement. Performance capability is
installed and the proven power of this technology optimized by serv&care. Customized service agree-
leader to innovate in mechanical separation technol- ments secure a high level of availability of plants
ogy, we plan and manufacture customized solutions and improve process reliability, so binding budgets
for our customers in the sectors below. can be drawn up and unplanned shutdowns avoided.
This supports our customers’ efforts to achieve abso-
lute cost control.
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Decanters and separators
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Product feed
Solids
discharge
Product feed
Clean liquid
phase
Discharge of
separated
liquid phase
Solids discharge
Operating water discharge
Bowl cross-section of a
self-cleaning separator
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Dewatering of sewage sludge
Water pollution control policy is posing growing challenges that have to be met
by secondary waste water purification. In future, a further increase in the sewage
sludge volume worldwide must therefore be expected.
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Rapid adaptation to environmental
conditions made possible by varipond®
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Thickening of sewage sludge
It Adds Up:
90 Percent Less Surplus Activated Sludge
Legal regulations relating to the elimination of phos- The name stands for “variable pond depth” when the
phorus and nitrogen and changes to the process machine is running. Until now, when feed conditions
technology of waste water purification have made fluctuated decanters had to be turned off and modi-
mechanical thickening of sewage sludge unavoid- fied in order to achieve a consistent concentration.
able. In normal situations, efficient thickening using Nowadays, varipond® makes it simple and reliable
GEA Westfalia Separator Group decanters can reduce to adjust the ideal setting during operation. The cen-
the volume of sewage sludge by up to 90 percent. trifuge adapts completely automatically to changed
An important contribution to this statistic is made feed conditions.
by varipond . Even where concentrations in the feed
®
fluctuate, it ensures consistent dry substance values The dry substance (DS) content of the sludge is mea-
in the discharge. sured online. This achieves accuracies of ± 0.3 percent
DS under operating conditions, allowing supervision-
GEA Westfalia Separator varipond ®
free operation even at night and at weekends. The
will not leave you out in the rain constant concentration allows the optimum design of
Waste water treatment plant operators are familiar the digestion tower of the waste water treatment plant
with situations like this: a sudden cloudburst and the and enables it to be operated more economically. The
drainage system can hardly contain the huge quanti- sludge is digested better. The increased quality enables
ties of water. Pumps and dewatering systems have to a higher gas yield to be obtained.
operate under high pressure to get the torrent under
control – a torrent which contains large quantities All the benefits at a glance:
of solids such as entrained sand and other residues. • 30 percent less sludge
This is where a fast-reacting system like varipond® • Fully-automatic feed control
is called for. • Reduced transport and disposal costs
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Mobile units and skid units
As far as the integration of treatment systems in Modular solutions for individual requirements
plants and processes is concerned, the Business Modular compact units / skid units are available for
Line Environmental Technology offers you a wide treating waste water – these are flexible and indi-
variety of solutions for every purpose. In addition, vidually adaptable. The “plug-and-play” design of the
both stationary and mobile systems are available, so mobile unit means it can be connected up immedi-
that whether you are a municipal facility or an indus- ately once it is in situ and, in addition to a decanter
trial company, you have the maximum flexibility with or separator, it already includes all the necessary com-
regard to different application locations. ponents such as polymer station, switch cabinet, feed
pump, solids conveyor and water supply, including
The mobile units are particularly advantageous wher- flushing device. All the components are installed on
ever rapid help or flexible deployment is required – a stainless steel frame which can be brought to any
from municipal waste water plants to the manage- location and used there without great effort.
ment of peak load to an enormous variety of indus-
trial fields to rapid support in the event of bottle-
necks. These systems and all the necessary units and
connections can be transported from place to place
quickly and easily in truck trailers, towed trailers or
in specially-equipped containers.
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Decanter skid unit for mobile
treatment of sludge
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Municipal waste water
All over the world, municipalities are having to deal with an ever-increasing volume
of sewage sludge. Economical and environmentally-friendly disposal depends on the
degree of solids concentration.
International policy on protection of seas and lakes terms of dry substance, separation efficiency and low
has committed in particular to cleaning waste water polymer consumption.
to a greater degree. A necessary consequence of this
strategy is a worldwide rise in the volume of All the benefits at a glance:
sewage sludge. As a result, municipalities face the task • High throughputs with maximum separation
of disposing of these rapidly growing quantities in efficiency
an environmentally friendly and yet cheap way. The • Permanently low disposal costs
solution is to dewater the sewage sludge as far as pos- • Minimal polymer requirement
sible, because the higher the concentration of solids in
the sewage sludge, the more economical subsequent
processes will be. With regard to incineration and the
saving of transport and landfill costs in particular, any
increase in solids concentration is something which
makes as much sense economically as ecologically.
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Processing of drinking water
Simply turn on the tap and water starts to flow – this is what people in industrialized
countries expect. However, every sixth inhabitant on this planet today does not have
access to clean drinking water.
This figure will be one in four in a few decades. Some of surface and ground water will become more and
researchers are forecasting that wars will be fought more important in future as population growth con-
over drinking water. Average per capita water con- tinues and as the environment becomes increasingly
sumption is currently estimated at 660 m 3 per year. contaminated. In the EU countries, drinking water
Of this figure, only between one and three percent are today is obtained from surface water (64 percent) and
actually used for drinking. The effective processing ground water (36 percent).
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Recovering drinking water from surface water
Various chemical processes are used for cleaning the
surface water, and decanters are subsequently used to
dewater the sludge obtained.
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Water treatment for the brewing industry
Beer. The fact that beer consists only of barley, hops, For many reasons, centrifugal separation technology
yeast and pure water should not disguise the fact that has become established in breweries as a forward-
beer brewing is one of the most complicated biochem- looking solution for waste water processing. The tech-
ical processes. A good brewer is essential for making nology has many advantages: decanters and separa-
a beer full of character. To take full advantage of his tors operate continuously, are extremely efficient for
art, and also to continue to consider environmental clarification and separation, and require minimum
protection, GEA Westfalia Separator Group provides energy and personnel. Processing installations for the
the brewer with powerful centrifugal separating tech- entire waste water system can operate in extremely
nology systems. restricted spaces and require the minimum of upfront
costs.
Production
waste water
Sand filter
Strainer
Industrial
Aerobic Water water
Sand filter
cleaning stage
Waste water
treatment
Sludge
Water
Solid disposal
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Waste water is not always waste water
Brewery waste waters mainly consist of two streams:
residual substances and cleaning agents. Residual
substances, such as yeast, fermentable sugar or kiesel-
guhr can be recycled as valuable substances into the
production process once solid and liquid components
have been separated. This reduces costs and boosts
the yield.
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Production
waste water
Water / concentrate
Strainer
Pre-treatment
Flotation
sludge
Flotation
Activation / SBR
Surplus
activated Dewatered sludge
sludge
Sedimentation
Solids disposal
Clarified liquid
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Water treatment for dairy operations
Lowering waste water costs by reducing the volume of waste water and waste water
freight – a major factor for determining the competitiveness of dairies.
The average volume of waste water in dairies is cur- Milk is not the only consideration …
rently 1.3 l / kg milk. This results in considerable waste … it is also necessary to consider the way in which the
water disposal costs. The centrifugal separating tech- downstream products are treated. The recycling of
nology from GEA Westfalia Separator Group paves valuable substances into the production process and
the way for major potential savings by minimizing the reduction of waste substances that can no longer be
the use of fresh water and reducing the volume of recycled enhance productivity, lower operating costs
residual sludge. and protect the environment. According to calcula-
tions by the Verband der deutschen Milchwirtschaft
Hygiene is the most important factor in milk pro- (Association of German Dairying), direct dischargers,
cessing and the production of dairy products. This i. e. companies with their own waste water processing
necessarily results in the use of considerable volumes facility, operate with costs that are up to two-thirds
of water for cleaning purposes. In addition, consider- lower than users of municipal waste water treatment
able quantities of waste water with volatile milk con- plants. After anaerobic or aerobic biological treatment
stituents, fats and proteins occur when milk is being of dairy waste waters, the decanter technology of
processed, particularly during evaporation and spray GEA Westfalia Separator Group provides a tried-
drying. Two main streams of waste water are pro- and-tested method for thickening residual sludge.
duced: process waste water which comes into contact Thickening and dewatering reduces disposal costs,
with milk, and process waste water which does not enhances competitiveness and protects the
directly come into contact with product. Decanters environment.
and separators from GEA Westfalia Separator Group
are ideal for providing savings, enhanced efficiency
and easy operation.
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Water treatment for fruit juice production
The valuable constituents in fruit, namely vitamins, mentation would otherwise start very easily. Residues
are intrinsic. This would appear to be obvious, of chemical substances (insecticides) from cultivation
although upon closer observation it is not quite so and residues from the production process also have
evident as the interior of the fruit starts in the peel, to be removed completely. This means that the wash
e. g. in the case of lemons or oranges, where the peel water has to be processed thoroughly because it can-
is processed into valuable by-products. When fruit is not be discharged into the sewerage system or into
processed into fruit juice there are stringent quality the environment in this state. Mechanical separation
and hygiene requirements as well as market-oriented of the solids is an ideal and cost-effective method for
considerations: higher levels of concentration reduce treating wash water.
transportation costs.
After straining and biological pre-clarification in acti-
Large volumes of fresh water are required for vation tanks, decanters thicken the residual sludge
cleaning the fruit, pipework, storage tanks and and the volume of the sludge is reduced; the dis-
bottles. Mechanical separation technology from charged solids are of a crumbly consistency and can
GEA Westfalia Separator Group provides a range be disposed of inexpensively. The process water can
of benefits for processing waste water in fruit juice be recycled into the cleaning cycle or discharged into
production and achieves excellent results as a result of the sewerage system in an environmentally friendly
its closed design and high dewatering capacity. manner. The volume of fresh water consumed is
reduced, resources are used efficiently and energy
Decanters and separators keep the vitamins costs are lowered. In this way, decanters and sepa-
Numerous substances are retained in the wash water rators from GEA Westfalia Separator Group make a
during the cleaning of pipework and storage tanks. major and inexpensive contribution towards ensuring
Many valuable organic substances (fruit residues with that everything is in its rightful place: the vitamins
a high sugar content) have to be separated because fer- in the juice, and clean water in the cycle of nature.
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Production
waste water
Water / concentrate
Strainer
Neutralization /
pre-treatment
Anaerobic
treatment
Sludge
Sedimentation
Decanter
Activation
Sludge
Sedimentation
Dewatered sludge
Clarified liquid
Solids disposal
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Production
waste water
Water / concentrate
Strainer
Pre-treatment
Sludge
Sedimentation
Decanter
Activation
Sludge
Sedimentation
Dewatered sludge
Clarified liquid
Solids disposal
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Water treatment for wineries
Decanters and separators are used both in wine production and in waste
water treatment in wineries.
“Wine is the poetry of the earth”, said Mario Soldati. separation technology is very beneficial not only to
The vintner who makes a good wine is therefore a maintain hygiene but also to reduce costs.
poet, and the wine cellar is his study. However, the
considerable amount of labour and effort involved Decanters and separators reduce the strain on
in the process, from cultivating the grape in the vine- vintners and the environment
yard and the processes of harvesting and pressing the Mechanical separation of solids is an optimum and
grapes as well as allowing the wine to mature, are fre- cost-effective method of cleaning wash water. After
quently forgotten. It is well known that decanters and straining and biological pre-clarification in activation
separators have an important and useful role to play tanks, the thickened residual sludge is dewatered by
in the production and filtration of wine. However, the decanters, and the volume of the sludge is reduced;
fact that they are also useful in waste water treatment the discharged solids are of a free flowing consistency
in wineries is not always appreciated. and can be disposed of inexpensively. The process
water can be recycled into the cleaning cycle or dis-
Large volumes of fresh water have to be used in the charged into the sewerage system in an environmen-
numerous stages of the wine-making process for tally friendly manner: the volume of fresh water
the necessary cleaning of transport vehicles, storage consumed is reduced, resources are used efficiently
tanks, wine casks, filter installations and bottles. The and energy costs are lowered. In this way, decanters
cellars themselves also have to be cleaned. This results and separators from GEA Westfalia Separator Group
in waste water with a high organic load consisting make a major and inexpensive contribution towards
of vine leaves, stems, vermin, dirt and yeast. This ensuring that the truth is retained in the wine and
mixture very quickly starts to ferment, which means that which clearly emerges remains in the environ-
that clarification is necessary. The use of centrifugal ment: clean water.
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Water treatment in the production of vegetable products
Dirt is Avoided
Decanters minimize the consumption of fresh water in the production
of vegetable products.
Extremely strict hygiene regulations are applied dur- tion. Mechanical separation of the solids is a simple
ing the processing of vegetables into convenience and cost-effective method of cleaning the wash water.
products, either deep-frozen vegetables, preserves or This reduces the costs of fresh water as well as storing
ready-made meals. Large quantities of organic sub- and disposing of the residues.
stances (vegetable waste) are also obtained when the
vegetables are cleaned; this waste can rapidly start to Rake, strainer, settling tank and decanter
rot. This makes it doubly necessary to devote a great A rake is the first cleaning stage in which coarse solids
deal of care to processing the wash water. Decanters such as vegetable leaves are separated and transported
and separators from GEA Westfalia Separator Group for further use, e. g. as animal feed. The wash water is
are ideal for these applications as a result of their pre-cleaned in this way and dirt and sand are removed
closed design and their high dewatering capacity. in a sand trap; the water is further purified in a bowl
strainer machine and discharged into a settling tank.
At the beginning there is an extensive full bath for the The wash water that has been treated in this way is
vegetables that have just been harvested and which now pumped into the decanter. Any fine substances
are still contaminated with various foreign substances, still contained in the wash water are now continu-
such as humus, insects, worms and other components. ously separated and discharged with a high dry sub-
The packaged products should contain only what is stance content. The separated solids can be processed
on the label. The high content of organic substances into animal feed, and the water that has been clarified
in the wash water means that extensive processing by the decanter is discharged into a retainer tank and
is essential because it cannot be discharged into the then to the waste water treatment plant.
sewerage system or the environment in this condi-
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Wash water cleaning in 1 Wash water 5 Bowl strainer machine 9 Clarified water
vegetable processing 2 Coarse solids 6 Rakes 10 To waste water treatment
3 Sand 7 Solids 11 Container
4 Sand trap 8 Decanter
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Water treatment in biofermentation
“Nature is a company which has not gone bankrupt Decanters recover valuable compost
for four billion years”, said Frederik Véster during the Decanters from GEA Westfalia Separator Group are
1970s, demanding that society ought to take nature used to dewater the fermented biomass from the
as its example. Modern environmental protection is fermenter by separating solid particles and
based on a process of product recycling instead of dewatering them to a free flowing dry consistency.
mere product disposal. Waste is unknown in nature The solids, which are discharged by the decanter
– nature cannot afford waste in the long term. under forces equivalent to 3000 to 4000 times
gravity, are a valuable fertilizer rich in organic
Anaerobic fermentation components. This fertilizer is suitable for use in
For the enthusiastic amateur gardener, the method gardening, agriculture and forestry. Strict quality
of composting organic waste for recycling natural controls guarantee that there are no hygiene-
fertilizer into the nutrient cycle may be sufficient; related problems. The centrate is recycled into the
however, a different method is necessary in the waste fermentation process or is sent for further
and disposal industry. The innovative method of processing. The process allows centrifugal separating
anaerobic biowaste fermentation was established in technology from GEA Westfalia Separator Group to
the mid-1990s. This technology has demonstrated its turn waste into valuable energy media and fertilizer.
worth as a method of recycling to save energy, protect
the environment and conserve resources. The advantages at a glance
• High separating capacity and
Wet fermentation good centrate quality
The size of the items of biowaste is reduced to a maxi- • High DS value in the solids
mum of 60 mm by removing all foreign substances which can be composted
such as plastics, metal and textiles. Water is then • Preliminary stage for further processing method
added and the mixture is treated at 70 °C for an hour. • Centrate recirculated to mashing
After sand has been removed and the fibres broken • Reduction of logistics and disposal costs
down further, this mixture of biowaste and water has • Closed substance streams due to
a grain size of less than 10 mm and can be fermented fertilizer production, recirculation and
under anaerobic conditions in a digesting tower. A where appropriate direct discharge
significant side effect of the fermentation process
is the production of biogas, which can be used to
generate electricity after it has been dried and cleaned,
and more than covers the fermentation system’s
own energy requirement. With up to 540 kilowatt
hours per 100 cubic metres of biowaste, this is an
environmentally sound and forward-looking method
of energy recovery, which will play a major role in
future energy policy helping to save limited resources
of fossil fuels and control the greenhouse effect.
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Water treatment in agriculture
Decanters in agriculture are used for recovering the ultimate from what otherwise
would “stink to heaven” and recycle nutrients for economic use.
The laws of physics say: energy is never lost, it is Phosphates: minus 90 percent nitrogen:
merely converted. In nature, this fact is the basis of minus 35 percent
life and has developed over millions of years. The Natural fertilizer can be spread in a manner that
ancient Egyptians revered the scarab as a holy animal is not detrimental to the soil, only after phosphate
because it uses what is discarded by other animals to and nitrogen concentrations have been reduced.
derive energy, thus closing the eternal cycle. Liquid Mechanical separation technology using decanters
manure from animal husbandry is a valuable natural from GEA Westfalia Separator Group is responsible
fertiliser used in modern agriculture – if it is properly for the traditional task of solid-liquid separation. The
introduced into the nutrient cycle of nature. decanter separates between 70 and 90 percent of
phosphate compounds and between 30 and
Inexpert spreading of liquid manure is frequently one 35 percent of nitrogen compounds.
of the main reasons for very high concentrations of
nitrates and phosphates in groundwater or surface Making proper use of recovered nutrients
water. There is a conflict between intense animal A liquid manure processing installation separates the
husbandry and a shortage of areas for disposing of solid particles and dewaters them to a free flowing
liquid manure. GEA Westfalia Separator Group has consistency. The solids discharged by the decanter
developed a cost-effective processing concept for this are suitable for processing into fertilizer, but must be
problem. The aim is to process the liquid manure and first treated hygienically. This is achieved by drying
the related surpluses of nutrients in the operations or composting.
and to ensure that the products obtained are used
properly. The continuous separation of solids and the Mobile from farm to farm
high dewatering capacity of decanters make them an To achieve optimum capacity utilization, GEA Westfalia
efficient and cost-effective solution for agriculture. Separator Group has developed a mobile system
which can easily and quickly be transported from
farm to farm on a trailer or container. All necessary
components such as pumps, conveyor technology
and its own power supply provided by a diesel gene-
rator mean that the decanter, with a capacity of up to
50 m³ / h, is completely self-contained.
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Tanning waste
water
Neutralization
Decanter
Polymer
solution
Biological
sludge
Biological Clarified
Dewatered sludge
treatment liquid
Solids disposal
Clarified water
To waste water
treatment plant
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Water treatment in tanneries
Tanneries belong to industrial sectors with the highest discharged directly into public sewerage systems. To
levels of water consumption. To make leather from solve the problem, biochemical processing of the waste
one tonne of raw material, experience has shown water is a standard operation in modern installations.
that up to 60 m³ of water are required. The volume of Decanters from GEA Westfalia Separator Group also
waste water, which contains high levels of alkaline and play a significant role.
organic substances is, of course, correspondingly high.
If the waste water is not appropriately pre-treated, When the waste water from the tanning process has
it cannot be directly discharged or processed i n been collected, and after a polymer has been added, the
municipal waste water treatment plants. Throughout decanters operate in a continuous procedure to remove
the world, decanters from GEA Westfalia Separator all organic substances, e. g. hair, from the thickened
Group, which ensure optimum pre-treatment for sub- sludge. The separated solids can be composted and are
sequent biological treatment, are used for appropriate also used in gardening or forestry applications. The
processing within tanneries. liquid phase is then subjected to biological treatment.
The resultant sludge is recycled into the dewatering
Leather production is one of the oldest trades. Modern process; the waste water can be sent safely to conven-
industrial-scale production still requires extremely tional municipal waste water treatment plants. The
high volumes of process water. The water is not only advantages of decanters provide optimum dewatering
needed for transportation in the production process capacity and use very little rinsing water. The closed
but also for various tasks such as unhairing or soaking system prevents aerosols from escaping; such aerosols
the hides. The waste water problem is correspondingly would otherwise pose a problem for humans and
acute – in European producer countries like Italy and the environment.
Spain but also in China, India, Korea, Brazil and the
USA, to name just the most important producers. As
a result of the specific production methods, the waste
water has high alkaline levels (pH value 10), is contami-
nated with chemicals such as sulphite and chrome,
and has a high level of organic substances. This means
that waste water from tanneries cannot usually be
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Water treatment in paint shops
Decanters and separators recover the paint and allow the environment to blossom.
Paint is applied in many areas of industry, for a wide content of 80 to 95 percent. The sludge obtained is
range of reasons: not just for better visual appearance; stored in a storage facility and then pumped into
protection against corrosion and improved surface the decanter. The solids discharge is disposed of or
qualities are also very important. However, what can recycled; the clarified phase is recycled back into the
be done with the waste water? process reducing the costs of waste water disposal and
the use of fresh water.
Waste water does not usually occur during the
manufacture of paint as the systems are closed to Decanters for water-based paints
water. However, waste water may occur in peripheral Today, environmentally friendly, water-based paints
processes, for instance in the cleaning of packaging are used specifically in the aviation and automo-
materials and mixing tanks. Such wash water contains tive industries, and in many other areas of indus-
residues of dispersed acrylate and vinyl resins, dis- try. Decanters from GEA Westfalia Separator Group
solved cellulose derivatives, together with residues separate paint residues from the water and ensure
of pigments and filling agents, solvents, traces of that it can be reused. The high-speed operation creates
acids or lyes from pH value adjustment as well as a large clarification area to ensure high throughput
residues of preserving agents. Such waste waters have capacities and better separation with a high dry
to be processed and decanters from GEA Westfalia substance content.
Separator Group are very effective and efficient for
these applications. Nature adorns itself with the most beautiful colors.
Decanters and separators from GEA Westfalia Separator
The use of decanters in painting installations Group fulfil a fundamental objective in this respect.
Waste waters in paint shops are mainly contaminated They draw a clear distinction between the colors of
with solvents, undissolved paint constituents and a nature and paints manufactured industrially by man:
high percentage of paint particles that can be coagu- color belongs in life; paint does not belong in the
lated. The use of decanters can considerably reduce environment.
disposal costs for the paint sludges with a water
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Waste water treatment in the 1 Pre-clarifying tank 6 Primary sludge 10 Clarified phase
paper industry 2 High-load biology 7 Secondary sludge 11 Landfill
(1st stage) 8 Flotation sludge 12 Drying
3 Sedimentation (various ink, paste sludge) 13 Incineration
4 Post-clarification 9 Capable of being
5 Activation installation dewatered individually and
(2nd stage) also together
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Water treatment in paper manufacture
Paper is Patient –
the Environment Is Not
Efficient waste water processing helps the paper industry to reduce costs and
protect the environment.
The paper-making process is one of the most water- tion in the costs of storing and disposing of material
intensive industrial production processes. This is that cannot be reused, the volume of fresh water is
because, without the physical properties of water, it minimized, and expensive chemical substances can
would not be possible for a consistent structure to be reused on several occasions.
be achieved when the constituents of paper are pro-
cessed in a sludge. A high level of water consumption Illustration by comparison
is inevitable in the processing of natural raw materi- The above diagram demonstrates the impact of using
als (wood, cellulose, vegetable fibres) and also in the centrifugal separation technology for processing
process of recycling waste paper. This creates a high waste water in the paper production process. Whereas
level of waste water for processing. The residues in valuable components are lost in processes without
the waste water are a problem particularly in the case decanters, mechanical separation means that most of
of de-inking: the process of recycling printed waste the constituents can be recovered and can be recycled
paper. This demonstrates the tremendous advantages into the production process. The old principle of “time
of using decanters and separators, both in terms of is money” means there is a two-fold benefit – for the
competitive advantages by way of reducing costs in environment and for the paper industry.
the paper industry and also for environmental protec-
tion by minimizing toxic substances. • Closed system, no aerosol emissions
• Maximum dewatering
Closed circuits • Corrosion protection for all components which
In addition to the above-mentioned constituents, fur- come into contact with product due to the use of
ther chemical substances are also added depending stainless steel
on the desired paper quality – for instance whiten- • High throughput capacity
ers, inks or dust-inhibiting agents – which have to • Continuous and cost-effective operation
be removed from the waste water at the end of the • Simple and flexible operation
production process. Decanters and separators make a • Low space requirement
major contribution towards separating reusable sub- • Low addition of fresh water
stances: they separate solids which can be disposed of
and clear water which can be recycled back into the
production process. Because of the high content of dry
matter that can be obtained, there is a dramatic reduc-
35
Water treatment in the pharmaceutical industry
No Risks or Side-Effects
So that waste water processing does not cause headaches.
The average life expectancy of man has almost dou- Clarification tank and separator
bled during the past 100 years. This has been owing It is necessary to use separators to remove solids
to knowledge of hygienic conditions, changes in from production waste water to a level that meets the
nutrition and living conditions and progress made specified limit values. A major advantage of separa-
in medical research. Today, many illnesses, which tors compared with conventional membrane filtration
decades ago appeared to be untreatable, can now be installations, which have been tested by the pharma-
treated by medical products. With its research and ceutical industry for comparison purposes, is that
development activities, the pharmaceutical industry there is no “clogging” phenomena so stable process
has made a major contribution to this development reliability is guaranteed. From the balancing tanks,
and the volume of medical products that is available the waste water is sent to aeration tanks for biological
today is almost unimaginable. treatment, then sent via pre-clarifiers to a compensa-
tion tank which is used as a buffer tank. The separator
Great quantities of chemicals and biological primary is then responsible for polishing the waste water. This
substances are required for making medical products. process clarifies the waste water sufficiently for it to
This means that the production waste water also be discharged directly into lakes and rivers.
contains a wide range of substances that cannot be
easily separated from the sewage sludges. Moreover,
conventional clarification and sedimentation tanks,
which cover a large area and require relatively long
purification times, make it very difficult to comply
with statutory limit values in the waste water.
36
Production
waste water Water Concentrate
Rake defatting
Neutralization /
pre-treatment
Sludge
Sedimentation
Anaerobic Sludge
Separator
Activation treatment
Sludge
Sedimentation
Dewatered sludge
37
1 2 3
4
M
M
7
8
9
10
11 12
13
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Water treatment in flue gas desulphurization and sewage sludge dewatering
China is fast catching up with the western industrial major industrial centres such as Tianjin near Beijing,
standard. However, further economic growth will only Shanghai, Guangzhou and increasingly in the “Golden
be guaranteed if energy production is able to keep triangle” of Shenzhen. The Taishan power station in
up with this development. Because the country has the South of Shanghai alone is expected to produce
large reserves of coal, it intends to step up the pro- 3 GW of power making it one of the largest coal-fired
cess of expanding its coal-fired power stations which power stations in China. The decanter type UCC 450
already supply approximately 70 percent of the coun- has already been installed in this plant to dewater
try’s overall power requirements. However, this means the flue gas washing liquid with a capacity of up to
that China is also facing an environmental problem. 20 m³ / h. Power stations of this size are planned and
Decanters from GEA Westfalia Separator Group are operated in the same way as a small city. Accordingly,
playing a major role in providing a solution. these “small cities” also require a corresponding waste
water treatment plant. The waste water treatment facil-
Flue gas, which contains sulphuric acid and is, there- ity makes ecological and economic sense and is there-
fore, toxic for the environment, is generated in coal- fore the second area of application for decanters in
fired power stations. A few years ago, the Chinese the Chinese coal-fired power station industry. Highly
state therefore started to equip existing as well as new efficient models such as the “Crocodile” UCD 305 are
coal-fired power stations with flue scrubbing installa- used for maximum dewatering of the biological sludge.
tions. The milk of lime used for neutralizing the flue The advantages of decanter technology compared with
gas is dewatered by various sizes of decanter and is the discontinuously operating chamber filter press are
converted into a consistency that can be used directly also becoming increasingly recognized in China.
by the gypsum construction industry for manufactur-
ing plaster board. Current figures indicate how great Decanters from GEA Westfalia Separator Group per-
the need is for decanters: China is one of the larg- form well when compared with other decanters pri-
est coal producers and consumers in the world. More marily because of their high throughput capacities
than half of the coal is consumed in power genera- both in absolute terms and also in relation to the solids.
tion. New power stations are being built, mainly in the
39
Treatment and purification of radioactive wash water
Energy is Necessary –
with Inbuilt Safety
Nuclear fission is not possible without radioactive water in the reactor as a closed-circuit system is used
material, so it’s natural that the process creates con- in this application to ensure that high concentration
taminated wash water. This water is not for cooling radiation cannot escape. However, radioactive solid
and liquid waste is obtained from processing and
treatment in the secondary areas of nuclear power
stations. Decanters and separators are used in such
applications.
40
First decanters, then separators – subsequently discharged into the sewerage system,
a reliable combination the levels of radioactivity are far below the statutory
The wash water is discharged into collecting tanks limit levels.
and then pumped to a decanter. Compared with the
pre-coat filters that were used previously, the decanter The combination of decanters and separators from
can considerably reduce the volume of solids because GEA Westfalia Separator Group guarantees optimum
the discharge concentrate from the decanter has a clarification and maximum protection of the environ-
water content of only 10 to 35 percent. The solids ment in this sensitive application, and the volume
that are not separated are homogenized by the cen- of solids for storage under secure conditions is con-
tripetal pump in the decanter discharge, and the clari- siderably reduced. It’s a safe, clean, cost-effective
fied wash water is sent to the separator for polishing. solution.
The polished wash water is collected in control tanks
and checked extensively for radioactivity. When it is
3
4
5 6
7
8
7
9 10
11
12 7 13
14 15
16 17
41
serv&care –
Proactive Service for Optimum Reliability on Board
Safety first: this is precisely what the service concept Training provided on site or in the modern training
serv&care stands for. centre of GEA Westfalia Separator Group ensures that
the plant operator’s employees receive training in the
Shipowners not only benefit from traditional proper handling of the high-tech installations. This
services such as inspection, maintenance, original provides additional safety.
spare parts and repair work provided by the original
manufacturer; they also benefit from proactive Authorized workshops worldwide
solutions which avoid risk, e. g. online and offline And if problems occasionally occur or if a spare part
monitoring with GEA Westfalia Separator wewatch®. is required at short notice, the specialists are able
These preventive services are the best pre-condition to attend to the ships quickly. This is ensured by a
for a smooth operation. global network with more than 50 sales and service
companies. Authorized workshops are able to service
Enhanced process efficiency also follows from every location in the world at short notice.
maximum operating reliability and machine
availability. Accompanying modernization or
upgrading to state-of-the-art technology also offer
the option of boosting performance as required.
42
serv care
serv&care accordingly makes for maximum operating In addition to traditional services
reliability, machine availability, process efficiency such as maintenance or repair,
serv&care also provides solutions
and budget security. And these benefits are
which avoid risk and with which
provided throughout the entire life cycle of the the installation availability can be
entire installation. proactively assured.
43
www.gea.com
We live our values.
process technology. GEA Group is listed in the STOXX® Europe 600 Index.
GEA Group is a global engineering company with multi-billion euro sales and operations in more than
50 countries. Founded in 1881, the company is one of the largest providers of innovative equipment and
The information contained in this brochure merely serves as a non-binding description of our products and is without guarantee. Binding information, in particular relating to capacity data and suitability for specific applications, can only be provided within the framework of concrete
inquiries. Printed on chlorine-free bleached paper · Printed in Germany · Subject to modification · Westfalia®, Westfalia Separator ®, wewatch® and varipond® are registered trademarks of GEA Mechanical Equipment GmbH. B_ET-13-01-0001 EN