FLOTTWEG DECANTERS

for Water Treatment and Wastewater Facilities

 CLEAN WATER IS AN INDISPENSABLE RESOURCE
Efficient Wastewater Treatment is a Basic Requirement

All water on earth circulates in a closed loop. It moves from land to sea Flottweg is ISO 9001 certified
to atmosphere, changing from ice to water to vapor several times. The and manufactures its products
total quantity of water on earth amounts to 1.4 billion cubic-kilometers in compliance with all current
of which 96.5 % is sea water in the oceans. Only 3.5 %, i.e. 49 million technical standards.
cubic-kilometers, is fresh water. However, more than half of this fresh
water is in the form of ice on the poles, glaciers and permafrost soil.

In modern water management there is a closed loop as well. This loop

comprises the way the water flows from drinking water to wastewater.
Germany – Flottweg’s home market – holds a leading position in water
management.

According to the figures of the German Association for Water, Waste-

water and Waste, 95 % of the wastewater is treated in wastewater fa-
cilities where 90 % of the chemical and biological oxygen, 77 % of the
total nitrogen and 90 % of the total phosphorus are eliminated.

Since the 1950s, when Flottweg started to build decanter centrifuges

and especially after the 1970s when Germany’s wastewater business
started to flourish, providing decanters for sludge dewatering and thick-
ening has been one of Flottweg’s core strengths. Today Flottweg De-
canters efficiently operate in treatment facilities serving population
equivalents from 5,000 to 10,000,000 all over the world.

Berliner Wasserbetriebe (Waste Water Facility of the City of Berlin)

2
 THE WASTEWATER BUSINESS
DESERVES ITS OWN PRODUCT LINE
The Flottweg C-Series

Over the last five decades Flottweg has acquired a great deal of
expertise in sludge thickening and dewatering. We know the special
requirements of the wastewater industry. Thus, Flottweg decided to cre-
ate a new decanter series solely manufactured for sludge separation,
called the Flottweg C-Series. This new decanter series incorporates
the latest know-how in mechanical engineering, manufacturing, and
control system fabrication. The result is a new series of environmental
Flottweg Decanter C3E
centrifuges featuring Flottweg’s quality, reliability and optimal price/per-
formance ratio.

Special features in bowl design, drive systems and control systems

assure optimal performance in terms of recovery, cake dryness, and
capacity. Special emphasis was put on the life cycle costs. The new
Flottweg C-Series excels with up to 30 % less power consumption com-
pared to standard decanters. Freshwater is only required to prepare
the polymer solution. The standard, double-walled sound insulated
housing eliminates the need for additional noise protection measures.
Easy accessibility makes servicing uncomplicated and wear parts can
be replaced on site which dramatically reduces downtimes due to main-
tenance.

Flottweg Decanter C4E

C2E

C3E

C4E
TECHNICAL INFO

C5E

C7E

Z92
Flottweg Decanter C5E

Flottweg Decanter Product Line for a clean environment

® = registered trademark for various countries

3
 FLOTTWEG OSE DECANTERS
for Sludge Thickening
In sludge thickening, surplus sludge, which is
generated during the biological stages, is con-
centrated from 1 % or less total solids content to
5 – 8 % before it is pumped into the digester.
As a result, the amount of sludge is reduced by
90 to 95 % in volume.
The Flottweg OSE decanter (OSE = optimal
sludge thickening) was created specifically for
this purpose. Today, the Flottweg OSE Decanters
stand out from the competition with their reliability
and cost efficiency.
Recent studies which took all relevant fixed costs
(capital and labor) as well as variable costs (con-
sumption of power, water, and polymer as well
as spare parts) into account, show that a thick-
ening decanter has advantages over other thick-
ening equipment. These advantages become
increasingly significant in the case of large ca-
pacities and long operation time. Flottweg OSE
Decanters are available for flow rates ranging
from 20 to 250 m3/h (90 to 1100 gpm) per unit.
waste
primary
water
clarification
TECHNICAL INFO
primary sludge
4
Customer benefits versus other
thickening techniques
Optimized operation/labor costs through:
• continuous and automatic operation
• low specific energy demand
• low or no polymer demand
• easy cleaning by flushing without dismantling
• durable wear protection
• on-site replacement of wear parts
Lower procurement costs because of:
• compact design, small footprint, and high specific capacity
• closed design that minimizes odor emissions, no special
vent line necessary
Versatility:
• Flottweg OSE Decanters are also suitable for processing
blended and primary sludge
For more information please see our flyer on OSE decanters, available
for download at www.flottweg.com.
aeration secondary
clarification
Flottweg OSE Decanter
surplus (waste) sludge
(0.5...1.0% ds)
thickened
(4...8% ds)
centrate sludge
FLOTTWEG HTS DECANTERS
for Sludge Dewatering

Customer’s benefits versus other Regardless of whether the sludge is transported

dewatering techniques
Optimally balanced performance:
• maximum cake dryness
• minimum specific power consumption
• minimum polymer demand
Optimized operational labor costs through:
• continuous and automatic operation
• easy cleaning by flushing without dismantling
• durable wear protection
• on-site replacement of wear parts and safety inspections
• no consumables such as filter aids, filter cloth, etc.
Flexibility:
• Flottweg HTS Decanters can be adjusted to varying feed
and operation conditions during operation automatically
via PLC or remote control
after dewatering, reused as fertilizer, disposed of
in landfills or incinerated – maximum dryness is
the most critical factor.
The other key factors are cost efficiency in terms
of consumption of polymers, energy, water and
spare parts, as well as continuous, automatic op-
eration at minimal costs.
All these criticial design features were already
taken into account at the beginning of the 1970’s.
Today, the result of this continuous development
is the complete Flottweg HTS Decanter Portfolio
for sludge dewatering which includes equipment
to handle capacities of 10 to 180 m3/h (40 to 800
gpm).

water
effluent

digestion

Flottweg HTS Decanter

digested sludge
(2...6% ds) dewatered
sludge
centrate (25...35% ds)

® = registered trademark for various countries 5

 HOW THE FLOTTWEG DECANTER WORKS

A decanter centrifuge can be viewed as a settling pond wrapped around
an axis. In the settling pond, solid particles, which are heavier than the
liquid, settle to the bottom driven by gravity and build up a sediment
layer on the bottom of the pond. In the rotating bowl of the centrifuge,
solid particles, which are heavier than the liquid, move to the inner di-
ameter of the bowl driven by centrifugal force and build up an annular
sediment layer on the inner surface of the centrifuge bowl. Since the
centrifugal force in the decanter is approximately 3000 x g instead of
1 x g in the settling pond, separating solid particles from a liquid in a
centrifuge becomes much faster and more efficient.
The sludge to be separated enters the bowl via
a stationary feed pipe. From the feed pipe it en-
ters the separation zone via feed ports in the
scroll body. In the separation zone, it separates
into a sediment layer and liquid layer. The sedi-
ment is scraped off the bowl wall via the scroll
conveyor and delivered out of the pond on the
conical end of the machine, also called the dry
zone, before it leaves via discharge ports on the
conical end of the bowl.

The bowl shell of a decanter centrifuge has a cylindrical – conical The separated liquid flows to the cylindrical end
shape. It rotates at a high speed creating the centrifugal force needed of the bowl where it is discharged by gravity via
for the separation. Inside the bowl, there is a scroll conveyor for the an overflow weir.
continuous discharge of the sediment which is packed on the inner sur-
face of the bowl wall. The scroll conveyor rotates at a speed relative to
the bowl speed. This differential speed is created by a rotating gear
box at the drive end of the bowl.
TECHNICAL INFO

The picture shows a

decanter scroll

6
 SPECIAL DESIGN FEATURES
of the Flottweg OSE and HTS Decanters

BOWL AND SCROLL MATERIALS OF

The high cake dryness obtained using the Flottweg
HTS Decanter is the result of the machine features: centrifugal dewa-
tering under high g-force and mechanical pressing. The bowl is shaped
in a “deep pond design” to provide a large bowl volume and a narrow
discharge diameter for low energy demand. The layout of bowl and
scroll in combination with a high-torque scroll drive results in high pres-
sure in the pressing zone located in the conical end of the bowl.
CONSTRUCTION
Flottweg exclusively uses high-quality stainless
steel for all wetted parts. All models are equipped
with bowls made of centrifugally casted duplex
stainless steel to ensure optimal strength and
corrosion resistance.

DRIVE SYSTEM
The bowl is driven via a motor which is controlled by a
frequency inverter (VFD). For the scroll drive, there is the Flottweg Simp
TECHNICAL INFO

Drive® - a self-regulating system consisting of a multi-stage planetary

gear and control system including a frequency inverter. The Flottweg
Simp Drive® controls the differential speed by monitoring and controlling
the torque that is generated when transporting the solids cake through
the centrifuge bowl. That means that the differential speed can be
extremely low to create the maximum pressure needed in the pressing
Flottweg Simp Drive®: Regulation of the differential
zone of the bowl in order to achieve the maximum cake dryness, even speed depending on the scroll torque

under varying load conditions.

WEAR PROTECTION DOSAGE OF POLYMER

All parts of the Flottweg OSE and HTS Decanters exposed
to wear are broadly protected against abrasion. The scroll flights are
hard faced with tungsten carbide. All ports for feed and cake discharge
are protected by bushings made of hard metal, or silicon carbide. The
bushings are field replaceable. Thick walls protect well against abra-
sion.
TECHNICAL INFO
FLOCCULANT AIDS
To some extent, the polymer demand in sludge
dewatering and thickening depends on the ma-
chine design. For maximum efficiency, the floc-
culated sludge must be created at the right spot
and at the right time. Therefore, the Flottweg
OSE and HTS Decanters are provided with a
special mixing pipe to create the flocculated
sludge directly before entering the separation
zone.

feed

solids discharge liquid discharge by gravity

Liquid-solid separation – Flottweg Decanter with gravity overflow

® = registered trademark for various countries 7

 THE NEW C-XI DECANTER SERIES
Higher G-Force Means Dryer Solids

Do you want to reduce your disposal costs to a minimum, and do you The advantages of the
want to make your process even more flexible? Then the C-XI decanter C-XI series at a glance
series is the right choice for you. This optimized decanter series was
specifically developed for the wastewater market. Requirements in this • Reliable force transmission at
area have evolved continually over the past few years. Certain types very high loads
of sewage sludge require additional dewatering. By developing a de- • Stronger gearbox for the more
canter centrifuge designed specifically for these requirements, Flottweg powerful drive
– as usual – stands out for its efficiency and quality because dryer • Higher g-forces for better
sludge means significant cost reductions (transport, disposal, etc.) for dewatering performance
operators of sewage treatment plants. How can this be done? • Better solid conveyance for
more throughput
MAXIMUM G-FORCES • Optimized scroll body for perfect
To help separate the remaining moisture from the sludge dur- conveying of the separated solids
ing dewatering, maximum g-forces are needed. The higher the maxi- • Minimum downtime thanks to the
mum g-force within the bowl of the decanter, the better the dewatering extremely maintenance friendly design
performance – in other words, the dryer the processed sludge will be. of the C-XI series
Since this is significantly dryer after handling using a C-XI decanter • Additional energy savings of about 30
centrifuge than with conventional decanter centrifuges or other systems percent are possible with the Flottweg
for sludge treatment, sewage treatment plant operators save enormous Recuvane®-System
costs. Depending on the size of the sewage treatment plant, a gain of • Top life span through highest quality

® = registered trademark for various countries

one percent dry substance (DS) can lead to savings of thousands of stainless steel and optimized wear pro-
euros. Decide on the new C-XI decanter from Flottweg today. tection packages
• Continuous outstanding separation re-
sults, due to an automatic and inde-
pendent regulation of the bowl and
differential speed (Simp Drive®)

* depending on the pond depth and the characteristics

of the sludge

8
FLOTTWEG SEPARATION TECHNOLOGY

MAXIMUM POWER specifically optimized to the needs of the sewage

MAXIMUM
POWER
High RPM is needed for decanter centrifuges to obtain the treatment market can result in even better quality
desired dewatering results. The forces associated with high RPM of separation and dewatering which lead to an

MAXIMUM
require a powerful drive, a reliable and reinforced gearbox, and perfect, increased dry substance.
automatic response to different load conditions. These requirements
are met using the Simp Drive®. Make your own decision about
the maximum power of the new C-XI by visiting our website
What does it mean to be “even better”?
Changing the geometry of the scroll body in-
G-FORCES

MAXIMUM
www.flottweg.com. creases the solid concentration within the de-

A MAXIMUM DRY SUBSTANCE
The result of an effective separation process within a decanter
centrifuge is embodied by maximum dry substance. Solids settle at
the inner wall of the bowl due to the influence of centrifugal force. The
scroll is the conveying tool in a decanter. It rotates at a differential
speed (in relation to the bowl) and transports the settled solids towards
the conically narrowing end of the bowl. A scroll slope or scroll geometry
DRY SUB-
canter bowl even more, which – due to the press-
ing action – leads to more effective dewatering
of the sludge and a higher content of dry sub-
stance. Within the C-XI decanter series, Flottweg
STANCE
is driving the C-series already successfully on
the market to never-before-seen heights of per-
formance.

CONVINCE YOURSELF
ABOUT THE MAXIMUM
FLOTTWEG EFFICIENCY!

WWW.FLOTTWEG.COM

w C-XI Series
The Ne
Made in Germany

9
 FLOTTWEG SYSTEMS ENGINEERING

In order to optimize the separation results, max-
imize machine reliability and minimize operating
costs, the centrifuge should be properly matched
with all surrounding plant components.
A Flottweg System can be stationary, mobile or semi-mobile. It can be
skid-mounted on a platform or installed in a closed container.
Our engineering team has many years of experience in the layout of
plant components such as control cabinets, pumps, flocculation units,
piping, etc. We know that customer requirements vary and depend on
process, location and other circumstances.

Customer benefits

• High separation efficiency due to

perfectly coordinated components
• Quick and safe commissioning due to
reduced control points
• High reliability and safety since
Flottweg assumes the responsibility
for the whole system
TECHNICAL INFO

• Maximum convenience for our

customers since there is only one
contact person for the complete system
• Long life span and high availability
due to our full support for the whole
operating system

Flottweg Touch Control

Flottweg Decanter C2E in a container as part of a whole system

10
GLOBAL AFTERMARKET SUPPORT NETWORK
No Matter Where You Are in the World

CUSTOMER SERVICE IS OUR STRENGTH Flottweg Services include:

Application-based project planning, high-quality manufactur-
ing and professional after-sales service are prerequisites for trouble- • Experienced advice on separation
free operation. Experienced and reliable service engineers from our processes
customer service department are ready to respond quickly if needed. • Pilot tests on-site or at the Flottweg
The Flottweg Service Group is also available to perform preventive Laboratory and Test Center
maintenance in order to avoid interruptions in production. • Selection and sizing of appropriate
equipment
QUALITY “MADE IN GERMANY” • Customer-specific automation/control
Flottweg is ISO 9001 certified and manufactures its systems and process integration
products in compliance with the most current technical • Design and construction of complete
standards. process systems
• Installation, commissioning, mainte-
nance, repair, spare parts and service
worldwide

AFTER-SALES CUSTOMER SERVICE

Even the best machinery needs to be maintained and serviced. Our service engineers and technicians are qual-
Flottweg has established a worldwide service network consisting of its ified for any kind of installation, commissioning,
own subsidiaries, branch offices, and representatives to provide our repair, and maintenance.
customers with local service and spare parts.

FLOTTWEG WORLDWIDE
Flottweg is headquartered in Vilsbiburg (near Munich), Germany, and countries worldwide.
has branch offices in Cologne and Leipzig as well as subsidiaries in
Australia, Brazil, Canada, China France, Italy, Mexico, Peru, Poland, Check out our website at www.flottweg.com to
Russia, and the United States, along with representatives in nearly all find a competent contact person.

11
 THE FLOTTWEG RECUVANE®-SYSTEM
The Simple Way to Reduce the Power Consumption
of Your Decanter Centrifuge

Increasing energy costs will result in higher operating costs of your de- Benefits of the Flottweg
canter centrifuge. The Flottweg Recuvane -System helps to reduce
®
Recuvane®-System
power consumption and therefore save money. There is, however, no
reduction of capacity.. • Reduced power consumption of your
decanter centrifuge (10 – 30 %)*
HOW IT WORKS • Quick pay back
The decanter needs energy to accelerate the sludge to the rotational • Easy retrofitting
speed. Normally, the centrate discharges radially by gravity over con- • Solely mechanical, robust design
ventional weir plates. The energy included in the water, however, gets • Existing separation processes do not
lost. need to be modified
• For optimum operation, it is possible to
Thanks to the special construction of the Flottweg Recuvane -System,
®
adjust different pond depths
the centrate water can be discharged in a specific way and the energy
recovered during discharge supports the main drive thus saving 10 to * depending on pond depth and sludge characteristics

30 % of the operating power depending on the pond depth and the

sludge.

reduced energy consumption

(up to 30%)*
TECHNICAL INFO

conventional design specific discharge using Recuvane®

® = registered trademark for various countries

Discharge of the centrate water

12
 BENCH MARK TEST WITH A
FLOTTWEG DECANTER C7E*
power consumption of the bowl [KW]

160,0

140,0

120,0
conventional design
TECHNICAL INFO

100,0

80,0

60,0
more energy recovery due to the Flottweg Recuvane®-System
40,0

20,0

0,0
40 60 80 100 120 140 160

capacity [m³/h]

* The diagram shows a benchmark test using the example of a Flottweg Decanter in a German sewage treatment plant.
The figures were determined for a decanter C7E.

THE RECUVANE®-SYSTEM IS AVAILABLE FOR THE FOLLOWING DECANTER CENTRIFUGES

SERIES WHICH ARE COMPATIBLE WITH RECUVANE®

Flottweg C-series C2E, C3E, C4E, C5E, C7E

Flottweg Z-series Z3E, Z4E, Z5E, Z6E, Z8E, Z73, Z92

ic
a schemat
e shows
The pictur ® lement
e -e
Recuvan

13
 FLOTTWEG OSE DECANTERS
for Sludge Thickening

TECHNICAL DATA OF FLOTTWG OSE DECANTERS

Type C2E-4 C3E-4 C4E-4 C5E-4 C7E-4 Z92-4
Materials of construction All product wetted parts are made of high grade stainless steel such as 1.4463 (Duplex) and 1.4571 (AISI 316T)
Dimensions* (L x W x H) 2700 x 840 x 810 mm 2980 x 940 x 900 mm 3520 x 1140 x 1030 mm 4100 x 1520 x 1210 mm 4800 x 1720 x 1400 mm 5880 x 2780 x 1730 mm
107" x 33" x 32" 118" x 37" x 36" 139" x 45" x 41" 162" x 60" x 48" 189" x 68" x 56" 232" x 110" x 69"
Gross weight* 1360 kg 1735 kg 2760 kg 5060 kg 8400 kg 18000 kg
3000 lb 3825 lb 6100 lb 11250 lb 19000 lb 40000 lb
Motor for bowl drive 5.5 – 7.5 kW 7.5 – 15 kW 15 – 30 kW 30 – 55 kW 55 – 110 kW 90 – 200 kW
7.5 – 10 hp 10 – 20 hp 20 – 40 hp 40 – 75 hp 75 – 150 hp 125 – 300 hp
Motor for scroll drive 2.2 kW 4 kW 4 kW 5.5 kW 5.5 kW 7.5 kW
Flottweg Simp Drive® 3 hp 5 hp 5 hp 7.5 hp 7.5 hp 10 hp
Capacity* 8 – 15 m³/h 15 – 30 m³/h 30 – 60 m³/h 45 – 90 m³/h 70 – 140 m³/h 120 – 250 m³/h
35 – 65 gpm 60 – 120 gpm 125 – 250 gpm 200 – 400 gpm 300 – 600 gpm 500 – 1100 gpm
* The listed figures are guidelines for information only. Actual capacity dpends on the characteristics of the product to be processed.

14
 FLOTTWEG HTS DECANTERS
for Sludge Dewatering

TECHNICAL DATA OF FLOTTWG HTS DECANTERS

Type C2E-4 C3E-4 C4E-4 C5E-4 C7E-4 Z92-4
Materials of construction All product wetted parts are made of high grade stainless steel such as 1.4463 (Duplex) and 1.4571 (AISI 316T)
Dimensions* (L x W x H) 2700 x 840 x 810 mm 2980 x 940 x 900 mm 3520 x 1140 x 1030 mm 4100 x 1520 x 1210 mm 4800 x 1720 x 1400 mm 5880 x 2780 x 1730 mm
107" x 33" x 32" 118" x 37" x 36" 139" x 45" x 41" 162" x 60" x 48" 189" x 68" x 56" 232" x 110" x 69"
® = registered trademark for various countries

Gross weight* 1360 kg 1735 kg 2760 kg 5060 kg 8400 kg 18000 kg

3000 lb 3825 lb 6100 lb 11250 lb 19000 lb 40000 lb
Motor for bowl drive 7.5 – 11 kW 11 – 18.5 kW 22 – 37 kW 45 – 75 kW 75 – 135 kW 160 – 250 kW
10 – 15 hp 15 – 25 hp 20 – 50 hp 55 – 100 hp 100 – 180 hp 215 – 300 hp
Motor for scroll drive 3 kW 4 – 5.5 kW 7.5 – 11 kW 15 kW 30 kW 30 – 45 kW
Flottweg Simp Drive® 4 hp 5 – 7.5 hp 10 – 15 hp 20 hp 40 hp 40 – 60 hp
Capacity* 5 – 10 m³/h 10 – 20 m³/h 20 – 40 m³/h 30 – 60 m³/h 60 – 120 m³/h 90 – 180 m³/h
20 – 45 gpm 45 – 90 gpm 90 – 180 gpm 125 – 250 gpm 250 – 500 gpm 400 – 800 gpm
* The listed figures are guidelines for information only. Actual capacity dpends on the characteristics of the product to be processed.

15
 Flottweg Separation Technology –
Engineered For Your Success

Flottweg SE
Industriestraße 6-8
84137 Vilsbiburg
Deutschland (Germany)
Tel.: + 49 8741 301-0
Fax: + 49 8741 301-300
mail@flottweg.com
www.flottweg.com
REPRESENTATIVE

PR-0004 L – 10 2 04/2016