Westfalia Separator

Industry
Mechanical Separation
Division

Take the Best - Separate the Rest

Components,
systems, installations

Chemical
Industry
Concentrating on the Essentials

Separation
technology in the
chemical industry

Efficient, powerful, reliable – for more

than 110 years, Westfalia Separator
has played a defining role in centrifu-
gal separation technology. The quality
of the separation process is the vital
factor that determines the quality of a
product, its cost-effectiveness, the
security of production and its environ-
mental compatibility. Westfalia’s
history, therefore, brings with it both
obligations to customers and a vision
for the company.

This is particularly applicable for the

chemical industry, which poses stringent
demands on the performance of a sepa-
rator or decanter. Concentrated acids or
lyes, high temperatures and increased
levels of wear pose the ultimate chal-
lenge to machinery. Safety has highest
priority.

Westfalia Separator | 2 | Separation Technology + Beverage Technology + Dairy Technology + Oils and Fats Processing + Chemicals,
 To meet this challenge, Westfalia
Separator now builds every machine
with these market requirements in mind.
All machines meet the most stringent
quality requirements such as DIN EN
ISO 9001 and are customised to meet the
individual needs of each specific appli-
cation. Westfalia Separator is the techno-
logy leader with worldwide operations
and is, therefore, able to select the special
materials appropriate to each specific
product, temperature and medium. For
instance, a separator in the TC series
which, through a new and unique
design, completely discharges its solid-
wall bowl when the separator is shut
down. This arrangement protects the
operator when cleaning the bowl and
reduces the work involved.
Pharmaceuticals, Biotechnology + Oils and Fats Recovery + Starch Technology, Industrial Biotechnology +
Gas-tight, explosion-protected machines
complying with the new directive ATEX
95 (RL 94/9/EG) are vitally important in
the chemical industry. This comprehen-
sive product range enables customers to
use a customised centrifuge in almost all
areas and all process stages of phase
separation irrespective of the capacity
required. However, ‘Take the Best’ in-
volves even more: service packages, in-
cluding teleservice, guarantee machine
availability and reduce maintenance
costs.
Attractive terms for returning used
machines and the reliability of a group of
international market leaders make the
life cycle benefit complete: an holistic
approach providing maximum cost-
effectiveness.
| 3 | Westfalia Separator
TNT – Entirely Safe
Nitro aromatic compounds
Nitro aromatic compounds are obtained
in a multi-stage, large-scale process.
Mononitration takes place in the first
reaction tank, and dinitration in a subse-
quent second tank. To ensure that the
process proceeds in a controlled manner,
a mixture of highly concentrated sulphu-
ric acid and nitric acid is added to the
overflow of the corresponding stages.
After nitration in the reaction tanks, the
liquid is pumped to a separator so that
the nitrated aromatic compound can be
separated from the waste acid. After the
reaction mixture of the second nitration
stage has been separated, the dinitro
aromatic compounds are pumped to a
multi-stage washing process to enable a
high degree of purity to be achieved for
the substances. The dinitro aromatic
compounds are then recovered in a drier
in the form of a crystalline substance.
Westfalia Separator | 4 | Marine + Energy + Oilfield + Industry + Environmental Technology + Engineering + Second Hand Machinery
TNT with its almost legendary explo-
sive power is probably the best known
of all nitro aromatic compound sub-
stances; however, it is by no means
the most important. Nitration of tolu-
ene is today used primarily in the
production of polyurethane, which has
become much more important in
recent years. Nitration of benzene
results in mononitrobenzene (MNB),
which is the basis of a second key
input product in the chemical industry,
namely aniline. Up to 95 per cent of
the entire global production of MNB is
thus used as the primary material for
isocyanates (MDI), pharmaceuticals,
rubber chemicals and most of the dyes
with which we are familiar.
Excellent team right down to the
smallest seal
Separators with a solid-wall bowl design,
for instance from the TC series, are nor-
mally used directly for nitrating aromatic
compounds. They separate the nitro
aromatic compound from the acid after
the nitration process and also from water
after washing. The purity of the nitro
aromatic compounds obtained in this
way is excellent. Separation takes place
in a very small space thereby signifi-
cantly increasing the safety of the instal-
lation. New chamber-type separators of
the type KC 100 are successfully used in
practical applications for cleaning the
sulphuric acid. This increases the opera-
ting lives of the separators in the ni-
tration stages by up to 100 per cent as
sulphuric acid cleaned in this way

significantly extends the intervals be-
tween the cleaning cycles.
With its aggressive media, the nitration
process poses extremely stringent de-
mands on separator design. A challenge
that Westfalia Separator has impressively
solved: from the bowl and all other com-
ponents that come into contact with
product right through to the smallest
seal, everything has been consistently
designed for this process. The problem
is particularly acute when processing
nitrating toluene or xylene; special mate-
rial (Incoloy 825) is used in virtually all
cases where the components come into
contact with product. And with liquid
centripetal pumps for both phases, the
separators meet the requirement for
safely discharging both the acid and the
organic phase under pressure.
+ Service Worldwide + Separation Technology + Beverage Technology + Dairy Technology + Oils and Fats
Condensate
Another popular benefit of the TC sepa-
rators is the location of the discharge
drain hole on the bottom of the bowl.
This prevents the operator from coming
into contact with the extremely toxic
organic substances.
Throughout the world, virtually all well-
known manufacturers of nitro aromatic
compounds use separators supplied by
Westfalia Separator – and most of them
have been doing so for many decades.
There are specific reasons why Westfalia
Separator has continued to be the main
supplier for this application. The new TC
generation continues this story of success
by meeting the customer's need for high-
er feed capacities, increasingly strict
installation requirements and operator
safety.
| 5 | Westfalia Separator
H Plus Variety

Hydrogen peroxide

The areas of application for hydrogen

peroxide are extremely varied: the
production of washing agents, for
bleaching paper, cellulose, wood,
textiles; for cleaning waste water and
drinking water; in the medical indus-
try as a disinfection agent; and finally
for ’bleaching’ hair. Nowadays, more
than 95% of the huge quantities of
hydrogen peroxide required for these
processes are made using variations of
the anthraquinon process. This process
comprises the four main stages of
hydration, oxidation, washing and
concentration.

In the hydration process, hydrogen is

added to the working solution in a reac-
tor in the presence of a catalyst. The
chamber-type separators remove the

Westfalia Separator | 6 | Processing + Chemicals, Pharmaceuticals, Biotechnology + Oils and Fats Recovery + Starch Technology,
 solid catalyst mass after the reaction has
been completed.
For the subsequent oxidation process, the
working solution is brought into contact
with air in the next reactor, resulting in
the formation of hydrogen peroxide.
In the next stage, a solvent extracts the
impurities from the hydrogen peroxide
in a multi-stage process. Separators with
a solid-wall bowl are used for separating
the aqueous hydrogen peroxide solution
from the solvent. The phase separated
from the hydrogen peroxide is heated,
dried and subsequently processed, and is
then returned to the hydration process;
this arrangement significantly reduces
the amount of chemical consumption.
Industrial Biotechnology + Marine + Energy + Oilfield + Industry + Environmental Technology + Engineering +
Maximum safety and separating
efficiency
Peroxides can detonate or explode even
in the absence of oxygen at comparative-
ly low process temperatures. The separa-
tors are accordingly explosion-protected,
and the temperatures at the critical
points are permanently monitored. The
design of the TC separators also provides
new methods of further improving sepa-
rating efficiency. Accordingly, the large
combination of centripetal pumps for the
light phase (usually hydrogen peroxide)
means that a higher clarifying area can
be used. Frequently, the use of a twin
centripetal pump with maximum separa-
ting efficiency is the only method of
discharging both phases under pressure.
| 7 | Westfalia Separator
Microbiological All-Rounder
Xanthane
Numerous positive characteristics
mean that the long-chain polysaccharide
xanthane is a product that can be used
universally. In baker's products, xanthane
is responsible for pore structure, greater
volume and an extended shelf life. It is
used in desserts, chewing gum and ice
cream as well as in dairy and yoghurt
products or fruit products to improve the
texture. Xanthane is also frequently to
be found in cosmetic lotions, creams,
shampoos, liquid soap and toothpaste
and animal feeds where it binds water or
controls flow properties. It is also used to
thicken emulsions for use in the oil drill-
ing industry.
This multi-talented product is the meta-
bolic product of a specific type of bacte-
ria. On an industrial scale, the bacteria
are bred in large fermenters, and the
metabolic products produced by the
bacteria are subsequently harvested. This
is where Westfalia Separator’s expertise
is useful. The actual process of recovery
downstream of the fermenter takes place
primarily in a two-stage process with
separators and/or decanters, whereby
the first stage is for clarification and the
second stage, namely the washing stage,
is used for dewatering the xanthane as
far as possible.
Westfalia Separator | 8 | Second Hand Machinery + Service Worldwide + Separation Technology + Beverage Technology + Dairy
Minimum shearing forces,
maximum margin
Two factors are particularly important in
the separation process: the control of
shearing forces and explosion protection.
Shearing forces have a major impact on
the quality of the long-chain saccharide,
and thus on the price of the product.
Westfalia Separator, therefore, uses a
special design to ensure gentle product
treatment and high throughput. Decan-
ters of the CA 505 and CA 365 series are
used for this application.
Particular attention has also to be paid to
explosion protection, as the solvents used
are alcoholic and pose a danger of explo-
sion. In this respect, Westfalia Separator
has been able to implement innovations
focussing on customer benefit as a result
of its many years of experience with
explosion-protected processes; one
method involves nitrogen blanketing of
the machines. In addition, Westfalia
Separator know how guarantees maxi-
mum safety and maximum product
quality. Westfalia Separator has, of
course, implemented the requirements
specified in the new ATEX guidelines for
decanters and separators. Several ma-
chines have already been successfully
commissioned for this process in accor-
dance with the ATEX guidelines.
Westfalia Separator is without doubt one
of the leading suppliers of centrifuges for
xanthane production.
 In Focus

Fluorescent substances

Little helpers ensure that your televi-

sion screen is not blank when you are
looking forward to an evening’s enter-
tainment: pigments that emit the
primary colours of green, blue and red
when subject to electron or ultraviolet
radiation. These pigments are applied
to the screens of colour tubes by a
special method. The fluorescent sub-
stance is dispersed in an aqueous
solution of polyvinyl alcohol and
ammonium dichromate and a layer of
this dispersion is subsequently applied
to the glass screen and then dried.
The layer is now exposed to UV light
where luminous points or lines are
subsequently to appear. When the
pigments are exposed, photochemical
reactions take place and make these
pigments insoluble. After exposure,
the glass screen is rinsed with de-
ionized hot water and the pigments,
which have not been fixed, are
washed out. The entire procedure
comprising coating, exposure and
rinsing has to be carried out separate-
ly for each of the three fluorescent classical task for chamber-type separators
substances. with their high degree of separation. It is
true that these machines have to be shut
down to be cleaned, however the method
Classical ’chamber music’ involved is still very gentle. Several
chamber-type separators are operated in
Separators are used for recovering the parallel to ensure the capacity and the
valuable pigments from the aqueous continuity of the process.
rinsing suspensions. Up to 90 per cent of
the pigments can be recycled in this way. As a result of constant improvements,
For this purpose, the relatively concen- Westfalia Separator automatic discharge
trated suspension residues of the fluores- mechanisms are also suitable for the
cent substances are pumped to a buffer application. The discharge system is set
tank equipped with an agitator. This is to cope with very slow and gentle sepa-
then followed by the clarifiers to separate ration that does not pose any strain on
the pigments from the aqueous phase. the sensitive products. Clarifying decan-
A very gentle process is used not to ters are then used to handle the process
damage the sensitive particles. This is a water.

Technology + Oils and Fats Processing + Chemicals, Pharmaceuticals, Biotechnology + Oils and Fats | 9 | Westfalia Separator
Specialists with Stamina

Oil additives

Good lubrication is necessary for a

long life; oil additives reduce the vis-
cosity of the lubricants and so reduce
wear and fuel consumption.

Clarifying decanters and clarifiers are

used for the production of oil additives
in an area that can almost be described
as traditional: after a precipitation re-
action. This reaction is used to remove
impurities from the working solution.
The previously dissolved and unwanted
components of the oil additive can then
be removed by centrifugal force.

Depending on the pre-concentration, the

separation process either uses decanters
or separators or, frequently, uses a two-
stage procedure with decanters and
separators. In general: If the solution has
a high solid content, a decanter is ideal;
these machines are more solids oriented
than separators. If the valuable phase,
which is discharged after the first sepa-

Westfalia Separator | 10 | Recovery + Starch Technology, Industrial Biotechnology + Marine + Energy + Oilfield + Industry +
 ration stage still contains solids, the user
can initially install a polishing separator
which removes ex-tremely fine particles
from the decanter overflow. The clarified
liquid phase, with the dissolved additi-
ves, is treated in further processes.
Heavy salts: sliding piston
During the recovery of oil additives it
is necessary to remove very heavy salts
that pose ’weighty’ challenges to a
discharge system. Westfalia Separator
has special separators, such as the self-
cleaning separator SB 60 with a sliding
piston that does not come into contact
with the product, which are ideal for this
particular application. Many references
confirm the machine’s capability in this
area.
to 170 °C – so that the centrifuges can be
operated 24 hours a day.
But without giving customers sleepless
nights. With gas-tight, explosion-protect-
ed centrifuges, Westfalia Separator gua-
rantees maximum safety. An ATEX
design is also available. Westfalia Sepa-
rator optimises the centrifuges so that
they are able to meet the specific condi-
tions present on every customer's prem-
ises. Centrifugation tests and Westfalia
Separator experience guarantee a perfect
configuration for the installation.

Every detail of an SB 60 is customised by

Westfalia Separator specifically to cope
with the ’hot’ operating conditions – up

Environmental Technology + Engineering + Second Hand Machinery + Service Worldwide + Separation | 11 | Westfalia Separator
Precious and Carrying Weight
Catalyst recovery
Catalysts are chemical
substances that speed
up the rate of a reaction
and which do not
undergo any change
themselves; they can,
therefore, be recovered
and recycled. This is a
valuable property as
catalysts such as plati-
num are simply too
valuable to be used just
once. In addition, the
product obtained with
the catalyst generally
has to be extremely
pure and free of heavy
metals and any traces of
catalyst. Thirdly, simply disposing of
the catalyst would have environmen-
tal implications.
Centrifugal separation is the most
popular method for recovering catalysts
that, subsequently, can be recycled con-
tinuously back into the process to im-
prove its cost-effectiveness, quality and
environmental compatibility.
Compact challenge
Very heavy solids frequently have to be
separated while recovering the catalyst.
However, this is only half of the chal-
lenge: some of the solids cake so strongly
on the wall of the bowl under the influ-
ence of centrifugal force that the dischar-
ge gap of the system may shift. Westfalia
Separator’s metering piston mechanism
is the right tool for handling solids that
become thus compacted. In this case,
complete discharges of the bowl ensure
a high degree of operating reliability.
Westfalia Separator | 12 | Technology + Beverage Technology + Dairy Technology + Oils and Fats Processing + Chemicals, Pharma
If maximum solid contents are required,
the patented HydroStop system, is an
option that has demonstrated its worth.
Decanters such as the CB 505 are also
used for maximum dewatering and
clarifying efficiency.
Chamber-type separators, which are able
to polish and concentrate the product at
low feed quantities, are also used. In the
new generation of chamber-type centri-
fuges, the liquid is discharged complete-
ly from the drain holes of the bowl, the
valuable catalyst remains in the cham-
bers and can thus be discharged manu-
ally more easily.
Also nozzle-type separators are increa-
singly used for recovering the catalysts;
these provide optimum clarifying results
with a defined solid concentration in the
nozzle discharge. Nozzles are available
in various special materials for indivi-
dual applications.
To ensure that every machine operates
reliably, Westfalia Separator uses its
experience, where necessary in conjunc-
tion with specific pre-trials, to select
the correct discharge system with the
appropriate parameters. If the discharge
process is not perfect, special controls
ensure that the large rotating masses are
stopped in plenty of time to avoid any
danger to the operator.

Paints are used in metalworking, in
machine and equipment engineering
and also in the automotive, furniture
and electrical industries. The focus is
not only on ’visual’ quality, but also
frequently on corrosion protection and
improving the surface properties. The
fact that there is hardly any product
that does not require a coating clearly
demonstrates the major economic
significance of paints.
Dyes and paints are a liquid phase con-
taining colour particles. What appears to
be uncomplicated at first sight proves to
be a genuine challenge upon closer in-
spection. This is because particles with
precisely the right size must be used to
achieve the desired colour or protective
function. The solution in this case is
again centrifugal separating technology,
with specific classifying decanters and
separators.
Put the good ones in the pot...
In classifying decanters and separators,
the separating conditions are adjusted in
such a way that only the desired particle
ceuticals, Biotechnology + Oils and Fats Recovery + Starch Technology, Industrial Biotechnology + Marine +
Evidently Functional
Dyes and paints
size class is retained in the end product.
The centrifuge removes all other particles
efficiently.
The very small particles of a few micro-
meters required in dyes and paints mean
that high speeds and large clarifying
areas are frequently required. Chamber-
type centrifuges, as well as continually
operating self-cleaning separators with
the HydroStop mechanism, have demon-
strated their worth in these applications.
To guarantee maximum quality, the
discharge system is controlled with sol-
vent. No operating water comes into
contact with the end product.
If organic solvents are used in produc-
tion, it is necessary to use explosionpro-
tected centrifuges incorporating special
fittings and materials. These Westfalia
Separator machines are equipped with
certified components and the product
chamber is gas-tight. The product cham-
ber, closing chamber and gear chamber
are blanketed with inert gas that reduces
the concentration of oxygen in the sepa-
rator to a non-critical level and keeps it
within safe parameters.
| 13 | Westfalia Separator
An Evergreen with the CD

Polycarbonate

Much was changed around 25 years

ago with the advent of the compact
disc. It changed stereo systems, record
shops and turned polycarbonate into a
world star.
Today, polycarbonates are some of the
most popular plastics as a result of
their excellent transparency and
impact resistant properties. They can
be found in numerous applications
such as electro-technology, equipment
construction, the car making industry
or for making lenses for spectacles.

Westfalia Separator | 14 | Energy + Oilfield + Industry + Environmental Technology + Engineering + Second Hand Machinery + Service
 Separators are used in the phase bound-
ary method in the production of polycar-
bonate in which the polycarbonate, after
the reaction, is dissolved in an organic
solvent. A second water phase contains
dissolved salts and unwanted additives.
Pure polycarbonate is obtained by distill-
ing off the solvent after being washed
electrolyte-free. The washing process is
carried out in a multistage process with
acid and completely desalinated water.
Separators with a solid-wall bowl are
used for separating the polymer solution
and washing liquid in the individual
washing stages.
Worldwide + Separation Technology + Beverage Technology + Dairy Technology + Oils and Fats Processing +
Single machines and complete lines
The aim is to achieve not only extreme
purity but also minimum residual water
content in the organic phase to meet the
market’s increasingly stringent product
quality requirements. These product
requirements are met precisely by using
separator technology at high speeds.
Solid-wall, disc-type separators of type
TA and TC are used at the acid stage;
these have all product-contact compo-
nents made of high corrosion resistant
materials. In addition to these single
machines, Westfalia Separator also sup-
plies complete process lines for washing.
| 15 | Westfalia Separator
Acid Variety

Phosphoric acid

Phosphoric acid is the ’source’ of such

different products as fertilizers and
cola drinks. It is manufactured on a
large industrial scale primarily by
breaking down phosphate rock with
sulphuric acid in a wet chemical pro-
cess. Calcium sulphate is precipitated
and removed by centrifuges.

However, calcium sulphate is a solid

that becomes very compact making it
one of the most difficult products
to discharge. At the external periphery
of the bowl, gypsum simply becomes
’concrete’. It cannot be reliably dis-
charged with a self-cleaning bowl.

Westfalia Separator | 16 | Chemicals, Pharmaceuticals, Biotechnology + Oils and Fats Recovery + Starch Technology, Industrial
 Continuous ’gypsum nozzles’

This is the reason why Westfalia

Separator for many decades has been
using special nozzle-type separators that
discharge the solids continuously
as a suspension.

If the customer wishes to dewater the

gypsum to a greater extent to use it
profitably, it makes sense to install a
decanter (e.g. of the type CB 505). The
same is applicable if there are high con-
centrations of solids in the feed.

It is frequently the case that decanters

and separators are used in two different
stages. Westfalia Separator machines
have demonstrated their ability in real-
life practical applications for all specified
requirements in the phosphoric acid
process.

Machines for recovering phosphoric

acid have all product-contact parts
made from special materials that resist its
corrosive properties. Upon request,
Westfalia Separator can also equip all
centrifuges with special explosion-
protected motors if they are to be used
in explosive atmospheres.

Biotechnology + Marine + Energy + Oilfield + Industry + Environmental Technology + Engineering + Second Hand | 17 | Westfalia Separator
Centrifuges for Every Area of Application

Separators and decanters

for the chemical industry

Machine types Max. total feed capacity Areas of application

(depending on product and process in l/h)

TA 7-01-506 1,000
TA 50-01-506 10,000
TC 100-01-506 35,000 Nitro-aromatic compounds
TC 150-01-517 44,000
KC 100-86-506 5,000

TA 7-01-506 2,000
TA 50-01-506 10,000 Hydrogen peroxide
TC 100-01-506 30,000

CA 505-21-32 30,000
CA 365-21-32 15,000
SA 100-06-777 25,000 Xanthane
SC 150-06-577 30,000

SB 60-06-576 10,000
SB 60-06-577 10,000
CA 365-21-02 10,000 Oil additives
CA 505-21-32 20,000

TA 50-06-576 1,500
TC 100-06-506 3,000
KC 100-86-506 5,000
Dyes and paints
OSC 5-01-006 100
SC 35-06-577 1,000
CD 305-01-32 1,000

KB 25-86-076 1,000
CC 458-00-02 35,000 Fluorescent substances
SA 45-36-076 2,500

Westfalia Separator | 18 | Machinery + Service Worldwide + Separation Technology + Beverage Technology + Dairy Technology +
 Machine types Max. total feed capacity Areas of application
(depending on product and process in l/h)

TC 100-01-506 35,000
TC 150-01-517 44,000 Polycarbonate
TA 275-01-567 120,000

DA 100-16-117 23,000 Phosphoric acid

CB 505-01-32 20,000

CD 305-00-32 2 t/h (dry)

CC 458-00-32 5 t/h (dry)
CA 505-00-32 7 t/h (dry) PVC
CA 755-00-32 12,5 t/h (dry)

Further applications:
• Agar agar • Latex (synthetic), etc.

• Aniline dyes • Lyes

• Barium sulphate • Fluorescent substances

• Boiler ash • Nitro compounds (nitration of

aromatic substances in nitration installations)
• Cellulose and derivatives
• Peroxides
• Printers' inks, etc.
• Phosphoric acid
• Dyes
• Polyacetates
• Filter backflush liquid from cellulose acetate
production, etc. • Polybutadiene, etc.

• Gum arabic • Polycarbonate

• Fungicides, etc. • PTA (purified teraphtalic acid)

• Herbicides • PVC

• Ink • Salts

• Insecticides • Suspensions with metals, oxides,

hydroxides and catalysts
• Catalyst separation
• Viscose, cellulose acetate, etc.
• Paints

Oils and Fats Processing + Chemicals, Pharmaceuticals, Biotechnology + Oils and Fats Recovery + Starch | 19 | Westfalia Separator
Extremely Rapid, Precise and Flexible

Discharge with HydroStop

HydroStop system

Discharge through
metering piston

Previous standard

0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2
Seconds

With the HydroStop system, Westfalia Extremely precise even with

Separator has developed a discharge
system that can be adjusted precisely
and reproducibly to the specific solids
concentration requirements of the
process. This patented discharge
system enables the discharge process
to be optimised extremely quickly. The
HydroStop system reduces the actual
discharge time to less than 1/10 of a
second, and permits partial discharges
at intervals of 30 seconds.
extremely small volumes
Older discharge systems were much
slower and less precise: there were sig-
nificant fluctuations in the volume and
thus the concentration of the solids. It
was not possible to exert any influence
over the process. Westfalia Separator
has completely solved these problems
with the HydroStop system: even small
volumes of 1.5 to 2 litres can be dischar-
ged reproducibly with an error of less
than 10 per cent. This innovative techno-
logy is the key to precise and rapid dis-
charges and to much higher and better
quality yields.

Westfalia Separator | 20 | Technology, Industrial Biotechnology + Marine + Energy + Oilfield + Industry + Environmental Technology +
 Precisely Metered Discharge Quantities
Discharge with metering
piston
If certain heavy solids have to be
separated, and if they also tend to
become very compact when subjected
to the influence of centrifugal force so
that the discharge gap of the discharg-
ing system can shift, the metering
piston is extremely useful. This mecha-
nism ensures complete discharges of
the bowl and so allows a high level of
operating reliability.
Quantity of opening water
is easy to set
A further advantage is that the desired
quantity of opening water can easily be
set with the metering piston. The meter-
ing device is filled with precisely this
Engineering + Second Hand Machinery + Service Worldwide + Separation Technology + Beverage Technology
quantity of water through the inlet valve;
compressed air is then forced into the
lower chamber of the metering device
through the valve. When the opening
water valve has been operated, the com-
pressed air acts on the piston of the
metering device, and the set quantity of
water is injected into the opening cham-
ber. This arrangement means that it is
possible for very precise discharge quan-
tities to be achieved.
The air pressure for the metering device
should ideally be 4 to 4.5 bar. The pressu-
re transformer installed in the metering
device ensures perfect discharge process-
es, thus overcoming line, valve and injec-
tion chamber resistances.
| 21 | Westfalia Separator
So That Nothing is Left Over

Bowl drain holes

The solid-bowl-wall separators of Simple and effective

the TC generation are used wherever
it is necessary to achieve optimum
separation of two liquid phases with
a very low solid content. Nevertheless,
preventing the eventual removal of
the solids is often not possible. Com-
plete protective clothing was previous-
ly essential for this work. With the TC
generation from Westfalia Separator
however, such protective clothing can
normally be left on the peg. This is
because the TC machines are the only
solid-wall, disk-type separators in the
world whose bowls are completely
drained when the machine is shut
down. Only small quantities of toxic
medium remain in the bowl to be
cleaned manually. The result: maxi-
mum safety even without full protec-
tive clothing.
The trick is extremely simple and effec-
tive: special drain holes are designed in
such a way that, during operation, they
are ’dry’ as a result of the centrifugal
forces. The liquid enters this area only
when the centrifuge slows down; it can
discharge completely from the bowl via
the drain holes, and is then collected in
downstream tanks via the frame dis-
charge. Under certain circumstances, the
drain holes provide a facility for CIP
cleaning without the bowl having to be
opened.

Westfalia Separator | 22 | + Dairy Technology + Oils and Fats Processing + Chemicals, Pharmaceuticals, Biotechnology + Oils and
 Maximum Separating Efficiency

The pair of centripetal

pumps for high density
differences

The centripetal pumps are the real

’dream team’ of the TC generation.
These centripetal pumps enable the
separating zones to be set precisely
even in conjunction with very high
density differences. For example, this
is the only way to achieve optimum
separating efficiency with nitro-aro-
matic compounds. In processes where
the light phase is the valuable phase,
the separating zone can be positioned
towards the periphery of the bowl,
whereby the light phase can be allo-
cated maximum clarifying area. At the
same time, the twin centripetal pump
is able to discharge the heavy phase
under pressure in an enclosed system.
This is a major advantage particularly
in the case of explosive or aggressive
media. Unlike processes that discharge
under gravity, nothing can be discharg-
ed onto the hood of the separator
thereby avoiding the significant cost
of making the hood corrosion resis-
tant.
Fats Recovery + Starch Technology, Industrial Biotechnology + Marine + Energy + Oilfield + Industry +
No pump, no costs
The centripetal pump consists of a cylin-
drical disc equipped with channels and
installed in the so-called centripetal
pump chamber of the rotating bowl. It is
stationary, and its external periphery is
immersed in the rotating liquid. The
liquid is discharged towards the centre of
the pump through the channels, and the
rotation energy of the liquid is converted
into pressure. This means that an addi-
tional pump is not necessary, thus achie-
ving savings in investment and operating
costs.
| 23 | Westfalia Separator
‘Hot Products’
Centrifuges for high
temperature applications
Separator SB 60
Particles suspended in viscous liquids
can only be separated efficiently if
their viscosity is reduced by raising the
temperature. For instance, the opti-
mum separating conditions in some oil
additives are at 160 °C.
However, if liquids are processed at a
very high temperature, it is necessary
for certain design-related challenges to
be solved in a separator. For instance,
stainless steels become significantly
less robust with increasing tempera-
tures. If special steels are not used, the
bowl speed must be reduced in line
with the permissible material tension.
Westfalia Separator | 24 | Environmental Technology + Engineering + Second Hand Machinery + Service Worldwide +
Steel on Steel
However, high temperatures also pose a
major challenge for seals. For the main
bowl seal, which seals off the twin-coni-
cal solids holding space of the bowl,
Westfalia Separator uses special combina-
tions of materials for the sealing material
and the sealing area as required. The
sealing surfaces of the replaceable rings
can be armour plated and polished.
Moreover, the area pressure resulting
from the bowl hydraulics is much higher
in these models. Westfalia Separator also
uses only specially developed ring seals
at the point at which the bowl seals the
hydraulically driven piston. Smooth,
permanent operation is also assured by a
suitably temperature-resistant oil as the
control medium and a cooling system
that ensures optimum heat distribution
throughout the separator. Separators
operating with high temperature prod-
ucts have built-in guards to protect the
operator from heat.

Solids
discharge
Decanter with oil
circulation lubrication
The oil circulation system comprises a
small pump and a cleaning unit to re-
move mechanical fines. The heat from the
bearing is stored in the oil and removed
with cooling water via an integrated air
cooler or a plate heat exchanger. The oil
circulation lubrication system accord-
ingly performs two very important tasks:
firstly it guarantees the desired lubri-
cating properties of the oil; and secondly,
Separation Technology + Beverage Technology + Dairy Technology + Oils and Fats Processing + Chemicals,
Discharge of clarified
liquid under pressure
Product
feed
it ensures that the bearing temperatures
remain within acceptable limits, resulting
in long bearing operating life even under
extreme conditions.
The same care is of course also applicable
for the decanter’s gearbox which not
only has to withstand the temperature
input of the feed product but also has to
transmit very high torques: for instance
during oil additive clarification or salt
processing. It’s extremely heavy work for
which Westfalia Separator uses appro-
priately designed gears.
| 25 | Westfalia Separator
Robust Armour Plating
Wear protection in
decanters
For maximum wear protection,
Westfalia Separator installs armour
plating as required to all points of a
decanter where increased levels of
wear can be expected, particularly
when the machine is used for process-
ing very abrasive solids. In this case,
Westfalia Separator welds a consistent
layer of hard metal on to the scroll
which, as a rotating part, is exposed
to particularly high levels of wear. This
is also applied to those areas in the
distribution system that require effec-
tive wear protection. The major advan-
tage of this consistent armour plating
is that the protected material is combi-
ned with the primary material in the
welding process.
Westfalia Separator | 26 | Pharmaceuticals, Biotechnology + Oils and Fats Recovery + Starch Technology, Industrial Biotechnology
Another wear point, which is particularly
well protected by Westfalia Separator,
is the point at which the solids are
discharged through the solids discharge
ports. However, these ports are not
protected in the same way as even hard
metal welded on to the surface in this
particular area would erode over a re-
latively short period and would require
expensive repair work.
Elegant and customer-oriented
Instead, Westfalia Separator uses special
sintered hard metal sleeves that provide
a much higher abrasion resistance. These
sleeves wear down to one side but can
be easily turned around. Users have to
replace the sleeves only when both sides
are worn. This requires much less main-
tenance compared with welding and
results in considerably higher availability
of the decanter. An elegant and customer-
oriented method of ensuring that wear
on the solids discharge is manageable.
 From Case to Case and Always Optimum
1. Inserting the lining in the
bowl bottom
The proper tool for the job; this is the
principle used by Westfalia Separator
for selecting materials. This is appli-
cable particularly for components that
come into contact with product, such
as the bowl, scroll or disk stack.
Strength, corrosion resistance and
hygienic specifications are important
criteria in this respect.
In general, the quality of the material
must increase as the requirements
become more stringent. The standard
material is the tried-and-tested stain-
less Duplex steel, which has high
strength and excellent corrosion resis-
tance. On the other hand, super-
Duplex steel is the preferred material
for more complex applications.
For particularly ’hard’ applications,
Westfalia Separator uses special alloys
such as Incolloy 825 or Hastelloy C4.
+ Marine + Energy + Oilfield + Industry + Environmental Technology + Engineering + Second Hand Machinery + | 27 | Westfalia Separator
Special materials
2. Dye penetration test after 3. Bowl bottom with lining
welding the lining in place
More would be waste
A genuine Westfalia Separator speciality
is the lining of solid wall bowls with
Incolloy 825 or even titanium palladium.
This know how is unique to Westfalia
Separator throughout the world. In this
process, sheets of the appropriate special
material are incorporated in the bowl top
and bowl bottom to ensure long corro-
sion protection. The load-bearing bowl
parts however continue to be made with
standard materials to permit high bowl
speeds. This procedure has specific
advantages: if it is really necessary, the
lining can be replaced; the use of the
expensive special material is reduced to
an absolute minimum.
Avoiding Sparks
Explosion-protected
centrifuges
Centrifuges are used in the chemical
industry for clarifying and separating
readily flammable liquids. Theoretical-
ly, such applications can result in criti-
cal concentrations of solvent vapours
and oxygen inside the centrifuge that
can cause explosions or fires. However,
the vapours must also be prevented
from escaping so as not to pose a risk
to the health of the operators. Both
these risks can be prevented reliably
by using gas-tight centrifuges from
Westfalia Separator.
No sparks, no static charges, no hot
bearings – the test criteria of the strict
European ATEX standard are of course
implemented in all Westfalia Separator
explosion-protected centrifuges.
In addition, before the start of operation,
the centrifuge is flooded with inert gas
and blanketed with a slight excess pres-
Westfalia Separator | 28 | Service Worldwide + Separation Technology + Beverage Technology + Dairy Technology + Oils and Fats
sure, so that no further oxygen is able to
penetrate. This is because fire is not
possible without oxygen.
When processing sensitive liquids, the
necessary inert gas atmosphere in the
separator is automatically monitored
throughout the entire operation.
Nothing is able to penetrate
this barrier
An essential design feature of the
Westfalia gas-tight separators is the neck
bearing bridge that separates the drive
with the motor and gearbox from the
product chamber. This bridge is blanke-
ted with inert gas, and the connecting
spindle is protected with dynamic special
seals.
The neck bearing bridge reliably prevents
the solvent from passing from the pro-
duct chamber to the drive chamber or
into the surroundings. This is beneficial
not only from the point of view of fire
and health protection, it is also not possi-
ble for solvent to dilute the oil, which
would diminish its lubricating efficiency
and thus pose a risk to the drive unit.
The same is also true in reverse: no oil is
able to penetrate the product chamber
and thus have a negative impact on the
quality of the valuable product.
 ATEX 95 (directive 94/9 EC)

A directive for machines operating in hazardous surroundings has been in force

in Europe since 1 July 2003. This affects numerous applications in the chemical
and pharmaceutical industries, particularly where gas-tight machines are used.
According to the directive, the first step is to carry out a risk analysis of the
relevant machines to identify any present or potential risks. The measures are
documented and the documentation is submitted to a ’designated authority’. In
specific terms, this means that Westfalia Separator decanters are now equipped
with safety-focussed vibration monitoring equipment, a temperature measure-
ment facility as well as an inert gas facility. All electrical equipment must have
been awarded an ATEX certificate or a manufacturer declaration. This directive is
only applicable to new machines.

A separate directive ATEX 137 (directive 1999/92 EC) is applicable for operators
of installations in hazardous areas. In this way, operators have also been obliged
to carry out risk analyses for existing installations. Machines and installations
must have been upgraded by no later than 1 January 2006. Westfalia Separator
offers its customers support for assessing and where necessary converting these
centrifuges.

Westfalia Separator improves inert gas concept

Requirements with regard to safety and reliability are becoming more stringent
for separators and decanters used in zones with a risk of explosion. The existing
inert gas concept has been improved to meet this requirement. The latest Europe-
an standards, as well as Westfalia Separator’s practical operating experience, has
been incorporated in the new concept.

As has been the case with most existing concepts, the atmosphere in the separa-
tor is displaced with inert gas before every start-up and the excess pressure is
maintained during operation to meet the requirement for minimum inert gas
consumption.

The fittings and measuring devices used have been subject to an extensive test
and have also been optimised as far as investment costs are concerned. The new
inert gas supply facility complies not only with the familiar directive 94/9 EC
(ATEX) but also with the TA Luft, i.e. product leakages from the equipment are
reduced to a minimum using state-of-the-art technology.

Westfalia Separator places great emphasis on complete and easy-to-understand

operator documentation as well as a carefully performed conformity assessment
procedure (CE symbol). The company also provides information concerning the
correct installation of separators and decanters in zones that are exposed to the
risk of explosion.

Processing + Chemicals, Pharmaceuticals, Biotechnology + Oils and Fats Recovery + Starch Technology, | 29 | Westfalia Separator
Think Globally – Act Locally

The whole is more than

the sum of its parts

When you are choosing a business part-

Oelde, Headquaters of the international operations of ner, not only the quality of the product
Westfalia Separator
is important. The parameters associat-
ed with the machine must also be right.
This is the Westfalia Separator philoso-
phy for an optimum life cycle benefit.
This includes individual solutions tailo-
red to your requirements as well as in-
telligent service packages, the avail-
ability of genuine spare parts and
economical operation throughout the
entire service life of the machine.
Comprehensive service starts with the
first discussions. In close co-operation
Niederahr, decanter production plant
with you, qualified specialists from West-
falia Separator will demonstrate solu-
tions customised specifically for your
requirements. This starts with the
project planning and extends to the
production and installation of the
machines.

Optimum customer support

guaranteed

Your employees will be familiarised with

Château Thierry/France, mineral oil separator the handling of the machines in training
production plant programmes and training on site or in

Westfalia Separator | 30 | Industrial Biotechnology + Marine + Energy + Oilfield + Industry + Environmental Technology +
 Subsidiaries and service companies
the modern Westfalia Separator training
are present in the following countries:
center. If rapid aid should unexpectedly
become necessary or if a spare part is
needed at short notice, Westfalia Separa- Europe North America
tor is at your service immediately. This is Austria USA
ensured by the global presence of around Belgium Canada
50 subsidiaries and service companies as Bulgaria
well as agents in over 60 countries. Your Croatia South America
The Czech Republic
satisfaction is our objective. Argentina
Denmark
Brazil
Finland
Chile
Quality is our programme France
Mexico
Germany
Great Britain Africa
As the world-wide leading company in
Greece
mechanical separation technology, West- Hungary South Africa
falia Separator is active in many branches. Iceland
If you have a requirement, ask us about Ireland
solutions with innovative separating tech- Italy Asia
Lithuania China
nology for applications in the beverage
The Netherlands India
industry, edible oil processing, dairy tech- Norway Indonesia
nology, chemicals, pharmaceuticals, Poland Japan
biotechnology, oils and fats recovery, the Portugal Korea
starch industry, industrial biotechnology, Romania Malaysia
Russia (CIS) The Philippines
marine technology, oil field technology,
Serbia Singapore
power generation, industrial technology Slovakia Thailand
and our range of engineering services Spain United Arab Emirates
and used machines from the manufactur- Sweden
er as the best alternative. Switzerland Australia
Turkey Australia
New Zealand

Engineering + Second Hand Machinery + Service Worldwide + Separation Technology + Beverage Technology | 31 | Westfalia Separator
 Beverage Environmental
Technology Technology

Dairy
Technology Marine

Oils and Fats

Processing Energy

Chemicals
Pharmaceuticals
Biotechnology Oilfield

Oils and Fats

Recovery Industry

Starch
Technology
Industrial
Biotechnology Engineering

Printed on chlorine-free bleached paper

Second Hand
Service Machinery

Global
Presence

Westfalia Separator
Industry
Take the Best – Separate the Rest

A company of mg technologies group

Westfalia Separator Industry GmbH · Werner-Habig-Straße 1 · D-59302 Oelde (Germany)
Tel.: + 49 25 22/77-0 · Fax: + 49 25 22/77-28 28 · Internet: www.westfalia-separator.com · E-mail: industry@gea-westfalia.de

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 suitablity for specific applications, can only be provided within the framework of concrete inquiries.
9997-1073-000 / 0105 EN Stu Subject to modification Printed in Germany