Flottweg Decanters for Water Treatment and Wastewater Facilities

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
of which 96.5 % is sea water in the oceans. Only 3.5 %, i.e. 49 million
technical standards.
total quantity of water on earth amounts to 1.4 billion cubic-kilometers
cubic-kilometers, is fresh water. However, more than half of this fresh
in compliance with all current
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
® = registered trademark for various countries
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
centrifuges featuring Flottweg’s quality, reliability and optimal price/performance ratio.
Flottweg Decanter C3E
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 compared 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 maintenance.
Flottweg Decanter C4E
C2E
TECHNICAL INFO
C3E
C4E
C5E
C7E
Z92
Flottweg Decanter Product Line for a clean environment
Flottweg Decanter C5E
3
FLOTTWEG OSE DECANTERS
for Sludge Thickening
In sludge thickening, surplus sludge, which is
generated during the biological stages, is concentrated 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
TECHNICAL INFO
water
primary
clarification
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
primary sludge
Flottweg OSE Decanter
surplus (waste) sludge
(0.5...1.0% ds)
centrate
4
thickened
(4...8% ds)
sludge
FLOTTWEG HTS DECANTERS
for Sludge Dewatering
Customer’s benefits versus other
dewatering techniques
Regardless of whether the sludge is transported
after dewatering, reused as fertilizer, disposed of
in landfills or incinerated – maximum dryness is
Optimally balanced performance:
the most critical factor.
• minimum specific power consumption
The other key factors are cost efficiency in terms
• maximum cake dryness
• minimum polymer demand
of consumption of polymers, energy, water and
spare parts, as well as continuous, automatic op-
Optimized operational labor costs through:
eration at minimal costs.
• continuous and automatic operation
• easy cleaning by flushing without dismantling
All these criticial design features were already
• 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
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).
via PLC or remote control
water
effluent
digestion
Flottweg HTS Decanter
digested sludge
(2...6% ds)
centrate
® = registered trademark for various countries
dewatered
sludge
(25...35% ds)
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 bowl shell of a decanter centrifuge has a cylindrical – conical
shape. It rotates at a high speed creating the centrifugal force needed
for the separation. Inside the bowl, there is a scroll conveyor for the
continuous discharge of the sediment which is packed on the inner surface 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
TECHNICAL INFO
box at the drive end of the bowl.
The picture shows a
decanter scroll
6
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 separated liquid flows to the cylindrical end
of the bowl where it is discharged by gravity via
an overflow weir.
SPECIAL DESIGN FEATURES
of the Flottweg OSE and HTS Decanters
BOWL AND SCROLL
The high cake dryness obtained using the Flottweg
MATERIALS OF
CONSTRUCTION
HTS Decanter is the result of the machine features: centrifugal dewa-
Flottweg exclusively uses high-quality stainless
in a “deep pond design” to provide a large bowl volume and a narrow
with bowls made of centrifugally casted duplex
tering under high g-force and mechanical pressing. The bowl is shaped
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.
steel for all wetted parts. All models are equipped
stainless steel to ensure optimal strength and
corrosion resistance.
The bowl is driven via a motor which is controlled by a
frequency inverter (VFD). For the scroll drive, there is the Flottweg Simp
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
zone of the bowl in order to achieve the maximum cake dryness, even
under varying load conditions.
WEAR PROTECTION
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
DRIVE SYSTEM
Flottweg Simp Drive®: Regulation of the differential
speed depending on the scroll torque
DOSAGE OF POLYMER
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
TECHNICAL INFO
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
want to make your process even more flexible? Then the C-XI decanter
series is the right choice for you. This optimized decanter series was
specifically developed for the wastewater market. Requirements in this
area have evolved continually over the past few years. Certain types
The advantages of the
C-XI series at a glance
• Reliable force transmission at
very high loads
of sewage sludge require additional dewatering. By developing a de-
• Stronger gearbox for the more
– as usual – stands out for its efficiency and quality because dryer
• Higher g-forces for better
operators of sewage treatment plants. How can this be done?
• Better solid conveyance for
canter centrifuge designed specifically for these requirements, Flottweg
sludge means significant cost reductions (transport, disposal, etc.) for
MAXIMUM G-FORCES
To help separate the remaining moisture from the sludge dur-
ing dewatering, maximum g-forces are needed. The higher the maxi-
mum g-force within the bowl of the decanter, the better the dewatering
performance – in other words, the dryer the processed sludge will be.
Since this is significantly dryer after handling using a C-XI decanter
centrifuge than with conventional decanter centrifuges or other systems
for sludge treatment, sewage treatment plant operators save enormous
costs. Depending on the size of the sewage treatment plant, a gain of
one percent dry substance (DS) can lead to savings of thousands of
euros. Decide on the new C-XI decanter from Flottweg today.
powerful drive
dewatering performance
more throughput
• Optimized scroll body for perfect
conveying of the separated solids
• Minimum downtime thanks to the
extremely maintenance friendly design
of the C-XI series
• Additional energy savings of about 30
percent are possible with the Flottweg
Recuvane®-System
• Top life span through highest quality
stainless steel and optimized wear pro-
tection packages
• Continuous outstanding separation results, due to an automatic and independent regulation of the bowl and
differential speed (Simp Drive®)
* depending on the pond depth and the characteristics
of the sludge
8
® = registered trademark for various countries
Do you want to reduce your disposal costs to a minimum, and do you
FLOTTWEG SEPARATION TECHNOLOGY
MAXIMUM POWER
High RPM is needed for decanter centrifuges to obtain the
desired dewatering results. The forces associated with high RPM
specifically optimized to the needs of the sewage
treatment market can result in even better quality
of separation and dewatering which lead to an
require a powerful drive, a reliable and reinforced gearbox, and perfect,
increased dry substance.
are met using the Simp Drive®. Make your own decision about
What does it mean to be “even better”?
automatic response to different load conditions. These requirements
the maximum power of the new C-XI by visiting our website
www.flottweg.com.
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
Changing the geometry of the scroll body in-
creases the solid concentration within the de-
canter bowl even more, which – due to the pressing action – leads to more effective dewatering
of the sludge and a higher content of dry sub-
stance. Within the C-XI decanter series, Flottweg
is driving the C-series already successfully on
MAXIMUM
POWER
MAXIMUM
G-FORCES
MAXIMUM
DRY SUBSTANCE
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
Flottweg assumes the responsibility
for the whole system
• Maximum convenience for our
customers since there is only one
contact person for the complete system
• Long life span and high availability
TECHNICAL INFO
• High reliability and safety since
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
Application-based project planning, high-quality manufactur-
Flottweg Services include:
ing and professional after-sales service are prerequisites for trouble-
• Experienced advice on separation
customer service department are ready to respond quickly if needed.
• Pilot tests on-site or at the Flottweg
maintenance in order to avoid interruptions in production.
• Selection and sizing of appropriate
free operation. Experienced and reliable service engineers from our
The Flottweg Service Group is also available to perform preventive
QUALITY “MADE IN GERMANY”
Flottweg is ISO 9001 certified and manufactures its
products in compliance with the most current technical
standards.
processes
Laboratory and Test Center
equipment
• Customer-specific automation/control
systems and process integration
• Design and construction of complete
process systems
• Installation, commissioning, mainte-
nance, repair, spare parts and service
AFTER-SALES CUSTOMER SERVICE
Even the best machinery needs to be maintained and serviced.
Flottweg has established a worldwide service network consisting of its
own subsidiaries, branch offices, and representatives to provide our
customers with local service and spare parts.
FLOTTWEG WORLDWIDE
Flottweg is headquartered in Vilsbiburg (near Munich), Germany, and
has branch offices in Cologne and Leipzig as well as subsidiaries in
Australia, Brazil, Canada, China France, Italy, Mexico, Peru, Poland,
Russia, and the United States, along with representatives in nearly all
worldwide
Our service engineers and technicians are qual-
ified for any kind of installation, commissioning,
repair, and maintenance.
countries worldwide.
Check out our website at www.flottweg.com to
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-
canter centrifuge. The Flottweg Recuvane -System helps to reduce
®
power consumption and therefore save money. There is, however, no
reduction of capacity..
Benefits of the Flottweg
Recuvane®-System
• 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
ventional weir plates. The energy included in the water, however, gets
• Existing separation processes do not
speed. Normally, the centrate discharges radially by gravity over con-
lost.
Thanks to the special construction of the Flottweg Recuvane -System,
®
the centrate water can be discharged in a specific way and the energy
recovered during discharge supports the main drive thus saving 10 to
30 % of the operating power depending on the pond depth and the
• Solely mechanical, robust design
need to be modified
• For optimum operation, it is possible to
adjust different pond depths
* depending on pond depth and sludge characteristics
sludge.
conventional design
specific discharge using Recuvane®
Discharge of the centrate water
12
® = registered trademark for various countries
TECHNICAL INFO
reduced energy consumption
(up to 30%)*
TECHNICAL INFO
power consumption of the bowl [KW]
BENCH MARK TEST WITH A
FLOTTWEG DECANTER C7E*
160,0
140,0
conventional design
120,0
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
Flottweg C-series
Flottweg Z-series
SERIES WHICH ARE COMPATIBLE WITH RECUVANE®
C2E, C3E, C4E, C5E, C7E
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
Dimensions* (L x W x H)
2700 x 840 x 810 mm
107" x 33" x 32"
Motor for bowl drive
5.5 – 7.5 kW
7.5 – 10 hp
7.5 – 15 kW
10 – 20 hp
15 – 30 kW
20 – 40 hp
30 – 55 kW
40 – 75 hp
55 – 110 kW
75 – 150 hp
90 – 200 kW
125 – 300 hp
Capacity*
8 – 15 m³/h
35 – 65 gpm
15 – 30 m³/h
60 – 120 gpm
30 – 60 m³/h
125 – 250 gpm
45 – 90 m³/h
200 – 400 gpm
70 – 140 m³/h
300 – 600 gpm
120 – 250 m³/h
500 – 1100 gpm
Materials of construction
Gross weight*
Motor for scroll drive
Flottweg Simp Drive®
C4E-4
C5E-4
Z92-4
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
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"
1735 kg
3825 lb
4 kW
5 hp
2760 kg
6100 lb
4 kW
5 hp
5060 kg
11250 lb
5.5 kW
7.5 hp
* The listed figures are guidelines for information only. Actual capacity dpends on the characteristics of the product to be processed.
14
C7E-4
All product wetted parts are made of high grade stainless steel such as 1.4463 (Duplex) and 1.4571 (AISI 316T)
1360 kg
3000 lb
2.2 kW
3 hp
C3E-4
8400 kg
19000 lb
5.5 kW
7.5 hp
18000 kg
40000 lb
7.5 kW
10 hp
® = registered trademark for various countries
FLOTTWEG HTS DECANTERS
for Sludge Dewatering
TECHNICAL DATA OF FLOTTWG HTS DECANTERS
Type
C2E-4
Dimensions* (L x W x H)
2700 x 840 x 810 mm
107" x 33" x 32"
Motor for bowl drive
7.5 – 11 kW
10 – 15 hp
11 – 18.5 kW
15 – 25 hp
Capacity*
5 – 10 m³/h
20 – 45 gpm
10 – 20 m³/h
45 – 90 gpm
Materials of construction
Gross weight*
Motor for scroll drive
Flottweg Simp Drive®
C4E-4
C5E-4
C7E-4
All product wetted parts are made of high grade stainless steel such as 1.4463 (Duplex) and 1.4571 (AISI 316T)
1360 kg
3000 lb
3 kW
4 hp
C3E-4
Z92-4
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
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"
1735 kg
3825 lb
4 – 5.5 kW
5 – 7.5 hp
2760 kg
6100 lb
5060 kg
11250 lb
8400 kg
19000 lb
18000 kg
40000 lb
22 – 37 kW
20 – 50 hp
45 – 75 kW
55 – 100 hp
75 – 135 kW
100 – 180 hp
160 – 250 kW
215 – 300 hp
20 – 40 m³/h
90 – 180 gpm
30 – 60 m³/h
125 – 250 gpm
60 – 120 m³/h
250 – 500 gpm
90 – 180 m³/h
400 – 800 gpm
7.5 – 11 kW
10 – 15 hp
15 kW
20 hp
* The listed figures are guidelines for information only. Actual capacity dpends on the characteristics of the product to be processed.
30 kW
40 hp
30 – 45 kW
40 – 60 hp
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
PR-0004 L – 10 2 04/2016
REPRESENTATIVE
[email protected]
www.flottweg.com