09/16 - decanter centrifuges, centrifugal extractors pieralisi · electrical and control panel...
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ENVIRONMENTAL APPLICATIONS
Pict
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1831
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/16
D E D I C A T E D I N N O V A T O R S
D E D I C A T E D I N N O V A T O R S
Via Don Battistoni, 1 - 60035 Jesi (AN) ItalyPhone +39 0731.2311- Fax +39 0731.231239www.pieralisi.com - [email protected]
Environmental Applications
1 .2 .3 . 4 . 5 . 6 . 7 . 8 . 9 .
10 .
Municipal wasteBio wasteBreweries waste waterFruit juice waste waterWineries waste waterWater purifyingPharmaceutical waste waterTannery waste waterSugarbeet processing waste waterTomato processing waste water
The indiscriminate use of the resources on Earth threatens the existence of life on the planet. Recovering these resources is the world’s future challenge for making human life on Earth sustainable. Especially for those resources that are not renewable, such as water, Pieralisi Group offers a longtime experience and a strong expertise to guarantee an important contribution to this mission.
We are a global presence with 16.000 installed plants. Since 1970, we design and develop solutions for sludge thickening and dewatering, basing on our large range of continuously innovated decanters and separators. Pieralisi centrifuges allow to recover industrial and process fluids by removing solid and liquid contaminants with significant environmental and economic advantages.
1Municipal Waste
2Bio Waste
Example of Process Flow DiagramProcess section involving Pieralisi technologies Example of Process Flow DiagramProcess section involving Pieralisi technologies
Raw Product
Sorting
Oil Removal
SolidSolid
Clarified Water
DewateringPag 12
Anaerobic Fermentation
BioreactorGasometer Electrical
Power Unit
Liquor
Screw Press
Composting
WWTP
Solid Removal
Oil Removal
Clariflocculation
Filtration
Disinfection
DenitrificationThickening
Equalization
Pre-aeration
Solids Disposal
Surface Water
Solid Disposal
Biogas
PrimarySedimentation
Oxidation Nitrification
AnaerobicDigestion
AerobicStabilization
SecondarySettlement
DewateringPag 12
ThickeningPag 10
Slud
ge A
naer
obic
Trea
tmen
t
Wat
er Tr
eatm
ent
Slud
ge A
erob
ic Tr
eatm
ent
Waste Effluent
ThickeningPag 10
DewateringPag 12
Clarified WaterClarified Water
D E D I C A T E D I N N O V A T O R S D E D I C A T E D I N N O V A T O R SEnvironmental Applications: Processes Environmental Applications: Processes2 3
5WineriesWaste Water
6Water Purifying
3BreweriesWaste Water
4Fruit JuiceWaste Water
Example of Process Flow Diagram
Example of Process Flow Diagram
Process section involving Pieralisi technologies
Process section involving Pieralisi technologies
Example of Process Flow Diagram
Example of Process Flow Diagram
Process section involving Pieralisi technologies
Process section involving Pieralisi technologies
Wet Sludge Disposal
Biogas
Sand filter
Sand Filter
Strainer
Anaerobic Reactor
Anaerobic Cleaning Stage
Waste Water
pH value adjusting
Process WaterWWTP
Production Process
Solids DisposalDewatered Sludge
DewateringPag 12
Water
Clarified Water
Activation Sedimentation
Anaerobic Treatment
NeutralizationPre-treatment
Clarified Water
Strainer
Waste Water
Production Process
Solids Disposal
Clarified Liquid
Dewatered Sludge
DewateringPag 12
Pre-treatment
Clarified Water
Strainer
Waste Water
Production Process
Activation Sedimentation
Solids Disposal
Clarified Liquid
Dewatered Sludge
DewateringPag 12
Sedimentation
Thickening
Multi-stageFiltration
Filtered Wateras Drinking Water
Chemical Treatment
Waste Water
Production Process
Solids DisposalDewatered Sludge
DewateringPag 12
Water
Clarified Water
D E D I C A T E D I N N O V A T O R S D E D I C A T E D I N N O V A T O R SEnvironmental Applications: Processes Environmental Applications: Processes4 5
9SugarbeetProcessingWaste Water
10TomatoProcessingWaste Water
7PharmaceuticalWaste Water
8TanneryWaste Water
Example of Process Flow Diagram
Example of Process Flow Diagram
Process section involving Pieralisi technologies
Process section involving Pieralisi technologies
Example of Process Flow Diagram
Example of Process Flow Diagram
Process section involving Pieralisi technologies
Process section involving Pieralisi technologies
Clarified Water
HomogenizationTank
Clean Water
Clean Water Make Up
Clarifier
Waste Water
Production Process
Solids DisposalDewatered Sludge
DewateringPag 12
Clarified Water
Clean Water
Solid Removal
Settling
Thickening
Biological Oxidation
Sludge
Clean Water Make Up
Solids DisposalDewatered Sludge
DewateringPag 12
Waste Water
Production Process
Polymer Solution
BiologicalTreatment
Waste Water
Production Process
DewateringPag 12
Solids Disposal
Waste Water
NeutralizationPre-treatment
Activation Sedimentation Sludge
Rake / Defatting
Waste Water
Production Process
Solids Disposal
Clarified Liquid
Dewatered Sludge
Anaerobic Treatment
DewateringPag 12
Clarified Water
D E D I C A T E D I N N O V A T O R S D E D I C A T E D I N N O V A T O R SEnvironmental Applications: Processes Environmental Applications: Processes6 7
Environmental Applications: ThickeningEnvironmental Applications: Thickening
4. Flushing Valve
A complete line of a solid-liquid thickening plant consists of the following equipment:
Sludge feeding pump (mono pump)Preparation unit for polymer solution (for liquid or powder active ingredients)Liquid polymer dosing pump Polymer solution feeding pump Sludge flow meterPolymer solution flow meterFlushing valvesMain control panelDecanter centrifugePump for thickened sludge
122a2b3a3b4567
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Thickening:volume reduction and solid concentration increase
Decanters are used for dynamic thickening in order to increase the solid concentration in the liquid up to 6-8% dry solid. Thickened sludge is usually sent to the following dewatering step.
The Thickening Solution
Sludge
Flushing Water
Water
Powder Polymer
Liquid Polymer
Water
4. Flushing Valve
Mixing and Activation Tank
Dosing Tank
1. Pump
2b. Pump2a. Dosing Pump
Drain
Tank
Flushing Water
5. Control Panel
2. Polymer Unit
TYPICAL VALUES
0,5÷2% DS
7. PumpTYPICAL VALUES
6 ÷ 8 % DS
100
80
60
40
20
0
0,5÷2% DS
IN
OUT
6÷8% DS
Thickening Process
Thickened Sludge
Clarified Water
3a. Flow Meter
3b. Flow Meter
Mixer
6. Decanter Centrifuge
D E D I C A T E D I N N O V A T O R S D E D I C A T E D I N N O V A T O R S10 11
4. Flushing Valve
4. Flushing Valve
Mixing and Activation Tank
Dosing Tank
1. Pump
2b. Pump2a. Dosing Pump
Tank
3a. Flow Meter
3b. Flow Meter
Mixer
6. Decanter Centrifuge
Environmental Applications: DewateringEnvironmental Applications: Dewatering
100
80
60
40
20
0
1÷5% DS
IN
OUT
20÷35% DS
Dewatering Process
Drain
7. Screw Conveyor
The Dewatering Solution
Drain
Flushing Water
2. Polymer Unit
TYPICAL VALUES
1÷5% DS
TYPICAL VALUES
25 ÷ 30 % DS
Solid Cake
Clarified Water
A complete line of a solid-liquid dewatering plant consists of the following equipment:
Sludge feeding pump (mono pump)Preparation unit for polymer solution (for liquid or powder active ingredients)Liquid polymer dosing pump Polymer solution feeding pump Sludge flow meterPolymer solution flow meterFlushing valvesMain control panelDecanter centrifugeScrew conveyor for solid cake trasportation
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Dewatering:volume reduction and solid concentration increase
Decanters are used for dynamic solid-liquid separation and dewatering; the inlet solid concentration increases up to 20-35% dry solid, depending on the sludge stabilization efficiency obtained in the previous treatment steps.
Sludge
Flushing Water
Water
Powder Polymer
Liquid Polymer
Water
5. Control Panel
D E D I C A T E D I N N O V A T O R S D E D I C A T E D I N N O V A T O R S12 13
Electrical and control panel
“Pieralisi Control System” is divided in two main sections: power and control. In the power unit are placed all the main switches and the variable frequency drivers (VFD) for both decanter and auxiliaries. The control module is based on a PLC and HMI with touch screen panel. A dedicated software, designed by Pieralisi automation department, is embedded in the PLC to automatically control the whole thickening and dewatering sections in each operating step: start-up, duty, flushing and shut-down. The HMI allows to navigate through several areas:• separation process monitoring• operating parameters control• alarms detection• trends displayThe last control release optimizes the separation performances and stabilizes the operation conditions by controlling the decanter in “torque mode”. The logic is continuously measuring the torque on the decanter scroll, keeping it stable at its set point value, by smoothly acting on the scroll differential speed.All Pieralisi control panels can be equipped with a dedicated module for remote connections and assistance.
Decanter Centrifuge
High efficiency separation unit capable to handle liquid mixture containing a considerable amount of solid particles. Decanter performances are related not only to process operating parameters but also to the mixture composition, density and viscosity of the different phases, solid density and particles size. The internal centrifugal force is the result of the rotational speed coupled with the large bowl diameter. The decanter is driven by a main motor connected to the horizontal shaft of the bowl. The product enters through the feed pipe into the centre of the bowl where it is accelerated generating the solid-liquid separation.The clarified liquid phase is discharged from the rotating bowl by means of special devices on one side of the bowl.The dewatered solid, collected on the bowl internal walls, is transported by the scroll and continuously discharged on the opposite side.Several options are available to configure the decanter accordingly to the requirements of each specific process. Solid scraper (a) and gate valve (b) are the most commonly used in environmental applications.
Preparation unit for polymer solution
Several additives are largely considered to increase the performance of thickening and dewatering plants. Polyelectrolyte is the type of additive most commonly used for environmental applications.Pieralisi polymer preparation unit is specifically designed to be operated both with powder and liquid additives according to the specific requirements of the client. The results is a fully homogenized and activated polymer solution with the concentration suitable for the requested performances. The system is suitable to work on a continuous base and its automatic control can be demanded to a dedicated local panel or integrated in the main control panel.
Screw Conveyor
The solid exiting from the decanter can be discharged by gravity on an underlying container or transported to a side container by means of a screw conveyor. The unique design of Pieralisi decanter allows to install both horizontal and inclined conveyors directly under the solid outlet.The layout of the conveying system is tailored on the specific path required on each site and can be based on a multiple solution with more than one element. In any case the control of each component and the automatic management of the transition sequences is implemented in the main control panel in accordance with the decanter operating status.
Flow Meter
The possibility to measure the flows to the decanter allows a more precise control of the operating parameters assuring cost optimization and more stable performances. Pieralisi installs on its unit only major brands flow meters with proven quality and reliability.
Flushing Valves
The flushing procedure is a key factor for the main components life cycle and long term performance stability. Thus, two specific cleaning sequence are automatically activated by the PLC before the centrifuge shut down or in case of necessity. Dedicated solenoid valves are installed on the circuits to allow the flushing of both the internal part of the rotating assembly and the case volume outside the bowl. The flushing cycle parameters can be adjusted from the HMI in accordance to the requirements of each plants.
Pumps
The centrifugal technology requires a constant inlet flow in order to keep stable separation conditions. For this reason, mono pumps (progressive cavity pumps) are usually installed to properly feed the sludge and the polymer solution to the decanter and eventually to pump the clarified liquid to the storage area. Each pump can be equipped with VFD, constantly monitored and automatically regulated by the main control panel.
Sludge – Polymer Mixer
The proper mixing of the activated polymer solution into the sludge is a key factor for the separation performances. Pieralisi static mixer is designed to blend the flows in a gently and effective way, guaranteeing the full contact of the polymer with the sludge solid particles.
a
b
a
b
D E D I C A T E D I N N O V A T O R S D E D I C A T E D I N N O V A T O R S14 15Environmental Applications: ComponentsEnvironmental Applications: Components
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Mun
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aste
Bio
was
te
Brew
erie
s w
aste
wat
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Frui
t jui
ce w
aste
wat
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Win
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s w
aste
wat
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Wat
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urify
ing
Phar
mac
eutic
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aste
wat
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Tann
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was
te w
ater
Suga
rbee
t pro
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was
te w
ater
Tom
ato
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aste
wat
er
1 2 3 4 5 6 7 8 9 10
ROTATING ASSEMBLY
Bowl
Steep coneShallow coneInner surface with linersInner surface with groovesWear protections solid discharge bushes (replaceable)Wear protections inner surface (flame spray)
Scroll
Single flightReduced pitch flightVariable pitch flightFlight with windowsFlight wear protections: sprayed tungsten carbide Flight wear protection: tiles (replaceable)Diffuser wear protections : plates (replaceable)
MATERIALS
BowlSAF 2205 Duplex stainless steelAISI 414 stainless steel
ScrollAISI 304 stainless steelAISI 316 stainless steel
Case
Painted carbon steel case and subframeStainless steel cylindrical bodyStainless steel solid-liquid chambersStainless steel subframe
Parts in contact with the product
Stainless steelTailored on the application and International or European standard
EXECUTION Installation areaSafe area (not hazardous area)Hazardous area: ATEX Zone 1Hazardous area: ATEX Zone 2
LUBRICATIONGearbox Oil bath
Bearings Automatic greasing
PROCESS CONFIGURATION
Liquid outlet
Two phases (1 liquid - 1 solid)Three phases (2 liquids - 1 solid)Interchangeable liquid outlet levelsLiquid discharge level adjustable during operation
DRIVES
Bowl driveElectric motorHydraulic motor
Scroll drive
Fixed differential speed (countershaft)Electric motor (back drive)Hydraulic motorRotovariator
DECANTER OPTIONS
Kits and Systems
Control panelCounter pressure valveCooling fanInertization systemSolids scraper deviceCyclone kitGate valve kitCIP washing system
PLANT OPTIONS
Kits and Systems
Filtering unitAdditive unitSolid conveyor systemHomogenizing systemFeeding pumpFlow rate measurement kitHeating system
02
01
02
03
04
03
04
Configuration Table
D E D I C A T E D I N N O V A T O R S16 Environmental Applications: Configuration Table