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  • The Screening Dewatering The Screening Dewatering The Screening, Dewatering The Screening, Dewatering and Drying Expertsand Drying Expertsy g py g p

    Centrifuge and Belt Press Centrifuge and Belt Press Centrifuge and elt Press Centrifuge and elt Press MaintenanceMaintenance

    Previous Slide

  • Brian LentIntroduction

    Western Regional Aftermarket Sales Manager

    Experience

    1976 1981 BIRD MACHINE Walpole MA

    Based out of Boston MA

    1981 1998 Humboldt Decanter -Norcross GA

    Based out of San Ramon CA

    1998 2006 BAKER PROCESS Walpole MA (Formerly BIRD)1998 2006 BAKER PROCESS Walpole MA (Formerly BIRD)

    Based out of San Ramon CA

    2006 to Present Andritz Separation Inc Arlington TX

    Based out of San Ramon CA

    2

    Buenos Aires

  • Long Term Maintenance of Dewatering Equipment

    Belt Press

    Centrifugeg

    3 Individual footer (e.g. title of presentation, date, name of presenter): Arial 9 pt, gray, align center, max. 1 line

  • Long Term Maintenance of Dewatering Equipment

    Dewatering Equipment like and other processing devices have there limits

    Centrifuge and Belt Presses both have a solids loading and a liquidCentrifuge and Belt Presses both have a solids loading and a liquid loading limit

    Belt Press units have a basic rule of thumb

    100 gpm per meter of belt width100 gpm per meter of belt width

    1000 #/hr per meter of belt width

    4 Individual footer (e.g. title of presentation, date, name of presenter): Arial 9 pt, gray, align center, max. 1 line

    Buenos Aires

  • Long Term Maintenance of Dewatering Equipment

    Centrifuges

    Centrifuges are sized by the Optimal capacity of the bowl configuration and volume that can be put through it at that optimum loading

    The solids loading is dependent on the feed solids THE HIGHER THE FEED SOLIDS THE LOWER THE FLOW to maintain the optimal performanceSOLIDS THE LOWER THE FLOW to maintain the optimal performance

    The liquid loading is also dependent on the feed solids THE THINNER THE FEED THE HIGHER THE FLOW RATE to maintain the optimal performance

    This is why in the market most companies have sizes that have similar sizes and geometry

    The newer designs are pushing that curve to its limits

    When these loadings are exceeded the optimal performance of these machines suffers drastically loss of % cake solids and flow through put

    5

    Buenos Aires suffers drastically loss of % cake solids and flow through put

  • How to calculate Throughput

    Known: Flow RateFeed SolidsSpecific Gravity of Feed Slurry (use 1.0 if unknown)Specific Gravity of Feed Slurry (use 1.0 if unknown)

    T = FR x 8.345 lbs/h x 60 minutes/h x FS% x SGSLSor simplified

    T = 5 x FR x FS x SGSL

    T --- Throughput in lbs/hr Dry SolidsFR --- Flow Rate in Gallons per MinuteFS --- Feed Solids in % Dry SolidsSGSL --- Specific Gravity of sludge or slurry (use 1.0 for municipal sludge)

    Example: Flow Rate = 100 GPMFeed Solids = 2.5 % DSSG Sludge = 1.0

    Throughput = 1 250 lbs/h DS

    Slide No. 6Andritz Separation Inc.

    Throughput = 1,250 lbs/h DS

  • SLUDGE FROM TYPICAL WASTEWATER TREATMENT

    Slide No. 7Andritz Separation Inc.

  • Long Term Maintenance of Dewatering Equipment

    From the simple sketch you can see that sludge is made up of waste andFrom the simple sketch you can see that sludge is made up of waste and that waste has the kitchen sink in it. The wastewater treatment plants try to remove the heavy particulate and screen most of the plastic and grit but a large amount still manages to get to the solids handling end of the plant where it is dewatered.

    Contrary to popular thought not all Poop is the same each sludge has its own characteristics, chemical make up, grit levels, ash content, settling

    t d th i di id l t thi k frates and any other individual component one can think of.

    With that thought how do we protect our equipment

    Most Belt Press units have

    Protected and coated frames

    Protected bearings and sealed housings

    Protected rollers

    Stainless steel fasteners and fittings

    Plastic and protective housings and covers

    8 Individual footer (e.g. title of presentation, date, name of presenter): Arial 9 pt, gray, align center, max. 1 line

    Buenos Aires Plastic and protective housings and covers

    Gear boxes and drives

  • Long Term Maintenance of Dewatering Equipment

    Having said this EVERYTHING REQUIRES SOME DEGREE OFHaving said this EVERYTHING REQUIRES SOME DEGREE OF MAINTENANCE

    The normal wear items for a Belt Press are

    The Belts normal wear is 2000 to 3000 hours but this depends on the grit and pressure applied to the rollers

    The Rollers the rollers have an normal life expectancy of 10 years again d di th it d li ddepending on the grit and pressures applied

    Tracking and tensioning systems (either pneumatic or hydraulic) have a life cycle also there life is dependent on the pressure, operating cycles and

    l h k i f th itgeneral housekeeping of the unit

    Drives / gear boxes there life cycle depends on lubrication changes, alignment and general housekeeping

    Bearings and seals these are the only items that require constant attention as far a grease and housekeeping

    The frame and ancillary equipment requires attention when it fails or is

    9

    Buenos Aires

    y q p qdamaged

  • Long Term Maintenance of Dewatering Equipment

    Belt press lubrication

    5.3.1 Lubricant Specification

    REFERENCE SYMBOLMOBILSHELLTEXACOA - GreaseMobilith SHC 460- - - -- - - -B - OilMobilgear 630Shell Omala Oil 220Meropa 220C - GreaseMobilux EP2Shell Alvania Grease R3Multifak EP2

    5.3.2 Lubrication ScheduleFrequency Lubricant

    1. Grease bearings monthly A2. Grease tracking device 1 month A3. Grease thrust rods on tensioning device 6 months A4. Check oil level in drive gearbox 80 hours B5 Ch il i d i b 10 000 h (2 ) B5. Change oil in drive gearbox 10,000 hours (2 years) B6. Repack bearings in drive gearbox 20,000 hours (4 years) C7. Grease bull gear & drive pinion gear 1 month A

    5.3.3 Lubrication Location*Graphics may differ from actual machine*Graphics may differ from actual machine

    All equipment should have a simple grease chart that can be followedIt is up to the customer to log these lubrication events

    10

    Buenos Aires

    g

  • Long Term Maintenance of Dewatering Equipment

    C t if h i il d i t i tCentrifuges have similar wear and maintenance points

    Most centrifuges in the market these days are outfitted with the following g y gstandards

    Bowls, bowl heads, conveyors and hard components are 316 SS or made from a casting type duplex Stainless Steel

    The feed compartments, feed ports, cake ports and conveyor tips are protected or made from a Tungsten Carbide or similar material

    Most have SS liners or covers protecting the solids and liquids dischargeMost have SS liners or covers protecting the solids and liquids discharge points

    Most have bearings are designed for L10 ratings and the seals are Buna or better depending on servicebetter depending on service

    Most bases are carbons steel with powder coating or epoxy coatings

    11

    Buenos Aires

  • Centrifuge Maintenance Requirements

    5.3.1 Lubricant Specification

    LUBRICANT LISTLUBE TYPE SKF Mobil Shell BPA. Grease SKF LGMT2 Mobilux EP2 Alvania EP2 Energrease LS EP2Centrifuge A. Grease SKF LGMT2 Mobilux EP2 Alvania EP2 Energrease LS EP2B. Grease SKF LGMT3

    C. Grease EXCLUSIVELYEnergrease PR EP 00

    D. Oil Mobil SHC X100 30 BP Super visco static627 20w50

    5.3.2 Lubrication ScheduleInnovative

    CentrifugeTechnology

    Quality

    Frequency Lubricant Quantity1. Grease bearing - feed end 200 hours A 20 Gr2. Grease bearing - drive end 200 hours A 15 Gr3. Grease thrust bearing - feed end 4000 hours B 100 Gr4. Change grease in drive speed inducer 4000 hours C 3000 Gr5. & 6. Grease electric motor bearings 3000 hours A see Vendor info

    Reliability

    High Performance

    5.3.3 Lubrication Location

  • Long Term Maintenance of Dewatering Equipment

    Maintenance Service Intervals

    Most suppliers have a standard chart that is used as a guide for theMost suppliers have a standard chart that is used as a guide for the customers to logically project the maintenance of a particular size centrifuge (the parts cost and labor vary by size) but they all have a specific repair interval.

    These type of charts can be used as guides for projected maintenance costs.

    The frequency of the intervals is dependent on the operating hours perThe frequency of the intervals is dependent on the operating hours per day, week and year.

    The first few years of a 4000 operating hour centrifuge is obviously less than a unit that is in service 24/7/365 unitthan a unit that is in service 24/7/365 unit

    13

    Buenos Aires

  • Andritz Centrifuge Features12 Centrifuge Maintenance Requirements12 Centrifuge Maintenance Requirements

    DESCRIPTION 200 HRS

    3000 HRS

    4000 HRS

    6000 HRS

    8000 HRS

    9000 HRS

    12000 HRS

    15000 HRS

    18000 HRS

    24000 HRS

    1. * Lubricate both support bearings EVERY 200 hrs X

    12. Centrifuge Maintenance Requirements12. Centrifuge Maintenance Requirements

    2. Renew grease in cyclo & thrust brg. X X X X X X 3. General inspection X X X X X 4. Inspect scrapers, deflector rings (D7L only) X X X X X 5. Inspection of drive belts X X X X 6. Mechanical inspect of feed b

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