How does Decanter Centrifuge Work?

Decanter Centrifuge

Introduction: Decanter centrifuge is a very common equipment that is often found in an oil or gas drilling site. A decanter centrifuge is a very important machine for oil and gas drillers. A decanter centrifuge is basically used to dilute the underground fluids and liquids.

The main job of a decanter centrifuge is to rotate the drilling fluids and in doing so breaking the concentration of those fluids. The whole working functions of any decanter centrifuges is pretty much complex. Here is a discussion given below about how a decanter centrifuge works.

decanter centrifuges
decanter centrifuges

The way a decanter centrifuge works:  As it is mentioned before the process of a decanter centrifuge is a bit complex. Usually,  decanter centrifuges depend on sedimentation, differential speed and G force to perform its job. A decanter centrifuge needs a centrifugal force in order to loosen the fluid.

The sedimentation rate is an important feature for the centrifugal process. If the G force or centrifugal force is very high, the separation process becomes very easy and effective. The size and shape of particles and their level of concentration determine the sedimentation rate of any decanter centrifuge.

The sedimentation rate also depends on the centrifugal force. Another important issue for the functionality of decanter centrifuges is the differential speeds. In a centrifuge two different parts rotate simultaneously. The first part that rotates is the exterior bowl and the second part that rotates is scroll conveyor. Sedimentation is gathered in the centrifugal cylinder as the result of varying speed of the two above mentioned separate parts.

If the differential speed of decanter centrifuges is too high, a little time is required to loosen up the concentration of waste fluids. So, it is very important to keep the differential speed of a decanter centrifuge minimal. Thus, a decanter centrifuge operates its functionalities.

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Decanter Centrifuge Defined Meaning

Decanter Centrifuge

Introduction: Modern gas and oil drilling sites are just a rigid manifestation of multi layered complex mechanism. Several gigantic equipments are set and operated in a single oil or gas drilling sites. The mechanisms of these equipments are very complex and very subtle. A very common equipment that is seen in an oil and gas drilling site is a decanter centrifuge.

A decanter centrifuge is a very useful equipment for any drilling site. Here in this article, we will try to provide a brief description about what a  really it is.

decanter centrifuge
decanter centrifuge

A brief description of a decanter centrifuges: A decanter centrifuge is a device that can create a very fast rotation that is basically used to dilute the fluid that is extracted from the gas or oil mine. Generally, the liquid that is extracted from a mine is of highly concentrated and coagulated. So, extracting minerals from them is practically impossible. In order to thin up the extracted fluids, a decanter centrifuge is used. By using the rotational speed of a decanter centrifuge, the highly concentrated are turned into minerals extractable thin liquid.

There are three basic designs of decanter centrifuges:

The first one is vertically oriented decanter centrifuges.
The second one is horizontally oriented decanter centrifuges.
The third one is conveyor or scroll decanter centrifuges.

In the vertically oriented decanter centrifuges, the fluids or solids are gathered vertically. Vertical decanter centrifuges are very effective for high temperature and high pressure work. A horizontally oriented decanter centrifuges gathers the fluids or solids generated from high rotation in horizontal orientation. A horizontally oriented decanter is very effective for high pressure works as it provides a strong organization due to its horizontal orientation. Lastly, a conveyor or scroll centrifuge is basically a rotating machine inside a bowl.

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Horizontal Decanter Centrifuge Operation and Maintenance

Horizontal Decanter Centrifuge

A machine running on a centrifugal force to separate different parts is called a centrifuge. Dehydrator Centrifuge is a common device that is usually found on oil or gas drilling sites.

Dewatering machine Centrifuge for oil and gas drilling machine, basically used to dilute the underground liquid and liquid. The main task of the settling centrifuge is to rotate the drilling fluid, thereby destroying the concentration of these fluids. The overall job function of anything is very complicated.

Centrifugal force is the body in the high-speed rotation by the power. They are commonly used to separate components of different densities, such as water and solids. Decanter centrifuge is a special type of centrifuge that separates

Horizontal decanter centrifuge
Horizontal decanter centrifuge

solid components from liquids such as drilling waste.

It plays an important role in waste water treatment, chemical industry and food processing. The performance of the settling centrifuge depends on several different factors.
Most of the drilling and handling equipment handling components of the mixture. It is necessary to separate them separately for further processing.

Three types of decanter centrifuges are used in the industry: horizontal, vertical and conveyor. It is basically a high-speed rotating bowl that separates the solid from the liquid matrix. In the case of a drilling industry, inputs are drilling waste.

Centrifuges are easy to install and require less maintenance. Even if skilled operators need to operate them, decanter centrifuges help save a lot of money and improve the overall efficiency of the industry.

Centrifuge provides more flexibility and better feedback mechanisms. This allows the operator to allow the machine to work under different settings to separate the different components. The space required to set up the machine is very small, easy to start or close, allowing multiple units to work at once.

Horizontal Decanter Centrifuge of Kosun with more than 20 years experience in solid control and deserve well recognized by clients all over the world.

 

Economic Configuration Decanter Centrifuge Operation and Maintenance

Economic Configuration Decanter Centrifuge

Economic configuration decanter centrifuge  is the final phase equipment for the drilling solid control system. Keeping the equipment up and running all the time without any downtime will go a long way in determining the overall operational performance of the drilling project.

While it is important to make sure the equipment is kept in good condition and well maintained, making sure that it is being operated in right manner is equally important. A qualified and well trained operator will know the intricacies of operating the equipment and even know to spot the signs to raise the alarm.

Economic Configuration Decanter Centrifuge
Economic Configuration Decanter Centrifuge

Decanter centrifuge is high cost equipment. It is imperative that it is maintained well, after all the economy of overall project will largely depend on such wise measures only.
Here we are outlining a few tips with respect to operation and maintenance of decanter centrifuges :
1. Preparing for start-up: Before starting the centrifuge check all electric control system and related components. Test the rotating belt manually for any glitch. Inspect the overall panel for any alarming signs.
2. Start the equipment: Most of the modern horizontal decanter centrifuge comes with touch panel now that have fairly user friendly command buttons. Using the touch panel, release relevant commands to bring the equipment to start.
3. Preventive procedure: Once you are done setting up the system, do not directly start feeding the system, let it run for 5 minutes, add water to clean the stuck or dried material.
4. Shutting down the equipment: Do not cut off the power all at once and bring the machine to a halt. Gradually slow down the feed and let the machine process the remaining material till it lasts. Repeat the washing and cleaning procedure.

Make sure that no manual handling is done while machine is operational as it may be very risky.

Decanter Centrifuge for Sale at Home and Abroad

Decanter Centrifuge

Decanter centrifuge equipment is used to serve the purpose. The equipment uses the centrifugal force to separate different materials for treatment.

Wherever there is a need to separate materials of different densities is involved, There are many types of centrifuges, decanter centrifuges , vertical centrifuge, etc.

Now building on this definition, we can imagine the vast application of such equipment in a variety of industrial scenarios, where different materials need to be separated. Let us pick oilfield drilling industry for an instance, where large volume of drilling waste is produced by the drilling process.

Decanter Centrifuge
Decanter Centrifuge

Not only the waste is harmful to the environment, if disposed directly without treatment, but it also contains large quantity of drilling fluid that needs to be extracted and restored. To accomplish this challenging task of separating the fluid, decanter centrifuges are deployed in drilling operations.

The working of a centrifuge could be understood as – If laid down in plain words – it uses the express rotation to separate different types of materials. In a more technical expression, a centrifuge is the equipment that uses the centrifugal force to separate substance based on their density using the principle of sedimentation.

Imagine a jar full of milk cream, when churned at good speed, it separates the cream into butter and skimmed milk. We know that different materials have different density, and the centrifugal force makes them move against the axis of the pit in which they are stored with the help of rapid rotations using mechanical force. Naturally the material with lowest density will make it way upward and the one with highest density will get settled at the bottom of the pit.

The centrifuge equipment is used in a variety of machines that need to filter the mixture of solids and fluids. It finds it application in number of industries ranging from food processing industry to oil and natural gas industry.

Drilling Decanter Centrifuge Advantage and Disadvantage

Drilling Decanter Centrifuge

Drilling Decanter Centrifuge is a device used in separating suspension of solids for drilling purpose. It has been designed for Oilfields and Industrial purposes that are seeking an environment friendly solution. Its speed ranges from 0n to 3900 RPM, generating centrifugal forces reach up to 3000G.

drilling decanter centrifuge
drilling decanter centrifuge

The main advantages of Drilling Decanter Centrifuge are;
1- It has a continuous dewatering in an enclosed unit, which reduces factory nuisances and cost of deodorizing premises.
2- The machines are cleaned automatically.
3- All mechanical safety mechanisms constitute part of the standard main equipment.
4- It is highly suitable for all sludge types, even the most difficult ones.
5- It is highly automatic and self-dependent machine with easy maintenance.
6- It has a very wide application range. The decanter centrifuge can conduct an effective separation as good as filtering centrifuge and can finish the separation despite failed filtering centrifuge.
7-Drilling Decanter Centrifuge can also be used for liquid clarification. It helps separation of lighter solids from heavier liquids.
8-It is usable in both high and low temperatures.
9-   It has a Great Adaptability. It is capable of producing force even greater than the gravity, precisely 14,000 times greater than the gravity.
10- It grades the particles based on the size.
The disadvantages of drilling decanter centrifuges are;
1- It is an expensive and time-consuming process.
2- It has a complex structure, which is not easy to operate by a nonprofessional.
3- Sediment washing has not been very effective through this device.
4- Foaming of liquids may occur occasionally.
5- It is mechanically complex and tedious process.
6- The downtime for cleaning lowers the efficiency of Decanters.
7-Sometimes, the solids can build up inside the Decanters and cause a lower efficiency.
8- The Prescreening may be necessary to weed out particles too large to fit through the nozzles.

Decanter Centrifuge manufacturers – Kosun  with more than 20 years experience in solid control system. Welcome to contact us.

Decanter Centrifuges of Related Common Challenges

Decanter Centrifuges

Decanter Centrifuges are used in separating suspension of solids phase with particle ≥2μm in diameter for drilling mud and fluids handling.

All machineries will have its own set of requirements to give its user the desired performance and durability and off course the much desired economy. After all “Return on investment” is the mantra that investors care to heed about.

Decanter Centrifuges
Decanter Centrifuges

When it comes to solid control equipments, this is no exception. A few careful measures go a long way to ensure that the operators will find the equipment reciprocating their care for them.
The first and foremost one in this aspect is the preventive maintenance of the equipment. The decanter centrifuge as such is low maintenance equipment and has a high capacity of handling the drilling waste treatment , but that should not mean for the operators to simply overlook the state of operation of the equipment.

A very common mistake committed by the operators is the continuous use of equipment without giving it rest and inspection for any wear. The moment any component is spotted showing any signs of wear, operators should consider fixing it, without just pushing it for further use, however small. As it goes with machinery, that all components work in sync, so even a worn out rubber could cause the breakdown of entire equipment. So watch out for any kind of wear or damage.

Another challenge faced by drilling industry in context of economic configuration decanter centrifugeis the lack of trained personnel or operators. With evolving technologies, decanter centrifuges have been made much more automated and need little operational attention. However, to maneuver the equipment to achieve the desired output, need of staffing appropriate personnel is of paramount importance.  With ever stringent health and safety regulations, rig operators struggle with their staffing needs.

The high turnover further adds to the problem. Finding the qualified and experienced operators and investing time in resources in training them to bring the up to speed is a very big challenge for project managers.

What are the Principles of Decanter Centrifuge of Kosun

Decanter Centrifuge

Decanter centrifuge separates the solid material mixed with some liquids that contaminates the water and converts the mud into sludge. It is an important component utilized in petrochemical, food processing and oil industries. These industries will not be able to function in the absence of Centrifuge. The centrifugal force is created by the decanter centrifuge and creates the centrifugal force by rotation.

Operational & Functional Principles of decanter centrifuge:
•    The principle of decanter centrifuge is based on the theory of gravitational separation. A component with high density settles at the bottom and the component with lesser density suspends upwards.

decanter centrifuge
decanter centrifuge

 

The decanter centrifuges increases the rate at which the component settles increases due to the use of continuous rotation. This force is from 1000 to 4000 times than the normal gravitational force. This method of separation gives fast results.
Example: When a glass is filled with mud and water, after few minutes the mud will settle at the base of the glass due to its weight. Since the mud is settled at the base become solid, the water comes upward that creates a separation between the mud and water mixture.

This method of separation by rotation can be compared to that of rides of amusement parks. In the same way the decanter centrifuges basically a bowl tube rotates at a very high speed. The bowl tube has an internal conveyor that moves at different velocity but in the same direction.

The decanter centrifuge is ideal equipment for treating waste water. There are various industries where these types of machines are vital.

The 2-phase separation method is used for Waste water treatment, sludge de-watering, and also food processing.

The 3-phase separation process separates two liquids like water and oil, which have different densities and cannot be mixed together, are separated. This 3-phase separation produces edible oil, bio-diesel and oil sludge.

Decanter Centrifuges – Advantage and Disadvantage

Decanter Centrifuge Manufacutures

Decanter Centrifuges  are   machines that are used in separating various densities in a liquid. The separating process is done very efficiently by a decanter centrifuge. There are many advantages and a few disadvantages as well of this equipment.

decanter centrifuges
decanter centrifuges

Advantages:
•    The appearance of Decanter centrifuges is clean and is almost odourless.
•    The decanter centrifuges device can be installed easily and is start up and    shutting process is very fast.
•    It needs minimum area for its operation.
•    The variety in size of the cylindrical bowl and the cone angle allows choosing various applications.
•    With different design curves the system is pre-programmed that calculates the type of sludge.  Due to its flexibility the machine has different functions like the operating for dewatering and thickening.
•     Compared to other smaller machines, the decanter centrifuge operates on a high throughput capacity that minimizes the requirement of units.
•    Its variety and reliability feedback option makes the decanter centrifuge easy to operate and effective.
•    The cost on labour has reduced as it does not require continuous attention for maintaining and operating.
•    The performance level of decanter centrifuge is much higher if compared to other competitive process.
•     For various industrial functions and processes decanter centrifuges are the perfect solution.

Disadvantages:
•    Biological solids with minute density cannot be separated by the decanter centrifuge. This is best done by the tubular bowl centrifuge.
•    At times the decanter centrifuge can be very noisy and also causes vibration.
•    Due to the high G-forces it consumes a large amount of energy.
•    The narrow range with changeable conditions limits the performance of the device.
•    Right type of sealing material should be selected that are both chemical and thermal resistant.
•    Compared to other varieties of centrifuges, the decanter centrifuge is cheaper.

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Decanter Centrifuge – Operation and Maintenance| Kosun Solid Control

Decanter Centrifuge

Decanter centrifuge is one of solid control equipment that  uses centrifugal force to aid to the separation of waste matter.

Drilling operations refers to the very process of extracting oil and gas from the earth for various commercial and industrial purposes. The industry is worth trillions of dollars today and is thus a very important part of any country’s development. In the past few decades, the demand for the products like gas and oil went up significantly. This led to a corresponding increase in the drilling activities all across the globe.

Like any other industrial activity, drilling too is bound to have some sort of waste produced as byproduct. This is termed as drilling waste and the term gained much popularity with the rising issues it caused to the environment. This in turn led to another class of waste management being introduced, known as drilling waste management. It involves several processes from maintenance, management and containment to subsequent handling and disposal of drilling waste promising better sustainability and conservation of environment.

decanter centrifuge
decanter centrifuge

In the various processes involves with drilling waste management , one important step is called waste maintenance. This was earlier done with conventional processes like settling and involves separation of the unwanted matter from the desired part and further storage and transportation. However, with advancements in technology and machinery, today the whole process id mechanized. The most popular equipment dedicated for the process is named decanter centrifuge .

As the name suggests, the machine uses centrifugal force to aid to the separation of waste matter. The machinery has a complicated design but with a very basic and simple concept. The mixed substance obtained directly from extraction is allowed to flow to a disc shaped structure. The disc is then rotated. This rotation calls the centrifugal and gravitational forces into action which facilitates the separation of drilling waste from the fuel. The fuel passes through the hole at the centre of the disk and the waste remaining in the structure is passed on for containment.

The equipment consists of moving parts and hence should be cleaned and kept smooth as possible to avoid reduction in efficiency. Also make sure to cut off the power to the machinery if it is to be dismantled for some purposes.