With the comprehensive advancement of industry and intelligent manufacturing, mechanical separation equipment has ushered in a wave of technological revolution. As one of the core equipment for liquid-solid/liquid-liquid/three-phase separation, disc centrifuges are widely used in biopharmaceuticals, food processing, petrochemicals, fine chemicals, environmental protection and recycling industries due to their high separation efficiency, wide adaptability and high degree of automation.
Based on traditional applications, the core performance parameters of disc centrifuges are gradually upgraded to “high speed” and “high precision” to meet the multiple needs of modern industry for processing capacity, separation purity, energy efficiency level and intelligent control.
Overview of the basic structure and separation principle of disc centrifuge
1. Core structure of the equipment
The disc stack centrifuge is a high-speed separation equipment with a precise structure. Its core components include:
Drum system: It consists of a group of discs arranged in a cone, which rotate at high speed to generate a centrifugal field.
Disc stack: The fluid distribution channel is formed by multiple layers of discs to increase the separation area and improve the processing efficiency.
Drive system: The drum is driven by an electric motor, and some high-end models introduce a variable frequency drive system.
Automatic slag discharge system: According to the characteristics of the separated materials, it is divided into intermittent slag discharge, timed slag discharge and fully automatic slag discharge.
Control system: Modern equipment is widely equipped with PLC+HMI touch screens to realize automatic start and stop, data collection, remote control and other functions.
2. Brief description of working principle
The raw materials enter the drum through the feed inlet and are distributed between the discs through the guide device to form an extremely thin liquid layer. The material generates a high g value (gravitational acceleration) under high-speed rotation, and the high-density components are thrown to the outer edge of the disc and discharged from the slag discharge port; the low-density components move closer to the center and flow out from the light phase outlet.
This process can be completed within 1 to 2 minutes and is suitable for separation scenarios of materials with micron-level particle diameter, low concentration and high output.
High-precision control technology
1. Definition and measurement standards of precision
The “separation precision” of disc centrifuges usually includes the following dimensions:
Solid content separation precision: suspended matter content in liquid after separation (ppm level);
Emulsion phase separation effect: purity of light and heavy phases in liquid-liquid separation (up to 99.8% or more);
Separation stability: maintain continuous liquid clarification under material fluctuation conditions;
Repeatability and consistency: batch stability and high degree of automation.
2. What technical support does high precision come from?
(1) Optimized flow field design
Use CFD (computational fluid dynamics) simulation to optimize the disc structure, feed distributor shape, and slag discharge channel path, so that the liquid flows evenly and stably between the discs, improving the separation efficiency from the source.
(2) Online monitoring and closed-loop feedback control
Use online turbidity meters, densitometers, and pressure sensors to monitor the state of the outlet material in real time, and automatically adjust the speed and feed flow rate through the PLC system to achieve dynamic and precise control.
(3) Fully automatic slag discharge technology
The high-precision slag discharge system automatically determines the timing and method of slag discharge based on load pressure and vibration data, avoids the back-mixing of residues, and keeps the separation chamber clean and stable.
Application in multiple industries
1. Biopharmaceutical industry
In the production of vaccines, enzyme preparations, and antibody drugs, high-speed disc centrifuges can achieve the following while maintaining the activity:
Separation of microbial cells;
High-purity protein concentration;
Continuous processing under aseptic conditions;
Minimum cell residue < 500ppm.
2. Plant extraction industry
Clarification of Chinese medicine concentrate;
Removal of fiber residues from plant protein;
Separation of coconut milk and almond milk;
Achieve continuous and stable production, with batch purity fluctuation less than ±0.3%.
3. Food and dairy industry
Cream separation, skim milk processing;
Yogurt fermentation liquid, soy milk filtration and clarification;
Liquid clarity increased by 1.5 times;
Save more than 15% cooling water per ton of dairy products.
4. Oil and fat chemical industry
Degumming and dehydration of animal and vegetable oils;
Recycling and purification of industrial waste oil;
The removal rate of water impurities in viscous oil can reach more than 98.5%.
“High speed” brings stronger separation ability, “high precision” brings higher product quality, and the combination of the two makes disc centrifuge the representative of contemporary high-end separation equipment. The future market will belong to those manufacturers who continue to invest in research and development, master core technologies, and can provide intelligent customized services.
As a powerful enterprise in the field of disc centrifuges in China, we always insist on driving development with technological innovation and leading product design with customer needs. We provide integrated solutions from sample testing, solution design, equipment manufacturing to after-sales service to help customers stand out in the fiercely competitive industrial environment.
