Flottweg Decanders

FLOTTWEG DECANTERSfor municipal waste and

industrial water treatment

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Clean water is an indispensable

resource – efficient wastewater

treatment is a basic requirement

Decanters for sewage

sludge processing

aeration tank

digestion

digested sludge

(2…6 % ds)

secondary

clarification

wastewater influent

primary

treatment

dewatering

FLOTTWEG

HTS-

DECANTER®

FLOTTWEG

OSE-

DECANTER

surplus (waste) sludge

(0.5…1.0 % ds)

thickening

(4…8 % ds)

solids

(25…35 % ds)

discharge

Typical wastewater treatment plant: mechanical and biological treatment

Decanter centrifuges are used

for the thickening and dewater-

ing of a variety of sludges at

different stages of wastewater

and water treatment.

Sludge dewatered in a

decanter centrifuge is typical-

ly suitable for reuse or dispos-

al, whether for agriculture,

incineration or landfilling.

Modern and effective waste

water treatment is determined

by high cleaning capacity:

the higher this capacity, the

higher the quantity of sewage

sludge which has to be thick-

ened and/or dewatered for

further processing.

In order to meet the require-

ments of different kinds of

wastewater sludge as well as

increasingly stricter legal

regulations, a variety of clean-

ing processes have been

developed.

In all processes sewage sludge

is generated which has to be

dewatered whether it goes to

agriculture, incineration or

landfills.

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FLOTTWEG DECANTERS – adaptable

to any waste water treatment process

FLOTTWEG

HTS-DECANTER®

surplus sludge

(0,8…1,5 % ds)

solids

(typ. 20…25 % ds)

dewatering

influent

effluent

influent influent

1. biological reactor 3. clarification2. biological reactor

4. clarification

Aeration plant with membrane reactor

® = registered trademark in various countries

Sequence Batch Reactor –

(SBR)

Biological treatment takes

place in several sequential

stages. Sludge from static post-

clarification is dewatered using

a decanter. Cake dryness in

the dewatered sludge normally

ranges between 20 and 25 % ds.

Aeration plant with

oxidation ditch

Biological treatment takes place

in an oxidation ditch. Sludge

from the static post-clarification

is dewatered using a decanter.

Cake dryness in the dewatered

sludge normally ranges

between 20 and 30 % ds.

Aeration plant with

membrane reactor

Membrane reactors are used

after biological treatment if the

water coming from the sewage

plant has to be particularly

clean, e.g. if it has to meet the

requirements for bath water

quality. This water can be reused

directly as process water or for

irrigation. Sludge from the

membrane reactor is directly

dewatered using a decanter.

Cake dryness in the dewatered

sludge normally ranges bet-

ween 20 and 25 % ds.

membrane

reactor

FLOTTWEG

DECANTER®

bioreactor

retentate

permeate

solids

(20…25 % ds)

waste water

Depending on the size of a

sewage plant as well as on the

origin of the sludge, different

processes for waste water

treatment are applied. As a

consequence, the diverse kinds

of sludge generated differ in

their physical and chemical

characteristics and thus in their

dewatering behavior.

Due to decades of

experience and consequent

development FLOTTWEG

DECANTERS provide the

optimum dewatering result

for any kind of sludge.

Sequencing Batch Reactor (SBR)

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FLOTTWEG OSE-DECANTERS

for the thickening of sewage sludge

FLOTTWEG OSE-DECANTERS –

advantages in comparison to other

thickening processes

Surplus sludge is thickened

from around 0.5 – 1 % dry sub-

stance to an adjustable 5 – 8 %

dry substance, thereby reducing

its volume by approximately

90 – 95 %. This significantly

supports the ensuing digesting

process; the digester's capaci-

ty can be used more efficiently.

An optimized digesting pro-

cess results in cost reduction

and in an improvement of

sludge quality.

Instead of pure surplus sludge,

it is also possible to process

mixed or primary sludge.

Based on many years of experi-

ence, the FLOTTWEG OSE-

DECANTER (OSE = Optimum

Sludge Thickening) was devel-

oped specifically for sludge

thickening. Its outstanding

qualities are high economic

effectiveness, high reliability, and

minimum maintenance cost.

As a rule, the additional use of

polymer flocculating aids is not

necessary.


are available for flow rates

ranging from around 20 to

250 m3/h (90 to 1100 gpm) per

decanter.

Compact design, small foot-

print, yet high flow rates

Closed design that prevents

odor emission.

Easy to operate and control

through continuous and auto-

matic operation.

24-hour operation without

monitoring.

Limited or no polymer demand,

thereby reducing operation

costs and supporting the

ensuing digesting process.

Low specific energy

consumption.

All product wetted parts are

made of high quality stainless

steel.

Wear protection results in low-

maintenance and long life.

Easy cleaning by flushing

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FLOTTWEG HTS-DECANTERS®

for the dewatering of sewage sludge

FLOTTWEG HTS-DECANTERS® –

advantages in comparison to other

dewatering aggregates

In order to ensure cost-effec-

tiveness, the dewatered sludge

has to be as dry as possible for

further processing – no matter

if the dewatered sludge is

transported, reused, disposed

of in landfills or incinerated.

The FLOTTWEG

HTS-DECANTER® (HTS = High

Dry Substance) is the conse-

quent step in development of

FLOTTWEG's SCHNELL-

DEKANTER from the 1970s.

It was developed especially

for high-efficient dewatering

of sewage sludge.

The FLOTTWEG HTS-

DECANTER® can handle

sludge flow rates from 5 to

150 m3/h (45 to 660 gpm).


Rotor with extra long, cylindri-

cal clarifying zone and opti-

mized cone angle provides

very high separation efficiency.

Scroll with specially shaped

feed zone, clarifying zone, and

pressing zone in the conical

part provides outstanding

results in dewatering.

High bowl speed and resulting

high centrifugal force allow for

flexibility in order to achieve

good dewatering results despite

often poor sludge quality.

Compared to conventional

decanter centrifuges, the de-

watered sludge is up to 10 %

drier with minimal polymer

consumption.

Cake dryness generally equals

the one achieved in filter pre-

sses with polymer conditioning

and often even exceeds it.

Nearly constant cake dryness

of the dewatered sludge, even

with varying feed concentra-

tion and rates.

24-hour automatic operation

possible

Small footprint through high com-

pactness and high flow rates.

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Assembly and function of

FLOTTWEG OSE and HTS-DECANTERS®

FLOTTWEG DECANTER Z6E-4

Scroll

The scroll rotates at a low dif-

ferential speed relative to the

bowl and conveys the deposited

solids toward the conical end

of the bowl. In order to achieve

high cake dryness, an appro-

priate scroll design is critical.

Special constructive measures

have been taken to cause a

compression effect

in the conical part of the

FLOTTWEG HTS DECANTERS®.

The best separation results are

achieved when the solids have a

maximum resident time in the

bowl which is achieved by

extremely low diffential speed of

the scroll. The finely adjustable

scroll gear named SIMP-DRIVE®,

with its powerful torque, allows

for handling a high solids load

necessary for high dewatering

(HTS).

Feed

Sewage sludge enters the feed

zone of the scroll through a

central feed pipe. The sludge is

then accelerated circumferen-

tially and delivered through

distribution ports into the bowl.

Bowl

The bowl has a cylindrical/

conical shape and rotates at a

preset speed optimized for

each individual job. Inside the

bowl, the sewage sludge

reaches full circumferential

speed and forms a concentric

layer at the bowl wall. Under

centrifugal force, the solids

contained in the sewage sludge

settle on the inside

wall of the bowl.

Dosage of Polymer

Flocculant Aids

Flocculant polymers

(polyelectrolyte) are used in

sludge dewatering and at

times in sludge thickening, in

order to enhance drainage

capacity and a clarifying effect.

The flocculant polymers enter

via a mixing pipe and are

thoroughly mixed with the

sludge in the feed zone to

make sure sludge flaking does

not occur before entering the

separation zone. This results in

an optimized use of polymer.

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Liquid-solid separation – FLOTTWEG DECANTER with gravity overflow

solids discharge discharge by gravity

feed inlet

Rotor Bearing

A special bearing design which

meets the requirements of

high-speed centrifuges results

in high availability and long life-

time. According to type and

application, the bearings have

grease or air - oil droplet

lubrication.

Overflow Weir

The clarified liquids flow to the

cylindrical end of the bowl

where they exit over weir

plates. Easily adjustable

precision weir plates allow for

the precise adjustment of the

pond depth in the bowl. Over-

flow is then collected in a

centrate chamber and dis-

charged by gravity.

Materials of Construction

For all product wetted parts,

FLOTTWEG exclusively uses

high-quality, corrosion- and

acid-proof stainless steel. The

bowl is made of high tensile

strength duplex centrifugal

casting, the scroll is of stain-

less steel centrifugal casting.

Wear Protection

All FLOTTWEG OSE and

HTS DECANTERS® have

comprehensive protection

against erosion. The scroll

flights are hard-faced with

tungsten carbide or tiles

(optional). All feed and dis-

charge ports are protected by


Solids Discharge

The solids are ejected with the

defined cake dryness through

ports at the conical end of the

bowl into the solids housing

and fall through the discharge

chute.

bushes made of different types

of hard metal, such as hard

cast or silicon carbide ceram-

ics which can be replaced on

site. Other areas exposed to

wear, such as bowl wall, feed

zone, housing, etc., also

feature highly efficient

wear protection.

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FLOTTWEG SIMP-DRIVE®

The FLOTTWEG SIMP-DRIVE®

controls the differential speed

in relation to the scroll torque.

Therefore the decanter adapts

itself to varying load conditions

and dewaters the sludge in

order to reach maximum cake

dryness. At the heart of it is a

multi-stage planetary gear, the

SIMP-DRIVE®, with special

coupling, which allows for en-

tirely independent drives capa-

bility of the bowl and the scroll.

Low specific power

consumption due to:

– High efficiency

– Completely motoric drive

system

High cake dryness:

– Uniform drive

– Constant torque

High availability:

– No over-dimensioned drive

motors

– No energy linkage via circuit

coupling

– Standard frequency inverters

and electric motors

applicable

You benefit from

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Noise Protection

All FLOTTWEG OSE and

HTS-DECANTERS® include a

noise protection cover as a

standard. Sound pressure varies,

depending on operating condi-

tions, between 75 and 85 dB(A).

FLOTTWEG SYSTEMS

FLOTTWEG provides complete

process lines on demand. Due

to many years of experience in

the layout and manufacturing

of thickening and dewatering

systems, FLOTTWEG is able to

offer customized optimum

solutions. Our own production

of control units and systems

allows for quick and compe-

tent handling of orders.

FLOTTWEG SYSTEMS are

available as permanent,

mobile, and semi-mobile units

(Plug and Play).

FLOTTWEG DECANTER Z4E-4


Technical Data

Type C3E-4 Z4E-4 Z5E-4 Z6E-4 Z73-4 Z92-4

Materials of All product wetted parts are made of high grade stainless steel such asconstruction 1.4463 (Duplex), 1.4571 (AISI 316 Ti), etc.

Dimensions

L 2 980 mm (118") 3 500 mm (138") 4 200 mm (165") 4 800 mm (190") 4 815 mm (190") 5 740 mm (226")W 940 mm (37") 1 000 mm (40") 1 600 mm (63") 1 705 mm (68") 2 350 mm (93") 2 780 mm (110")H 900 mm (35") 1 200 mm (48") 1 150 mm (45") 1 500 mm (60") 1 500 mm (60") 1 730 mm (68")

Gross weight* 1 700 kg 3 000 kg 6 200 kg 9 230 kg 11,000 kg 16,200 kg3 800 lb 6 700 lb 13,700 lb 20,500 lb 24,500 lb 36,000 lb

Motor for 18,5 kW 22 – 30 kW 45 – 75 kW 55 – 90 kW 75 – 110 kW 110 – 200 kWbowl drive 25 hp 30 – 40 hp 60 – 102 hp 75 – 122 hp 102 – 150 hp 150 – 272 hp

Motor for 4 kW 4 kW 5,5 kW 5,5 kW 5,5 kW 7,5 kWscroll drive 5 hp 5 hp 7,5 hp 7,5 hp 7,5 hp 10 hp(FLOTTWEGSIMP-DRIVE®)

Feed capacity 15 – 30 m3/h 20 – 40 m3/h 35 – 70 m3/h 50 – 90 m3/h 80 – 130 m3/h 120 – 250 m3/h60 – 120 gpm 90 – 180 gpm 150 – 300 gpm 200 – 400 gpm 350 – 600 gpm 500–1000 gpm

* The listed figures are guidelines for information only. Actual capacity depends on the characteristics of the feed.


for thickening

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FLOTTWEG DECANTER Z92-4

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* The listed figures are guidelines for information only. Actual capacity depends on the characteristics of the feed.

FLOTTWEG HTS-DECANTERS®

for dewatering

FLOTTWEG DECANTER C3E-4


Type C3E-4 Z4E-4 Z5E-4 Z6E-4 Z73-4 Z92-4

Materials of All product wetted parts are made of high grade stainless steel such asconstruction 1.4463 (Duplex), 1.4571 (AISI 316 Ti), etc.

Dimensions

L 2 980 mm (118") 3 500 mm (138") 4 200 mm (165") 4 800 mm (190") 4 815 mm (190") 5 740 mm (226")W 940 mm (37") 1 000 mm (40") 1 600 mm (63") 1 705 mm (68") 2 350 mm (93") 2 780 mm (110")H 900 mm (35") 1 200 mm (48") 1 150 mm (45") 1 500 mm (60") 1 500 mm (60") 1 730 mm (68")

Gross weight* 1 700 kg 3 000 kg 6 200 kg 9 230 kg 11,000 kg 16,200 kg3 800 lb 6 700 lb 13,700 lb 20,500 lb 24,500 lb 36,000 lb

Motor for 18,5 kW 22 – 37 kW 45 – 90 kW 75 – 110 kW 90 – 132 kW 160 – 250 kWbowl drive 25 hp 30 – 50 hp 61 – 122 hp 102 – 150 hp 122 – 180 hp 218 – 340 hp

Motor for 4 kW 7,5 kW 7,5 – 15 kW 15 – 22 kW 22 – 30 kW 30 –45 kWscroll drive 5 hp 10 hp 10 – 20 hp 20 – 30 hp 30 – 40 hp 40 – 61 hp(FLOTTWEGSIMP-DRIVE®)

Feed capacity 5 – 20 m3/h 15 – 30 m3/h 25 – 50 m3/h 40 – 70 m3/h 50 – 110 m3/h 80 – 150 m3/h20 – 80 gpm 60 – 120 gpm 100 – 200 gpm 160 – 280 gpm 200 – 440 gpm 320–600 gpm

Representative:

PR

– 0

004 L

– 1

0 4

0

5 /

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FLOTTWEG OSE and HTS-DECANTERS®

for thickening and dewatering

of sewage sludge

Robust design

FLOTTWEG OSE and HTS

DECANTERS® are designed

to meet the requirements for

sewage sludge processing.

They stand out for:

– long lifetime

– high availability

– low maintenance downtime

Service

FLOTTWEG DECANTERS

are designed and manufactured

for ease of operation and

maintenance:

– minimum lubrication of bearings

(grease or oil-air)

– outside-mounted gearbox

– interchangeable rotors

– on-site interchangeable

wear parts

All these features result in

our machines' unique availability

at minimum maintenance cost and

downtime.

ISO certification

FLOTTWEG is ISO 9001 certified

and manufactures all products

in compliance with all current

technical standards.

FLOTTWEG products

are designed and manu-

factured in GERMANY!

References

FLOTTWEG OSE and

HTS DECANTERS® are operating

reliably in many municipal and

industrial wastewater treatment

plants around the world, in big

cities such as Hamburg, Berlin,

Baltimore, Rome, Athens, Los

Angeles, Sydney, and others, but

also in small towns with mobile

waste management and industrial

companies, such as dairies,

tanneries, breweries, paper mills,

and refineries.


Flottweg Decanders

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