MegaMacs Centrifuge unit

The Centrifuge unit is self-contained mobile processing system for the secondary phase of separation of liquefied industrial sludge. In addition it can provide a power source to drive various peripheral equipments to extract and pre-process sludge.

Centrifuge unit process description

The feed enters the rotating bowl through a stationary feed pipe and is accelerated out of the feed chamber towards the bowl wall. The centrifugal force generated by the rotation, rapidly settle out the solid particles against the bowel wall. They are transported, by the helical screw conveyor, towards the conical end of the bowl and ejected through the solid' discharge ports.

As the clarified liquid flows along the bowl, centrifugal forces cause the oil and water to separate. This can only be achieved when the correct pretreatment with heat and or additives has been completed.

The water phase moves towards the periphery of the wall and the oil is displaced towards the axis of the bowl. Both oil and water travel axially toward the opposite end from which solids are discharged. A separation disc at the large end of the screw conveyor prevents the remixing of the two liquid phases prior to their discharge. Purified water that passes under the separation disc is discharged over adjustable weir plates on the head wall of the decanter bowl into a separate housing. Purified oil exits via dip tubes fitted through the bowl wall into a separate housing.

Centrifuge unit equipment specification

Trailer specification
Length	480" (12,2 m).
Width	96" (2,44 m).
Height	156" (3,96 m).
Weight	Nominal 55,000 lbs (24.9 ton).
Brakes	S cam, air operate spring brakes.
Wheels and Tires	11R-225 Tires mounted on aluminum wheels.
Equipment specification.
Fuel Capacity	Nominal 600-gallon reservoir with level gauge.
Engine	Caterpillar C-9 275 BHP @ 2200 RPM.
"Three phase" Centrifuge	Three phase centrifuge with full hydraulic main and back drive. Speed 2,800 - 3,300 RPM. Maximum Gravity 3,165 G's. Maximum Capacity 18-20 tons per hour.
Light Phase Pump	Progressive Cavity Pump. 144 GPM @ 87 PSI.
Heavy Phase Pump	Progressive Cavity Pump. 144 GPM @ 87 PSI.
Water and oil collection tanks	Two tanks for collection of water and oil after three phase centrifuge.
Solid conveyor	Discharge solids from three phase centrifuge.
Hydraulic System	System 1 - 52 GPM closed loop system powers the centrifuges main drive at pressures up to 4,000 PSI. System 2 - 23 GPM open loop system powers the centrifuge back drive at pressures up to 3,700 PSI. System 3 - 120 GPM main open loop system that is flow and pressure compensated up to 2,500 PSI powers the balance of the machine and provides for 3 auxiliary circuits to power peripheral equipment.
Uint control system	The unit equipment listed is operated from a central control station.

^ TopThree phase centrifuge

The heart of the system is a horizontal three phase decanter centrifuge that has been modified to provide removal of multiple phases on a continuous basis. The centrifuge features a fully adjustable hydraulic main drive and a unique self-regulating hydraulic back drive. This allow to avoid traditional methods using a two stage separation system such as two phase decanter centrifuge, to remove the solids, followed by a disc separator to split the two liquid phases and complete separation in one stage using one unit.

The combination of these two drives provides a system with multiple advantages over a standard fixed speed main drive and geared back drive, which include the following:

• No gear box to maintain;
• No shear pins to replace;
• No components breakage due to excessive overloading;
• No torsional vibration (chatter). Vibration is hydraulically dampened;
• Direct reading of torque in discharge;
• Minimum moisture in discharge;
• Cleaner centrate;
• Less sensitive to feed fluctuations.

^ TopUnit control system

All hydraulically driven equipment operated from a central control station. The control station is equipped with controls to adjust the speed, and where applicable, the rotation of the centrifuge as well as pumps and conveyor. It also has instruments for monitoring each of the hydraulically driven components' loads and where applicable, rotating speeds. Additional controls for diesel engine are also at this location. The entire unit as well as the peripheral equipment is powered by the onboard hydraulic system which utilize an advanced load-sensing technology to reduce wear and tear and improve fuel economy.

Hydraulic system control

^ TopWater and oil collection tanks

1. Water collection tank
2. Oil collection tank

^ TopSolid conveyor

Solid conveyor to discharge solids from three phase centrifuge

^ TopEngine

Engine Specification

Cylinders and Arrangement	In-line six cylinder
Bore	112.0 mm (4.41 inch)
Stroke	149.0 mm (5.87 inch)
Aspiration	Air-to-air aftercooled
Displacement	8.8 L (537 in3)
Firing Order	1-5-3-6-2-4
Rotation (flywheel)	Counterclockwise
Valve Lash (inlet)	0.38 mm (0.015 inch)
Valve Lash (exhaust)	0.64 mm (0.025 inch)

Caterpillar C-9 275 BHP @ 2200 RPM.






The Caterpillar C-9 Engine is designed for electronic controls. The integral on board computer controls engine operation. Current operation conditions are monitored. The Electric Control Module (ECM) controls the response of the engine to these conditions and to the demands of the operator. These conditions and operator demands determine the precise control of fuel injection by the ECM.

The electronic engine control system provides the following features:

• Engine speed governor
• Automatic air/fuel ratio control
• Torque rise shaping
• Injection timing control
• System diagnostics

^ TopHydraulic Systems

System 1 - 52 GPM closed loop system powers the centrifuges main drive at pressures up to 4,000 PSI.
System 2 - 23 GPM open loop system powers the centrifuge back drive at pressures up to 3,700 PSI.
System 3 - 120 GPM main open loop system that is flow and pressure compensated up to 2,500 PSI powers the balance of the machine and provides for 3 auxiliary circuits to power peripheral equipment.

All systems are equipped with full flow filtration while the main open loop system provides full flow cooling. The 270 Gallons nominal capacity hydraulic reservoir is equipped with temperature and level gauges while the hydraulic filters and minimum tank level are monitored electrically.

^TopLight and Heavy Phase Pump

1. Light (oil) Phase Pump
2. Heavy (water) Phase Pump

^ Top