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Given enough time, gravity will always separate fluids of different densities. Oil and water form their own layers, and particles are drawn together and either float to the top or settle at the bottom. You can see it when you look at the different layers formed in a bottle of Italian dressing that’s been left sitting undisturbed.
But it takes time: Fine sand or silt will settle out of suspension in under an hour. Colloidal particles can take years.
Centrifugation is this exact same process, but highly accelerated. This gives us control over various aspects of that separation: How long it takes, how accurately various materials are separated from each other, and how the captured water, oil, chemicals, sludge, slurry, and particles are routed from there.
In many applications, industrial centrifuges and decanters have proven to be the most effective methods of separating and filtering oil, water, and suspended solids. Depending on your application, that can translate into long-lasting (and cleaner) coolant, increased tool life and product quality, decreased maintenance and downtime, or new revenue streams. But the bottom line is always the same: lowered costs and improved ROI.
Over the last 20 years, we’ve combined this technology with existing barrier-based and non-media separator technology—as well as new fundamental research into fluid analytics, chemistry, and purification strategies—to craft custom solutions for a wide range of industries. These include metalworking and manufacturing (stainless steel, aluminum, etc.), utilities and wastewater, glass grinding, biotech and pharmaceuticals, food and beverage, ethanol and biodiesel, waste oil and waste vegetable oil processing, agriculture, and more.
A centrifuge speeds up the natural sedimentation process by spinning materials at high speed, artificially generating a force thousands of times greater than gravity. That rotational speed, coupled with mechanically sound design, makes it possible to directly manipulate many factors that govern how commingled materials behave.
Trucent’s CentraSep DX Series centrifuge machines offer both two-phase and three-phase processing. (“Two-phase” is liquid-liquid separation, usually separating water-based and oil-based liquids or a liquid from a solid; “three-phase” refers to liquid-liquid-solid separation, which separates a water phase, oil phase, and solids.)
The separation takes place in the centrifuge’s bowl, which rotates at high speeds. The diagram above shows a three-phase (liquid-liquid-solid) centrifugal separation process. First, commingled water/oil/particulate flows into the bowl through a feed pipe (1) and into the distributor (2), where it is accelerated until it reaches the bowl’s rotating speed. It is then conveyed to the bowl (3) where the separation takes place. This bowl is divided by many thin discs (the so-called “disc stack”), which dramatically increases the unit’s separation efficiency. In water-based coolant applications, the “light phase” (usually tramp oil) flows toward the center of the bowl and leaves the disc assembly via its inner edge. The clean coolant (or “heavy phase”) flows toward the bowl periphery. The two liquid phases exit the bowl from separate points. Here, two centripetal pumps (4 and 5) convey each phase separately under pressure to its respective outlet port (6 and 7).
Simultaneously, the solid impurities (9) collect on the underside of the discs. They are continually forced to the periphery of the bowl (8), where they are periodically discharged automatically through the discharge holes. The discharged solids are collected into an outer annular chamber connected to a damping sludge tank, where they drain away through a pipe.
We’ve invested a great deal in centrifuges—but we do not limit ourselves to centrifuges. At Trucent, we’re dedicated to a process-oriented approach: We work with you to holistically understand your entire process so that we can find the right intervention, use the right technology, and match it to the right application.
In order to make the most of this approach, we’ve spent decades investing in a team composed of more than equipment experts and engineers. We bring together people who understand decanter centrifuges, separators, non-disposable media filtration, and other equipment and people who understand fluid separation at a fundamental level, in addition to being familiar with your fluids and your processes/industry.
And we can go one step further: Trucent can install a team in your plant to run and manage all your fluids and filtration technology on a daily basis. Your in-house Trucent team will handle fluid buying and filtration, monitor those fluids, and maintain your entire centrifuge systems and filter solution.
Service has been the backbone of our business for decades. If you already have a centrifuge, we can help you get more out of it. Trucent Centrifuge Parts and Repair will refurbish, repair, maintain, and program all makes and models of disc stack centrifuges. If you’re new to media-free filtration, we’re here to work with you and find the right solution, one that will work reliably over the long haul. Our team will get you up and running, train your team, and offer ongoing centrifuge parts, maintenance, and service packages.
No one else offers this level of comprehensive service with centrifuges.
Every solution begins with a conversation. Contact us today to begin that conversation or schedule a no-obligation on-site consultation. A Trucent engineer will “walk your process,” sampling your fluids pre-process, post-process, and at every important stage along the way. We’ll take samples back to our lab for analysis, and then design an oil purification/liquid separation system to meet your spec and your business goals. Every solution is pilot tested in our labs. If needed, we’ll run a no-obligation trial on-site as well.
Trucent provides our customers with comprehensive industrial centrifuge and oil separation/filtration solutions. We can help you maintain your existing centrifuge—or design an entirely new industrial liquid/solid separation solution. We can install one piece of equipment—or an entire team to manage all your technology for you. The goals remain the same: Cleaner fluid, longer tool life, higher quality work, lower costs.
A transmission component supplier had dozens of independent machine tools, each with its own sump. Their existing filtration system was unable to maintain appropriate purity specs, forcing them to frequently “top off” their metalworking fluids. This approach overwhelmed the sumps, sending perfectly good metalworking fluid down the drain.
A Trucent team introduced a new approach to fluid management that included reengineering the customer’s centralized purification system. This approach reduced their coolant concentrate usage by 60%. Consequently, the customer documented decreases in waste treatment costs and water usage. In just four months they saved $30,000 in tooling costs.
“Quick responses, personal service, and knowledgeable technicians are able to achieve desired results with little fuss or disruption of our process.”
Our team will come out for a free on-site consultation.
Every solution begins with a conversation.
With the largest fleet of separation technology, advanced engineering, and chemistry capability across a wide array of industries and experienced operations personnel throughout North America, you can count on us when you need us most.