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Three-Phase Centrifuge Systems

Three-Phase Centrifuge Separation

CentraSep DX Series: Flexible Disc Stack Centrifuges

The CentraSep DX Series of disc stack centrifuges can dynamically switch from being a three-phase separator to a two-phase separator, effortlessly moving from liquid-solid separation to liquid-liquid-solid separation. This makes the DX an asset in many facilities, where it can be deployed at several different stages in a single production process. Think of your CentraSep DX as a standalone programmable filtration module that can efficiently take on whatever separation task you throw at it with minimal operator intervention.

Centrifuge 101: Two-phase Separators vs. Three-phase Separators

Every centrifuge is basically an accelerated settling tank. In a settling tank, gravity pulls the densest materials out of suspension, where they collect on the “settling surface” at the bottom of the tank. 

A centrifuge speeds this process by applying centrifugal force many times that of gravity. This is accomplished by spinning a roughly cylindrical bowl while introducing fluid into the bowl. The centrifugal force generated by the spinning replaces the force of gravity and the outside of the centrifuge’s spinning vessel serves as the settling surface where the densest material collects. 

One of the defining differences among industrial centrifuges is between two-phase separators and three-phase separators. “Two-phase” and “three-phase” refer to how many materials the centrifuge can separate at once. A two-phase separator, like the CentraSep S-126, is generally used to separate a liquid from a solid. (That’s why two-phase operation is often called “liquid-solid separation.”) A three-phase separator removes a solid from suspension while also separating two liquid phases and is thus also called a “liquid-liquid-solid separator”. 

In many industrial centrifuges, the overall shape of the vessel is such that denser material collects and is forced out of one end of the centrifuge, while less dense material flows out the other. Two ends means two-phase separation. Such a centrifuge might be used to pull paint sludge from wash fluid, for example.

But some models go further, changing the interior structure of the centrifuge bowl. This makes it possible to separate multiple materials at once. For example, a good three-phase disc stack centrifuge can remove metal particles from cutting fluid while also separating the cutting oil and any tramp water that’s infiltrated it—all in a single pass.

CentraSep DX Disc Stack Centrifuges

When it comes to industrial three-phase separators, vertical disc stack centrifuges (i.e., “disc bowl centrifuges” or “conical plate centrifuges”) are of special interest because of their flexibility and performance. 

Among vertical disc stack centrifuges, the CentraSep DX Series leads the pack. CentraSep DX disc stack centrifuges have two top outlets (labeled #6 and #7 in the following diagram) and a separate solids collection and discharge at the bottom (labeled #9). With three discharge points, you can have continuous three-phase operation: two different liquid phases flow from the top outlets and sludge or other solid particles drop out of the lower discharge.

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The key element is the “disc stack” (labeled #3). The “discs” are a series of cone-shaped plates arranged in a vertical stack inside of the centrifuge vessel. These increase the amount of available settling surface. Having a greater settling surface doesn’t just speed the separation process and decrease retention time. It also gives you greater control over what’s happening inside your centrifuge. By building your centrifuge with specifically “tuned” stack arrangements, angles, spacings, and shapes, you can accurately control how materials will be separated and allow adjustments in operation to cope with changes in liquid flow and composition.

Owing to this enhanced zone of separation control, the CentraSep DX Series can handle challenging three-phase separations with 70 percent efficiency (or better) on a single pass. When you find yourself running a simpler liquid-solid separation, you can quickly switch to two-phase operation and bump up to nearly 90 percent efficiency on a single pass.

A Process-Oriented Approach to Three-Phase Centrifugal Separation

Trucent is dedicated to a process-oriented approach to separation and purification. We’ve spent decades building teams that bring together people who understand equipment, people who understand liquid separation at a fundamental level, and people who understand your specific fluids, processes, and industry. That team works with you to find the right intervention, use the right technology, and match it to the right application.

Service has been the backbone of Trucent’s business for decades. Trucent Centrifuge Parts and Repair refurbishes, repairs, maintains, and programs all makes and models of high-speed disc stack centrifuges—not just our own.

And we aren’t just here to help when something breaks. 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 do more than just handle fluid purchasing and manage separator technology. They’ll pinpoint contaminants at their source and find ways to separate them from your flow as early as possible.

The results: Top performance in your plant, every single day, hassle-free. No one else offers this level of comprehensive service.

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 liquids pre-process, post-process, and at every important stage along the way. We’ll take samples back to our labs for analysis, then design a separation solution that will meet your spec and your business goals. Trucent pilot tests every solution in our labs, trialing on-site as needed. We never ask anyone to commit to a theoretical solution until we know it will work in the real world.

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Comprehensive Purification, Filtration, and Liquid-Liquid/Liquid-Solid Separation Solutions & Services

Trucent comprehensively addresses your centrifugal and centrifugation needs. We can help you maintain your existing centrifuges and decanters—or design an entirely new liquid-liquid-solid separation solution. We can install one piece of equipment or an entire team to manage all your filtration technology on a daily basis. The goals remain the same: Cleaner fluid, longer tool life, higher quality parts, and a healthier bottom line.

CentraSep Centrifuge DX Series Overview
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CentraSep Centrifuge DX-1040 Technical Data Sheet
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CentraSep Centrifuge DX-1020 Technical Data Sheet
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CentraSep Centrifuge DX-1010 Technical Data Sheet
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CentraSep Centrifuge DX-1002 Technical Data Sheet
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CentraSep Centrifuge DX-905 Technical Data Sheet
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Die Caster Reduces Operational Costs

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Die Caster Avoids Shutdown, Saves Over $200,000

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Plant engineers determined that an annual discharge and cleaning of the central coolant system would pay off in reduced operational costs.

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On top of preventing over 12,500 gallons of chemicals from entering the waste system, the facility was able to bank the overtime hours and over $200,000 in savings.

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