Westfalia Separator
Industry
Mechanical Separation
Division
Chemicals,
Pharmaceuticals
and Biotechnology
Contents
Preface
3 Innovation is our Tradition
Chemistry
4 The Element of Safety
Pharmaceutical Biotechnology
12 The Cell Culture
of Medical Advance
Extraction
23 The Gentle Laboratory
Mineral Processing
31 The Key to the Nanocosmos
Service
38 Westfalia Separator WESERVE®
Westfalia Separator
Industry
Innovation is our Tradition
It takes up to ten years to develop a drug and requires investments in the
billions to improve existing processes and to develop new products and
processes; this is the challenge we must rise up to.
The industrial production of chemical,
pharmaceutical and biotechnological
products places high demands on the
process technology used. Here, in particular, on mechanical separation technology, which is gaining in importance
in these markets. This is because the efficiency of the separating process is increasingly impacting the quality of the
end product as well as the economy and
environmental-compatibility.
Westfalia Separator has played an instrumental part for more than 110 years in
the advancement of mechanical separation technology. The separators, decanters and process lines represent quality at
its highest level and state-of-the-art
mechanical engineering and process
technology.
Innovations with substance
The basis for the innovative strength of
the company are enormous investments
in research and development as well as
close cooperation with universities,
research establishments and industry.
Using this approach, Westfalia Separator
has developed numerous innovative
separating processes and brought them
to market by applying first-class engineering. Today, the company can
handle over 2500 processes.
Westfalia Separator utilises this potential
and the process engineering advantages
of centrifugal separation technology in
the chemical and pharmaceutical industries and in biotechnology.
The separating systems and process lines
from Westfalia Separator set international
standards in all their fields of performance
in terms of constant quality, safety and
hygiene that meets CIP and SIP requirements. They are also distinguished by high
availability and economic operation.
Success in demanding markets
The centrifuges and process lines
provided by this business unit have a
proven track record in the processes of
clarification, separation, classification,
concentration and fractionation. The
broad application spectrum includes
human blood fractionation, the recovery
of plant extracts for medication and the
recovery of insulin. Westfalia Separator
has also made possible significant
progress in the separation of microorganisms and their fragments, for
example, in the production of vaccines,
interferon, antibiotics and enzymes. In
the recovery of superfine particles down
to the nano range the centrifuges assure
all specified quality grades by way of an
extremely precise classification cut. They
provide maximum protection and safety
where concentrated acids and explosive
materials are processed, for instance in
the chemical industry.
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The path to good cooperation
The customers of the Business Unit Chemistry, Pharmaceuticals and Biotechnology
benefit from short decision-making processes and specialists who are among the
best in their field. They bring up-to-date
expert knowledge, motivation and
personal responsibility for their work
results into the partnership.
Chemicals, Pharmaceuticals and Biotechnology – Chemistry
The Element of Safety
In hardly any other sector of industry does safety have such a high priority as
in chemistry. Where concentrated acids and explosive substances are part of
day-to-day business, separators and decanters must show that they are made
of strong stuff.
Without chemistry modern civilisation is
unimaginable. Since its alchemistic
beginnings it has developed quickly in
recent times to become a natural science
that proves time and again that it is the
engine of progress. Names such as
Michael Faraday (benzene), Marie Curie
(radium) or Justus Liebig (mineral fertilisers)
are examples that are linked with discoveries and inventions that today we cannot imagine being without.
The secret rulers in everyday life
Whether tensides in detergents, PVC in
floor coverings, or phosphoric acid in
soft drinks: chemistry rules the world.
There is practically no part of life that is
not, to a greater or lesser extent, influenced by the developments in the
chemical industry. However, it is a long
Westfalia Separator
Industry
way from commercial printing inks, latex
mattresses or artificial leather bags. In
the chemical and petrochemical industries
many complex and resource-intensive
processes are required to extract those
materials from which an extremely wide
variety of everyday goods are subsequently produced.
The mechanical separation of substances
and phases is a core element of these
processes. Separators and decanters are
subject to extraordinary requirements.
Concentrated acidic and alkaline compounds, explosive mixtures, high temperatures and pressures demand everything
from the materials concerned. The fact
that Westfalia Separator’s technology is
able to prove itself under these extreme
conditions is shown, for example, in the
production of polyethyl-enterephthalate,
better known as PET.
In many situations reusable bottles made of
PET put the competition in the shade. They
are not only significantly lighter than glass
bottles, but also stand out in comparison with
other plastic bottles by providing a better
barrier function for gases such as carbon
dioxide and oxygen.
PET – multitalented, with a unique
future
Since mass-produced plastics were first
manufactured at the start of the 1920s,
they have been amongst the most soughtafter industrial materials ever produced.
The demand for end products made out
of plastic is developing at a breathtaking
speed, so that petrochemistry is permanently faced with the challenge of devel-
oping technologies that are economically
and ecologically adequate for the
production of market-driven products.
Currently the plastic PET is creating particular interest. For this material alone the
worldwide consumption in 2000 was
already 29 megatonnes.
Polyethylenterephthalate, better known as
PET, is one of the most important plastics for
the future. With the extraction of terephthalic
acid, one of the two chemical intermediate
products, Westfalia Separator is making an
important contribution to its non-stop progress
worldwide.
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Xanthan is a microbiological multi-talented
substance that keeps food fresh for longer and
provides a ’pleasant feeling in the mouth’.
The long-chained polysaccharide is the
metabolic product of a special type of bacteria
that is cultured in fermenters. Westfalia
Separator’s know-how comes into play when
the xanthan is harvested. Decanters wash,
clarify and remove water from the substance
By far the largest proportion of this
quantity was in the production of PET
fibres, e.g. for carpets, upholstery, clothing, or seatbelts. PET fibres are particularly easy to clean and are resistant to
deformation when subjected to mechanical and thermal loading. In addition to
its use as PET film, this plastic is of outstanding significance for the drinks
industry. PET bottles put their competition in the shade in the most important
sectors. Compared with conventional
glass bottles, bottles made of PET are
much lighter. Transportation and handling are therefore much easier. At the
same time PET bottles provide a significantly better barrier to gases such as
carbon dioxide and oxygen when compared with other plastic bottles. Thus
the drinks can maintain their quality for
significantly longer. Last but not least,
they are also suitable as reusable products and can be recycled at the end of
their lives.
Technology from Westfalia Separator is
used in the production process of this
plastic at various stages. For the production of PET purified terephthalic acid (PTA)
is required as an intermediate product.
This dual acid-organic compound is in turn
extracted with the aid of centrifugal
separation forces. Centrifuges play a
major role in the recovery of catalysts.
Special nozzle separators separate the
catalysts out of the carrier liquid from
the catalysis process and in this way
provide a double advantage: firstly the
catalysts can be fed back into the
production process so that the latter
becomes more economical and resourcefriendly; secondly, the catalyst product is
now very pure and thus possesses
optimal quality for the next process step.
Since in catalyst recovery one is dealing
with an ignitable product, the separators
are designed to be explosion-proof so as
to eliminate any safety risks.
as far as possible.
With the compact disc, polycarbonate has
climbed up the hit list of international
materials. For its extraction Westfalia
Separator supplies both individual machines
and also complete process lines to guarantee
extreme cleanliness and a minimal residual
water content in the organic phase.
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Ship’s hulls can today be manufactured from
so-called sandwich layers. Here very large
quantities of polyurethane (PU) are foamed in
between two steel walls, to improve
buoyancy.
From nitroaromatics to
sandwich hulls
An equally impressive example is the use
of separators in the production of nitroaromatics. Trinitrotoluene, abbreviated
to TNT, is an aromatic compound of this
kind, which in this case arises from the
nitration of toluene. If one thinks of the
immense explosive energy of TNT, it is
easy to imagine why production has to
take place in a secure bunker. The
nitration of aromatics such as benzene,
toluene and xylene is one of the most
important processes in the chemical
industry. For generations now it has
been impossible to imagine this process
without Westfalia Separator’s separators.
However, the production of explosives is
today no longer the most important
reason for nitrating an aromatic. While
MNB (mononitrobenzene) is produced
from the nitration of benzene, this also
lays the foundation stone for an
important intermediate product: aniline.
Up to 95 percent of the world’s production of MNB is used in the manufacture
of aniline, which is then used as the
basic material for isocyanates, pharmaceuticals, synthetic rubbers and the
majority of the dyes with which we are
familiar. The nitration of toluene on the
other hand is primarily of significance
today for the manufacture of polyurethane (PU) – a material for which the
global demand has risen dramatically in
recent years, primarily because the car
industry places great store on the use of
this versatile and extremely cost-effective
material. A further example of largescale industrial utilisation is the sandwich
method of construction, a groundbreaking
technology that has revolutionised the
whole steel construction industry. Sandwich technology is used in bridge building,
in the construction of sports stadiums and
in shipbuilding, where it is optimising
the safety and longevity of modern ships.
In the so-called sandwich plate system
(SPS), fluid PU is filled into the hollow
space between two steel plates, and by
virtue of its adhesive effect connects the
steel. The PU solidifies within a few hours
into a compact elastomer, providing
ships’ decks and external sidewalls with a
new stability. At the same time this
sandwich filling is sufficiently elastic to
absorb vibration, or to distribute the
impact of a collision evenly.
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Nitroaromatics are aromatic compounds that
are generated from the nitration of aromatics
such as benzene or toluene. From the nitration
of benzene, for example, mono-nitrobenzene
(MNB) is produced, the intermediate product
from which in turn another intermediate
product of worldwide importance is produced:
aniline - the basic material for many pharmaceuticals, synthetic rubbers and the majority of
the dyes with which we are familiar.
Explosion-proof centrifuges from Westfalia
Separator offer maximum safety and costeffectiveness. A quite essential design feature
of the gas-tight separators is the sealing
chamber, which separates the drive with motor
and gearbox from the product space. The
sealing chamber prevents the passage of
solvent from the product space into the drive
space or the environment. This innovation is
not only relevant for reasons of fire and
environmental protection. It also means that
solvent is unable to thin the oil, reducing its
lubrication properties and endangering the
drive unit.
And vice versa: no oil can gain access to the
product space, something that would have a
negative effect on the quality of the resource.
Protective suits remain in the lockers
Incoloy protects against corrosion
The separators in the TC range, which
are used in the manufacture of nitroaromatics, provide perfect all-round
protection for people, the machinery
and the environment. All parts that are
in contact with the product are configured in a special acid-resistant material
that is able to withstand the etching
effect over the long-term. The fact that
special protective suits for the personnel
can remain in the lockers is thanks to
technical details such as the special exit
holes in the bowls of the separators.
They ensure that when the machine is
stationary no product remains behind,
so that operators can no longer come
into contact with the critical substance.
Furthermore the total separator is manufactured in an explosion-proof configuration that conforms to the testing criteria
of the strict European ATEX directive. In
addition to the explosion-proof form of
construction the Westfalia Separator
centrifuge is purged before the start of
operations with a so-called inert gas,
and is subjected to a slight overpressure
so that no oxygen can penetrate from
the environment: where there is no
oxygen there can of course be no fire.
Manufacturers of synthetic products
working with Westfalia Separator therefore profit not only from cost-effective
production, but at the same time are
setting standards for the total protection
of people and the environ-ment.
Westfalia separator centrifuges are used
for the separation both of the nitro aromatic from the sulphuric acid after nitration, and also of the water after washing.
In general it is separators in the TC range
that are used in the nitration of aromatics.
The cleaning of the sulphuric acid is
undertaken by special type KC 100
chamber separators.
TC generation separators are impressive
down to the smallest detail, as shown by their
technically refined centripetal pumps. These
pumps enable exact adjustment of the
separating zones even with very high
differences in density. Only in this way can
an optimal accuracy of separation be achieved,
as for nitroaromatics, for example.
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All today’s international market leaders
are working with this advanced technology because of the many advantages
that extend across the whole of the
process chain. The compact machines
work in a very confined space. With the
enclosed removal achieved by centripetal
pumps they remove the phases that are
to be separated under pressure and free
of foam. Moreover, from the accuracy of
separation the nitroaromatics extracted
exhibit a high level of cleanliness.
Machine components are also of an
unusually high quality. Depending on
product and temperature, Westfalia
Separator is able to use the special
material Incoloy for separators used in
nitration; Incoly is a material that benefits
from extremely high resistance to
corrosion.
Worldwide, only Westfalia Separator has
the know-how to coat separator bowls
with Incoloy. Also centripetal pumps,
centripetal pump chamber covers, the
disk stack and the regulating rings can
be manufactured in solid Incoloy without
any problems. Needless to say, all seals
are also uniformly designed to deal with
the aggressive materials. All alternative
manufacturing processes for the production of nitroaromatics require some
reaction stages that have risks attached.
The potential, therefore, for these continuously operating separators, appears
great.
Colours and paints contain the smallest
coloured particles. Only if these have the
correct size can the colouring and protective
function be achieved as required. The solution
lies in centrifugal separation technology.
Classifying decanters and separators guarantee
that only particles of the required size remain
in the end product.
Solid-liquid
Clarification
Suspension
Water
Washing
Liquid-liquid
Separation
of liquids
concentration
removal
of emulsions
Separator with
Sulphuric acid
chamber bowl
Disk separator
Nitration
with non-self
of aromatics
cleaning bowl
Peroxides
Polycarbonate
Separator with
Cellulose
self-cleaning
Printing colours
bowl
Oil additives
Xanthan
Nozzle separator Catalytic
Barium sulphate
CTA
segregation
Hydroxides
(Crude
Phosphoric acid
tereph-
CTA
thalic acid)
Decanter
Printing colours
Barium sulphate
Boiler ash
Catalytic
segregation
Oil additives
Phosphoric acid
Xanthan
Oil additives
PVC
Xanthan
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Westfalia Separator
Applying the coating
to the bowl bottom
Dye penetration
test after fusing of
the coating
Bowl bottom with
finished coating
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The optimal separation conditions are – e.g.
for many oil additives – at 160 °C. The SB 60
Westfalia Separator machines fulfil not only
Separator has been specially developed for
the strict European directives for areas where
such high-temperature applications. Special
there is the risk of explosion (ATEX).
steels, flexible bowl rotational speeds and
high-tech seals ensure a high product quality
With the inert gas design that has been further
and eliminate any safety risk for the operating
developed new standards are being set with
personnel.
respect to safety and reliability.
Advantages in summary
Optimal separation of two liquid
phases with very low solids content
Minimal shear force
Use of double centripetal pumps
(removal of both separated phases
under pressure) even with high
differences in density
Metering piston mechanism for
strongly compacting solids
Exact metering of discharge
quantities
HydroStop – extremely fast,
accurate and flexible ejection
Discharge holes for discharge with-
out residues of critical substances
when the machine is stationary
Special centrifuges for hightemperature applications
Separation in the smallest space
increases safety
High level of product cleanliness
Gas-tight, explosion-proof
machines conforming to ATEX 95
(RL 94/9/EG)
High corrosion resistant materials
Special materials for productcontacted areas for protection
against acids, etc.
Maximum protection against wear
Applications of separators and decanters
a) In organic and inorganic
chemistry:
Aldehydes / alcohols
Barium sulphate
Recovery of alkaline salts (boiler ash)
Celluloses and derivates
Printing colours / inks
Colours / paints / resins
• Aniline colourings
• Clear lacquers
• Coloured lacquers
• Epoxy resins
• Amide resins
• Phenolic resins (bakelite), etc.
Gum arabic
Catalytic segregation
Cosmetic and hygiene products
Alkalis
Luminescent materials
Solvent recovery and clarification
Nitration of aromatics
Nylon, caprolactam
Oil additives
Pesticides
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Peroxides
• Recovery of peroxides
• Recovery of working solutions
Phosphoric acid
Polyacetates
Acids (inorganic and organic)
Suspensions with
• hydroxides
• metals
• oxides
• salts
Viscose, cellulose acetate
Xanthan
b) in petrochemistry and plastics
manufacture:
Plastic suspensions
(e.g. PVC, polyacetate)
Polycarbonates
PTA (purified terephthalic acid)
Chemicals, Pharmaceuticals, Biotechnology –
Pharmaceutical Biotechnology
The Cell Culture
of Medical Advance
Pharmaceutical biotechnology researches and develops the high-tech
medicines of the future. For its highly sensitive biomaterials a correspondingly
protective process is absolutely essential.
For the development of high-tech medicines
biotechnology needs recombinant proteins.
These are proteins identical to human proteins
that can be extracted with the aid of
genetically modified micro-organisms.
While small proteins such as insulin can also
be synthesised from bacterial cultures,
for more complex proteins mammalian cell
cultures are required.
Medicine in the 21st century can look
back at amazing successes. Many of the
diseases that previously had devastating
effects have been completely conquered,
while others have lost much of their
terror. Nevertheless enormous challenges
remain. Diseases continue to propagate,
and certain diseases, now as before,
remain unsolved puzzles.
Pharmaceutical biotechnology has moved
into position to become a major hope for
the future. This applications-oriented
science has assumed an absolutely key
role in modern pharmacy. While much of
its earlier work involved the fermentation
of bacteria and yeasts for industrial-scale
production of low molecular drugs, such
as antibiotics, the spectrum today is very
much broader. It extracts vaccines,
insulin from biomass, enzymes, human
blood proteins, and synthetic pharmaceutical products, for new medicines
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that are often ground-breaking. One of
its most significant areas of activity is
currently centred on the production of
so-called recombinant proteins. These
are proteins that are identical to human
proteins, such as insulin, which can be
extracted with the aid of bacterial cultures
or yeasts. In these highly sensitive production processes Westfalia Separator’s
centrifugal separation technology plays a
key role. It has the task of separating out
the valuable resources from the fermentation phase and making them available
for further processing. Optimal product
protection and maximum levels of product cleanliness are the most important
objectives here. How Westfalia Separator
has overcome these challenges is demonstrated by the prime example of advanced
cell culture technology using mammalian
cells.
Research into human stem cells is one of
the most significant future medical fields.
The experience gained with mammalian cell
cultures is providing a valuable impetus.
Cell culture technology with
mammalian cells – mankind’s hope
for the future
When the cultivation of mammalian cells
was still in its infancy in the 20th century,
academic questions took first precedence. The procedure was used to
understand better how cells function,
with the intention of allowing this
knowledge to flow into tumour research,
for example. But in recent times cell culture technology using mammalian cells
has executed what amounts to a quantum leap. Today it makes possible applications that would be unimaginable
without this technology. These include,
for example, experiments with transgenic
animals: here it is only the cultivation of
mammalian cells that makes possible the
transfer of the foreign genetic material.
Within industrial-scale utilisation the
develop-ment of pharmaceutical proteins
is assuming particular significance. Here,
cell culture technology is the first choice,
because the proteins can be exhibited
with the mammalian cells in their active
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Westfalia Separator
form, the so-called quarternary structure.
While relatively small proteins such as
insulin can also be synthesised with the
aid of bacterial cultures, many others are
so complex that their production relies
on recombinant cells of animal origin.
And cell culture technology can satisfy
the growing worldwide demand for
blood clotting factors, monoclonal antibodies, interferon and other protein
substances. At the same time the development of these cultivation techniques
is assuming even greater significance,
since it also provides an important
impetus to stem cell research.
The production of biotechnology resources can
be separated into a manufacture phase
(upstream process) and a purification phase
(downstream process). In comparison with
production techniques using microorganisms
such as bacteria or yeasts the downstream
process steps can be significantly reduced by
the use of mammalian cell cultures.
Hydrohermetic feed system for high
vitality
To remove contaminants and unwanted
solids reliably from the production
process, centrifugal separation technology comes into play. It is easy to understand that the cell bodies are extremely
sensitive. If one wishes to generate
pharmaceutical levels of quality, the
production process must therefore work
both protectively and reliably. Only in
this way can high vitality and protein
activity be achieved. Particular attention
must be given here to ambient effects,
such as shear stress, that can influence
the characteristics and productivity of
the cells negatively. Westfalia Separator
has therefore optimally adapted its
separators to cell culture technology in a
number of critical details. One of the
most important innovations in this
context is the hydrohermetic feed developed internally within the company. This
feed system avoids the generation of
shear forces as the product enters the
Mammalian cells are cultured in fermentation
liquids with low solids content. This allows the
use of mechanical separation technology with
high performance separators providing very
good yields. The products are handled gently.
Clarifiers from Westfalia Separator provide
biotechnologists with an instrument that is
oriented toward both the product and the
market.
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High mass
flow rate
in the feed
Low mass
flow rate
in the feed
The production of biotechnology resources can
Viscosity-controlled nozzles (VISCON®) ensure
be separated into a manufacture phase
constant concentrations in solids removal in
(upstream process) and a purification phase
Westfalia Separator’s nozzle separators. Thanks
(downstream process). In comparison with
to VISCON® technology, separators in the
production techniques using microorganisms
HFA range are setting the standards in the
such as bacteria or yeasts the downstream
refinement of starter cultures, hormones and
process steps can be significantly reduced by
pharmaceutical proteins.
the use of mammalian cell cultures.
separator bowl. Thus the product enters
under the surface of the liquid. The patented system enables a fluid level up to
the axis of rotation, under which level
the flow of product can be gently fed
into the filled bowl and accelerated. In
this way maximum protection of the cell
walls is guaranteed with absolute product
cleanliness at the same time. This has
been confirmed by a series of scientific
tests at the University of Bielefeld.
Westfalia Separator VISCON® –
constant concentration in solids
removal
Nozzle separators using the Westfalia
Separator VISCON® system are setting
new standards in solids removal. The
viscosity-controlled nozzles are not
positioned at the edge of the bowl, as is
the case with conventional separators,
but on a smaller diameter within the
bowl. The nozzles were moved, because
pressures up to 250 bar are present at
the periphery of the bowl, whereas
towards the centre they are significantly
lower. Similarly therefore, the separated
micro-organisms are only subjected to
shear forces that are significantly lower.
As a result of these innovations in product
addition and removal, the cell activity of
the separated cells increases significantly.
However, the product-oriented configuration of the machines, as well as their
marketable cost-effectiveness, contribute not only to success in the cultivation
of mammalian cells. The following
examples demonstrate the range of use
of the separators in a very wide variety
of processes in modern biotechnology.
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Westfalia Separator
In many biotechnological processes, such as
the recovery of vaccines, an aseptic process
is the prime requirement. The separator
must therefore not only be easy to clean, but
must also be part of a sterile system that is
completely enclosed.
Steam sterilisation (SIP), fully automatic
cleaning facilities (CIP), and a special design for
clean-room applications ensure that machines
and facilities from Westfalia Separator are the
natural choice for these sensitive applications.
The highest sanitary and hygienic demands are
fulfilled by a facility built to conform to GMP
standards.
Aseptic processes for vaccines
Prevention is better than cure: when in
1796 the English country doctor Edward
Jenner developed the first protective
vaccine against smallpox, it quickly
became clear that this new form of prophylaxis would be a blessing for mankind.
Today it is possible to hold many dangerous diseases in check through the
immunisation of broad swathes of the
population. In poorer countries in
particular, where it is difficult to meet
the costs for the treatment of diseases
that have already run riot, vaccination
has huge significance as a preventive
measure. The frantic attempts to develop
vaccines to counter the global menace
of the AIDS virus are making the
economic context ever more significant.
Westfalia Separator’s centrifuges are
supporting procedures for the development of both live vaccines and also
serum vaccines. While live vaccines come
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from weakened agents and serve as true
prophylactics, people who are already ill
can be treated with serum vaccines
(serum with antibodies from immunised
people). In both procedures an aseptic
process is absolutely essential for extraction of the vaccines. The separator must
therefore not only be easy to clean,
but must also be part of a sterile system
that is completely enclosed. Westfalia
Separator’s sterile separators demonstrably fulfil this requirement, as exemplified by the design of the approx. 500
separators with steam sterilisation
capability installed worldwide.
Sterilisation is carried out on the stationary machine using superheated steam at
a pressure greater than atmospheric,
and a temperature of more than 121 °C.
After sterilisation, sterile air enters the
separator to cool it and provide a protective environment until the next product
run. The sterilisation process firstly avoids
any cross-contamination between different products that are passed through the
same separator. At the same time it also
prevents toxic bacteria or living germs
that could harm people from penetrating
from the ambient environment (biocontainment).
The chemical cleaning process CIP
(cleaning in place) cleans process lines
without the need to dismantle or open
up individual units. A 2 percent caustic
soda solution in hot water at a temperature of 80 °C is used as the cleaning
fluid. It is circulated around the system
until all organic sediments are dissolved
with no residues. For the dissolution of
inorganic sediments a 0.5 percent nitric
acid solution at a temperature of up to
80 °C is used. The last step in the CIP
chain is then a washing process using
highly purified water.
With the HydroStop system Westfalia
Separator has provided an ejection system
that, with respect to solids concentration,
can be adjusted exactly and reproducibly to
meet specific requirements. The system
reduces the actual ejection time to less than
one tenth of a second, and allows partial
ejections in the 30 second cycle. The bottom
line is that use of HydroStop ensures better
utilisation of the resources introduced and
hence a higher yield.
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Westfalia Separator
Diabetes – inhale insulin instead of
injecting it
Worldwide, around 150 million people
suffer from the metabolic disease of
diabetes. To avoid dangerous sugar levels
and severe kidney or heart circulation
diseases, patients who are insulindependent must inject insulin daily – a
procedure that is rightly unloved,
particularly by those for whom it is not
yet an established routine. On the search
for more gentle methods American
researchers have now made a discovery.
They have developed a procedure that
makes it possible simply to breathe in
the proteins using an inhaler. These find
their way into the bloodstream via the
fine passages of the lungs. Results from
studies have shown that the effect of
the inhaled insulin works faster than for
the injected form. For the production of
this insulin preparation a new process
has been developed in which a number
of separators of quite different designs
play key roles. At the start of the process
a nozzle separator separates the biomass
after fermentation. There follows the
homogenisation stage and a downstream second nozzle separator undertakes the classification, in other words,
it separates the cell fragments and cell
content materials. In two further separators the valuable heavy phase is first
washed and then concentrated. After
several intermediate biochemical steps
high-performance clarifiers undertake
the final tasks and separate a foreign
protein out from the then-fluid substance.
After a number of concentration phases
the insulin crystals are separated in selfcleaning clarifiers and delivered as
concentrated insulin. The finished
medicine eventually consists of an
insulin powder that can be inhaled.
Thus, in the future, a single deep intake
of breath through an inhaler will be
sufficient to take in an exactly defined
quantity of the insulin powder via the
lungs. Millions of diabetics will simply
be able to breathe a sigh of relief.
The 2-room design in the HyCon hyperconcentrator provides excellent sterile
processing. The drive section (drive and motor)
and process room (bowl and solids removal)
are hermetically separated from one another
in this special separator facility by means
of a gas-lubricated mechanical seal. Any
contamination of the working room by the
drive components is excluded in this manner.
Moreover it is possible to discharge the
solids enclosed in a so-called endless bag and
to process them further.
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Low temperature applications for
plasma proteins
Blood is well-known to be a very special
fluid. It transports oxygen and nutrients,
removes toxins and renders agents of
disease harmless. Without the five to six
litres of blood that flow through each
adult person practically nothing in the
human organism would work properly.
However, blood is not only our basis of
life. At the same time it is also the basis
for an industry operating worldwide
whose products provide much more
than just vital blood transfusions through
blood banks held by hospitals, state
bodies or relief organisations. The
valuable resources of this industry are
much more to be found in the form of
individual blood constituents that aid the
systematic fight against many diseases.
To extract these therapeutic building
blocks the human blood plasma
fractionation procedure using the socalled Cohn method has been developed.
This form of fractionation is understood
to include the separation of proteins of
the plasma phase with the aid of physical
and chemical processes. From the
proteins it is possible to separate out
many valuable individual substances,
such as fractions of fibrinogen, gammaglobulin, alpha and beta-globulin or
albumin. These plasma protein particles
are medically multi-talented agents that
display their properties in different infectious diseases, compensate for a lack of
nutrition, or contribute in operations to
the control of bleeding, to name just a
few examples.
For their fractionation Westfalia Separator
supplies special separators with coolable
bowls and housings. Here one is dealing
with a classic low temperature application in which the dominant criterion is
maintenance of temperature within a
window from - 3 to - 6 °C. If the process
temperature were to deviate even just
slightly from this very narrow range there
would be a failure in the gradual precipitation of the blood proteins. The
clarifiers are therefore fitted with a triple
cooling system that guarantees a specific
product temperature with a tolerance of
only + / - 0.3 °C.
The triple cooling system is a special feature
for low temperature applications such as
the fractionation of blood plasma proteins.
It ensures accurate maintenance of product
temperature with a tolerance of +/- 0.3 °C,
and has excellent thermal balance at the
same time.
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Westfalia Separator
Starter cultures – throughout the land
That Westfalia Separator’s centrifugal
separation technology also plays an
important role in micro-organisms other
than for medical use is shown by the
example of starter cultures. Whether
probiotic yoghurt, beer or wine: starter
cultures are to be found throughout the
land. The food industry cultivates and
harvests the helpful micro-organisms
and also uses separators in the processes
involved. After cultivation in the fermenters the bacteria must be processed
and separated from the fermentation
solution. Firstly the microorganisms are
separated from the liquid phase, a
process step in which amongst other
designs, nozzle separators and selfcleaning disk separators are used in
configurations that can be steam-sterilised.
The concentrated bacteria are then freezedried, packaged in the absence of oxygen,
and stored at low temperatures. In this
way their activity remains stable for
months, before being processed into
foods and landing on the shelves of the
supermarkets.
Enzymes – the process accelerators
Depending on where the desired resource
The industrial application of enzymes is
similarly multi-faceted – complex organic
protein compounds that are present in
every living cell, and as catalysts accelerate the decomposition of, for example,
starch, protein, fat or sugar, without
themselves being consumed in the
process. A wide range of industrial sectors
prize enzymes as valuable proteins for
the production of important everyday
products such as shampoo or detergents.
Separators and decanters from Westfalia
Separator undertake the task of separating out the intracellular or extracellular
enzymes in an undamaged state from
the fermentation broth at high concentration. For only at this level of quality
can the tiny helpers reliably make their
big impact.
resides, a differentiation is made between
extracellular (lying outside the cell) or
intracellular (lying inside the cell) products. For
synthetic pharmaceutical products and
enzymes Westfalia Separator supports both
extracellular and intracellular extraction.
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Advantages in summary
Gentle product feed and solids
removal through the avoidance of
shear forces
High yield and product vitality
Exactly metered discharge
quantities, even for the smallest
volumes
HyCon 2-room design
Aseptic process in completely
enclosed systems
Steam sterilisation (SIP) and
cleanability (CIP)
Separator and plant components
with little dead legs
Laser-welded spacers (gap-free)
Surface roughnesses of Ra
< 0.8 μm or better
Necessary pipework slope
of at least 2%
Machine types
Product outputs*
Self-cleaning separators
50 – 20,000
Comprehensive qualification of
facilities: clean room installation
through design qualification (DQ),
installation qualification (IQ) and
functional qualification (OQ) in the
context of FAT and SAT
Process qualification ((PQ) as
required jointly with the operator in
the context of SAT including
support for the first test run
Special applications:
Separators for low temperature
applications
Insulin from biomass
Applications
Mammalian cell cultures
Steam-sterilisable
Aseptic processes, Vaccines
Starter cultures, Pharmaceutical proteins
Mammalian cell cultures, Hormones
Separators with Westfalia
3000 – 30,000
Separator VISCON® nozzles
Hormones, Starter cultures
Chamber bowl separators
100 – 3000
Hormones, Pharmaceutical proteins
300 – 1000
Human blood plasma fractionation
Hyperconcentrator –
500 – 1500
Hormones, Pharmaceutical proteins
Westfalia Separator HyCon
Enzyme
Amylolytic enzymes
Proteolytic enzymes
Lipases
Cellulases, etc.
Starter cultures, Enzymes
Pharmaceutical proteins, Hormones
50 – 10,000
General human vaccines
Hepatitis A and B
Influenza
Meningitis C
Pneumococcal vaccines
Mumps, measles, rubella
Polio
Diphtheria
Tetanus
Whooping cough
Veterinary vaccines
FMD etc.
self-cleaning separators
Westfalia Separator’s separators
help in the recovery of many
pharmaceutical agents:
Enzymes, Pharmaceutical proteins
Human blood plasma fractionation
* dependent on product and process in litres/hour
Starter cultures (bacterial cultures)
Lactobacillus
Leuconostoc
Streptococcus
Bifidobacteria, etc.
Human blood proteins
Cryoprecipitate (factor VIII)
Fibrinogen
Globulin
Albumin, etc.
Synthetic pharmaceutical products
Pharmaceutical proteins
Interferon
Interleukin
Heparin
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Westfalia Separator
The term extraction is derived from the Latin
word ’extrahere’ meaning the process of
extracting out or dissolving out. Extraction is,
therefore, defined as the removal of a material,
or a number of materials, from a substance.
The sensitivity of pharmaceutical agents
requires a gentle laboratory. Westfalia
Separator’s centrifugal separation technology
is forward-looking and based on the most
product-friendly methods.
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Chemicals, Pharmaceuticals and Biotechnology – Extraction
The Gentle Laboratory
Pharmaceutical agents are extremely sensitive and precious. The use of
separators and decanters ensures their gentle extraction and thus forms
an important basis for medical advance.
They are the sought-after entities of the
life sciences: vitamins, plant and organ
extracts, antibiotics, enzymes and hormones, to name just the most important
of the biological agents. Herbal medicines
and agents have developed into a sector
with special potential for the future. They
promise both natural and innovative
approaches to healing and treatment
that are propelling medical advances.
From the herb garden to
phytopharmacology
ically manufactured agents have primarily
been used, but orthodox medicine is
once again increasingly turning to herbal
ingredients. However, in olden times
herbal plants were only used in simple
preparations, e.g. as cooking additives
or medicinal teas, but current use is
becoming much more complex. Plants
are now the raw material for special
extracts that can be derived with the aid
of highly technical processes. At the
same time phytopharmacology has
developed into a unique science that is
unlocking the medical secrets of the
plant world step-by-step.
Healing plants have always played a
significant role in medicine, from the
priests of early advanced cultures such
as the Aztecs and Egyptians, to the
monastery herb garden of the Middle
Ages or the traditional healing methods
of the Far East. In modern times synthet-
Phytopharmaceutical products are the names
given to drugs derived from plants or parts of
plants, also for plant preparations that can be
used in orthodox medicine in the same way as
they are used in natural healing methods.
Usually extracts of complex mixtures of
materials are used rather than pure substances.
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Westfalia Separator
A jungle full of possibilities
Extraction for sensitive agents
Worldwide there are around 500,000
types of higher-order plants, of which
approximately 70,000 serve as the basis
for medicines. If one considers that in
total only 5 – 10 percent of plants have
been studied with regard to their
constituent materials and pharmacological effects, it becomes clear just
how much potential is still unharnessed
in the plant world. Researchers see
particular promise in the future for those
types of plants that are indigenous to
the rain forests. Alongside the great
jungles of the Amazon basin or Borneo,
the oceans are also viewed as an almost
inexhaustible source of plants with
possibly groundbreaking significance.
The extent to which herbal agents are
already established today, even in
orthodox medicine, can be shown by
a very wide range of examples. For
instance echinacea, a dry extract from
the echinacea-pallida root, has proved
itself as a restorative drug for immune
defences; umckaloabo is extracted from
the root of the pelagonium reniforme
that grows in South Africa and is an
agent that is prized for its antibiotic and
expectorant properties; and night candle
oil is used in the treatment of neurodermitis because it acts as an antiinflammatory and immune suppressant.
As different as the areas of herbal agent
applications are, they all have one thing
in common: they are all extremely
sensitive materials that can only display
their medicinal qualities if they have
been appropriately and gently treated in
the biotechnological extraction process.
The structure and biological activity of
these substances rely on special environmental conditions. The method of
extraction lends itself particularly well to
this purpose. The extraction process
must be matched exactly to parameters
such as pH value, temperature, concentration and the labile structure of the
important substances. Further considerations are interfacial tension, energy
input, cleanliness and the difference
in density between the phases, also
the dwell time for extraction. How well
a phytopharmacological drug works
depends highly on adequate and continuous metering of the plant extract.
Industrial standardisation is therefore of
the greatest importance.
Herbal extracts are defined as concentrated preparations of fluid, solid or
viscous consistency. They are generally
extracted by means of maceration
(extraction with water or alcohol until
equilibrium is attained) or percolation
(exhaustive extraction with water or
alcohol). The choice of extraction medium
is a decisive factor in the production
process. Water-soluble constituents
(hydrophiles) can be extracted with
water, in contrast substances that are
soluble in fat (lipophiles) are extracted
with alcohol or other solvents from a
certain part of the plant.
In comparison to competitor separation
methods such as distillation, concentration and membrane technology,
extraction has proven itself in many
applications as the more efficient,
selective and cost-effective method. It is
not only extremely gentle but also
stands out in terms of its low energy
requirement. Thus extraction is seen as
the first choice of method, particularly
under the following process conditions:
Small differences in boiling point
between the components to be
separated
Heat sensitive or unstable
substances
Non-volatile substances, recovery
and cleaning of catalysts or heavy
metals
Mixtures with inorganic
components that can lead to the
encrustation of vaporiser heating
surfaces in thermal separation
processes
Separation of small mass fractions
of a very volatile component
Ancient Egypt is seen as the advanced culture
that first made use of the principle of
extraction. In Nefertiti’s time, colours and
scents were extracted from natural substances
in this way.
Westfalia Separator covers all
methods and modes of operation:
Phases
Type of
method
Liquid-liquid
Single-stage
Multi-stage
Co-current Counter-current Crossflow
x
x
x
x
Liquid-liquid-solid
x
x
x
x
Liquid-solid
x
x
x
x
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Extraction for the example of liquid-liquid extraction:
Before extraction
Mixing
After extraction and
separation
Extraction solution
LM + X (extract phase)
Solvent
(LM)
The basic prerequisite of liquid-liquid extraction
is that a miscibility gap is formed between the
solvent and the carrier material (the fluid in
which the extract is dissolved). This means that
the carrier material and the solvent can only
mix together to a limited extent. From a
certain concentration two phases form with a
clearly defined phase interface.
Liquid mixture
(X + Y)
Carrier fluid Y
(raffinate phase)
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Westfalia Separator
The TC 100 separator for liquid-liquid
extraction is fitted with a solid bowl disc rotor.
Depending upon the product properties the
Direct extraction of antibiotics
rotor can be fitted with exit holes that enable
drainage of the suspension from the rotor
when stationary. This has the advantage that
during maintenance activities contact
between operating personnel and the process
media is avoided as far as possible. At the
same time this provides the option of chemical
cleaning (CIP) without the rotor having to
be opened up. In the gas-tight configuration
that is always essential when using solvents
the separator is fitted with explosion-proof
components.
Westfalia Separator’s ability to consistently connect pharmaceutical and
economical dimensions is shown in the
example of the direct extraction decanter.
Extraction always consists of mixing and
separation, processes that are seen to be
individually complex. Westfalia Separator
has, therefore, developed an extraction
decanter, specifically for the extraction
of agents, that unifies both the mixing
and separation processes in one machine.
This patented method of direct extraction
has no competitors and is setting future
trends for the pharmaceutical industry.
What this means in practice is made
clear in the example of the extraction of
antibiotics. Antibiotics form the most
important group of drugs in the fight
against infectious diseases. With around
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Westfalia Separator
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13 percent of total drug consumption
they have the highest market share of
any drug products. The pharmaceutical
industry extracts antibiotics from fermentation broths, a process for which Westfalia
Separator’s extraction decanters are tailormade.
Previously penicillin was usually extracted
in a fluid-fluid counter-current process
with upstream filtration for the removal
of fungal mycelia and contaminants.
Today, continuous direct extraction using
decanters has become accepted because
the improvement in method also brings
greater cost effectiveness.
From the leaves of the red foxglove (digitalis
purpurea) the phytopharmacologists extract
the alkaloid digitalis. This agent has the
medicinal property of regulating heart activity.
The extraction decanter in the CA 505-29-10
range enables direct extraction of resources
from the fermentation broth. As a result of the
Extraction process
Phases
Liquid-liquid
Liquid-liquid-solid
Liquid-solid
÷7
÷ 7
Solid content in % < 0.1
÷ 15
÷ 60
÷ 6o
saving on the filter stage the patented method
not only requires minimal space, but also
reduces operating costs and increases total
(by volume)
yield. This model has an effective throughput
Separator with
capacity of 8,000 to 10,000 litres per hour.
solid-wall bowl
Self-cleaning
separator
Self-cleaning
clarifier
Nozzle separator
Clarifying decanter
Extraction decanter
To deal with the very wide variety of extraction
Suitable for light solvents
processes – according to phase or solids
Suitable for heavy solvents
content – an equally wide variety of separators
Rain forests are viewed, alongside the oceans,
and decanters are called upon, as the above
as the most important reservoir for new herbal
table shows.
agents. Of some 500,000 types of higher plant
forms worldwide, fewer than 10 % have so far
been investigated pharmacologically.
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Westfalia Separator
Total yields up to 98 percent
Extraction without boundaries
By using a decanter it is possible to
process suspensions with a high solids
content. Because of this it is a highly
suitable method for direct extraction of
antibiotics from a culture solution with a
high mycelia content. The filtration step,
previously an obligatory part of the
process, has now become obsolete. The
space requirement is significantly less
and the loss of resource associated with
the filtration is avoided in the continuous
process. As a result, the total yield
increases to up to 98 percent. In comparison to filtrate extraction, the direct
extraction process operates significantly
more cost effectively, if for no other
reason than the fact that filter consumables are no longer required. The
fermentation broth does not experience
any thinning with filter wash water, so
that the solvent requirement and the risk
of infection are reduced to the same
extent. A final consequence is that the
new method also reduces the waste
water load and volume. With this innovative technology, intelligent Westfalia
Separator process engineering is securing
medical advances without placing
unnecessary loading on to the environment. This is holistic thinking at work.
In addition to direct extraction it is of
course possible to obtain many other
extracts from natural substances with
the aid of centrifugal separation technology. The large numbers of applications
are illustrated in examples worldwide: in
India dyes such as indigo or paprika are
produced using clarification processes
with decanters and separators; in Bulgaria
rose oil is extracted from rose petals in this
manner; and the stem of the poppy plant
provides high-quality morphine. Whether
vaccines, vitamins, essential oils or
alkaloids such as quinine and caffeine,
the list of resources and agents that can
be extracted cost-effectively using
separators and decanters from Westfalia
Separator continues to grow.
Advantages in summary
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Very clean phase separation for a
high total yield
Ideal for products with small
differences in density
• Short contact time avoids
decomposition of resource
• Separation of systems with small
differences in density and high
viscosities expands the range of
solvents that can be used and leads
to higher product qualities
High loading and optimal
throughput in the smallest space
Unrivalled direct extraction from
the fermentation solution
minimises operating stages and
reduces costs
Avoidance of operating
malfunctions caused by solid
contaminants
Explosion-proof centrifuge
configuration
Gas-tight configuration with
connections for inert gas
blanketing / ATEX
Extraction in pharmacy
Plant extracts
Alkaloids
• Morphine
• Codeine
• Caffeine
• Cocaine
• Ergot
• Quinine
• Rauwolfia
• Digitalis etc
Herbal medicines
Special pharmaceutical agents
Medicinal teas
Essential oils
Scents
Steroids / hormones
• Corticosteroid
• Growth hormone
• Testosterone etc
Organ extracts
• Insulin
• Pancreatin
• Lab
• Placenta extract etc
Pectines
Vitamins
Aromatic materials
Antibiotics
• Penicillin
• Erythromycin
• Tetracyclin
• Bacitracin
• Clavulanic acid
• Cyclosporine etc
Statins
• Lovastatin
• Pravastatin etc
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A nanometre (nm) is defined as the millionth
part of a millimetre. This approximately
corresponds to a chain of 5 to 10 atoms. For
purposes of comparison: a human hair is
around 50,000 times larger in cross-section.
Chemicals, Pharmaceuticals and Biotechnology – Mineral Processing
The Key to the Nanocosmos
With Westfalia Separator’s centrifuges it is possible to extract the tiniest particles down into the nanoregime. Raw materials for a technology with infinite potential for innovation.
The leaves of the lotus flower are self-cleaning.
This is because of the nanostructure of the
surface of the leaf. The nanoparticles allow
water to roll off at high speed, so that any dirt
is carried along with it. Today this so-called
lotus effect is already being used industrially
e.g. for dirt-repellent exterior paints or sanitary
ceramics.
At first glance innovations such as
windows with scratch-resistant coatings,
intelligent sun protection materials or
ultralight computer displays have little in
common. But seen through a scanning
tunnel microscope they have a lot in
common: the nanoparticles that as a
result of their unique properties have
actually made these products possible for
the first time.
In the think-tanks of the international
research institutes scientists and engineers
are working at full stretch on the fascinating opportunities of nanotechnology.
More and more applications are appearing
on the horizon that are revolutionising
people’s lives in many sectors. So it is not
surprising that nanotechnology is
emerging in all the important sectors of
industry as the field in which the most
important innovations of the 21st century
can be reaped. A look into the nanocosmos quickly makes it clear that it is
difficult to overestimate the potential for
the commercial utilisation of this
technology.
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Westfalia Separator
Nanotechnology:
smaller, faster, cleverer
While science has been working for
decades in accordance with the creed of
“ever higher, ever further” these objectives
have been redefined by nanotechnology:
“smaller, faster, cleverer” are now the
global watchwords. Nanotechnology
(derived from the Greek word “nano” =
“dwarf”) is opening up the world of the
very smallest objects. It describes the
production, investigation and application
of structures and materials that have a
size of less than 100 nanometres. This is
an order of magnitude that is surpassed
only by the atoms themselves. With the
development of the scanning tunnel
microscope in 1981, science first opened
up access to the nanocosmos. Since that
time the research and utilisation of the
tiny particles has pushed forward into
more and more new domains.
“Dwarves” with gigantic capability
What is it that gives these nano particles
their particular quality? Researchers have
established that here phenomena occur
that cannot be observed in the case of
larger particles. Most importantly these
include quanta effects that sometimes
seem to totally contradict the laws of
the everyday world. If the size of a
particle comes down to the order of a
nanometre it is suddenly characterised in
terms of quite different properties. The
reason for this is that the proportion of
surface atoms strongly increases. These
surface atoms are often more highly
reactive than atoms in the interior of the
particle. Thus metals become, for
example, semiconductors or insulators.
These new mechanical, optical, magnetic,
electrical or chemical properties must be
utilised in a systematic manner.
The materials of which new dreams
are made
Today nanotechnology has already led to
products in which nanoparticles play a
central role. Examples are provided by
the dirt-repellent coatings that work
according to the so-called lotus effect.
Mobile phones, MP3 players, or diode
lasers can now for the first time be
optimised using the results of nanotechnology. At the same time the
foundations are being laid for the
production of ever-smaller data stores
with ever greater storage capacity,
photovoltaic windows, ultralight motors,
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Westfalia Separator
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or artificial joints that as a result of
organic nanosurfaces have greater biocompatibility. For many sectors of industry
their future success and competitiveness
depend on how well they succeed in
converting nanotechnology into innovative
products.
Ultrafine particles as raw materials
for industry
Anyone who now wishes to trade or
work with nanoparticles, whatever the
industry sector, requires the raw materials
to be of optimal quality. It is exactly at
this point that Westfalia Separator’s
process and plant know-how comes into
play. Early on the company recognised
the significance of nanotechnology –
as it did previously for microtechnology –
and it has developed appropriate
methods for the extraction of ultrafine
particles down into the nanoregime. The
separators and decanters make possible
the separation of materials into different
particle sizes and fluid densities in a
continuous process. The centrifugal
separation forces provided by Westfalia
Separator are already being used in the
extraction of inorganic pigments such as
kaolin, calcium carbonate, mica, talcum
and titanium dioxide. Both precious
metals and base metals can be reliably
extracted in this manner.
Examples of possible future
applications:
Automotive:
Omnifunctional sensor systems
Multifunctional paints
Super-grip tyres
Ultralight engines and body parts ...
Chemistry / pharmacy / medicine:
Functional clothing
Programmable materials
Special cosmetics
Artificial skin and organs
Super absorbers ...
Optics:
Data media with nanostructures
X-ray optics
Nanoparticles for photographic films
Optics with functional coatings ...
Biotechnology:
Neuroprosthetics
New DNA sequencing methods
Wearable bio-chips
Systematic modification of cellular
structures ...
Food:
Sensorised packaging
Membranes for water treatment
Functional nanoparticles as colouring
materials ...
Energy:
More cost-effective solar cells
More efficient energy storage media
Independence from the oil sector ...
Building:
Intelligent exterior surfaces
Special coatings
High-performance adhesives
Light construction materials ...
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Westfalia Separator
How can geckos run along the ceiling? With
nanotechnology: the gecko’s foot is covered
with extremely fine hairs that are so soft and
smooth that they can approach the surface
structure to within the distance of a
nanometre. In this way the so-called Van der
Waals bond starts to take over, which by virtue
of millions of points of adhesion evolves into a
load-bearing phenomenon. However, this
attraction is also weak enough for the gecko
to be able to release his feet when he wants
to. This is a fantastic principle that material
scientists wish to imitate synthetically.
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Very precise classification cut
Thickening and dewatering
Product quality and selling price for the
particles are aligned with their size
distribution and level of cleanliness.
High-value particles, according to recognised “high grade” quality, are distinguished by the fact that they are smaller
than 2 μm and have a narrow distribution
of particle sizes. Westfalia Separator’s
highly developed separator and decanter
technology achieves the required level of
quality by very precise classification.
A further area of activity is in thickening
or dewatering ultrafine particles in liquid
suspensions. Here the concentrations of
solids are not only controlled and
stabilised, but also optimised in the end
result. A further economic advantage lies
in the significant improvement of the
rate of recovery of the solid material.
This classification enables:
Fluids and fluid mixtures, with and
without solids, can be optimally clarified
or separated. Here the technology enables
minimisation of the contaminant components at the same time as three-phase
separation.
Recovery of high-value materials
Separation of different types of
particles
Separation of ultrafine particles
and contaminants
Clarification and separation
Nozzle separators work as separators and
clarifiers. They are mostly used for the
thickening and classification of solids from
suspensions. The solid concentrate is
continuously expelled through nozzles on to
the bowl periphery in the solids catcher and
led off. To increase the maximum achievable
concentration the concentrate is fed back
With regard to distribution of particle
sizes, there are the following optional
procedures:
via a concentrate duct as directly as possible
ahead of the nozzles. These machines can
also be used in washing processes. Westfalia
Separator’s high-speed separators open up
Displacement of the particle size
distribution
Modification of the particle size
distribution
Alignment towards the smallest
grain sizes
practical solutions in all areas of application
of micro and nanotechnology: The selfcleaning separator has a double-conical solids
holding space in which the sediments that
are centrifuged from the fluid phase collect.
When this solids space is filled, an annular
gap is hydraulically opened and the sediments
are discharged at full rotational speed.
Westfalia Separator decanters employed in
mineral processing are horizontally supported,
solids-oriented, solid-bowl scroll centrifuges.
They are used primarily to clarify, classify, or to
dewater in the partial flow, from suspensions
with a high proportion of solids. A further area
of application is the separation of two different
liquids whilst simultaneously centrifuging out
solids.
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Westfalia Separator
Application example:
calcium carbonate
Special machines for extreme performance
The way in which Westfalia Separator’s
know-how comes into use in practice is
demonstrated by an example from the
paper industry. This industrial sector
requires calcium carbonate (CaCO3) as a
coating for papers that have to satisfy the
very highest demands, e.g. for photographic prints. The decisive criterion for a
quality coating is the level of whiteness.
Therefore CaCO3 from limestone or chalk
is only partially suitable because of its
relatively low level of whiteness. While in
earlier times the paper was bleached
further, today industry can avoid this
environmentally unfriendly procedure.
The solution lies in marble. With a level
of whiteness of around 93 percent,
CaCO 3 from marble is the ideal raw
material for optimal coating. Westfalia
Separator’s decanters have demonstrated
that they are the ideal solution for
extracting this raw material. With the
addition of water the marble is finely
milled in giant stone mills and mechanically separated from darker foreign body
constituents. At this point the work of
the decanter centrifuges begins. After
the CaCO3 suspension has left the last
stage of the mill at the required particle
size, decanters with capacities of between 20 m3 / hr and 50 m3 / hr classify
the suspension into ultrafine particles at
the desired size. In the next step highperformance decanters perform the
necessary dewatering. The result is a dry
substance content of up to 72 percent
– a paste-like mass of pure CaCO3.
Given that in the extraction of this raw
material very large volumes are processed
with a very high density of 2.7 g / cm3, it
becomes clear that highly developed
special machines are required in this
sector. Westfalia Separator’s decanters
achieve this extreme level of performance
by using high acceleration, and in this way
attain an extremely high dry substance
content. Their robustness and resistance
to wear ensures that even in continuous
use they are extremely reliable. The
decanters score further in comparison
with other methods: when measured
against the press filter technique, the
advantage of the centrifugal method lies
in the continuity of its process. And compared with vaporisation technology the
energy consumption is significantly
lower. These are arguments that are also
of great significance in other industry
sectors.
It is well known that gold is one of the most
valuable precious metals in the world; and not
only as a financial investment or in jewellery.
Nanotechnology is being tested in the
manufacture of catalytic converters using gold
nano particles and also for odour eliminators.
One very effective area of application is for airconditioning systems in cars. Here the gold
particles destroy bacteria and so prevent a
build-up of odour.
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Westfalia Separator
Industry
Advantages in summary
Extraction of materials down into
the nanoregime
High-value particles with sizes
< 2 μm and a narrow distribution
of particle sizes
Separation from solids, which in
their consistency or behaviour can
be amorphous, granular, crystal-
line, fibrous, glutinous, soft, hard,
or severely eroding
Decanters for all separation
processes in 2-phase or 3-phase
models
• Variable drives with torque-
dependent differential speed
control for constant and extremely
high concentrations of solids,
even with fluctuating feed
concentrations
• Adapted drive concepts for high
torques: three-phase AC motors
with frequency converter for
control of the bowl speed, or
motors for controlled torque
starting
• Product-matched materials and
sealing systems
Separators with concentrate feed:
feedback of the concentrate as
directly as possible ahead of the
nozzles to increase the maximum
achievable concentration
Industry
37
Westfalia Separator
Westfalia Separator WESERVE®–
Because the Machines Must Run
This is the premise that Westfalia Separator used to develop the compre
hensive service programme – Westfalia Separator WESERVE®.
Right from the start Westfalia Separator
specialists will work closely with you to
develop systems specifically for your
requirements. This starts with the project
planning and continues through the production, installation and commissioning
of the plants.
Service contracts designed to meet your
needs and the availability of genuine
spare parts ensure economic operation
throughout the entire lifecycle of the
machines.
developments, improvements and innovative ideas to give you the best after
sales service available. You benefit from
knowledge gained by a global player:
Westfalia Separator.
Optimum customer support assured
Your employees learn how to handle the
equipment in training programmes held on
site or in the modern Westfalia Separator
training centre.
If assistance is required quickly or a spare
part is urgently required, our world-wide
presence backed up by sales and service
companies are there to provide immediate solutions.
Authorised repair workshops
guarantee quality and safety
Through its global communication platform and authorised repair workshops,
Westfalia Separator exchanges the latest
38
Westfalia Separator
Industry
Service at any place in the
world – round the clock.
Industry
39
Westfalia Separator
Beverage Technology
Dairy Technology
Oils and Fats Processing
Chemicals, Pharmaceuticals
and Biotechnology
Oils and Fats Recovery
Starch Technology and
Industrial Biotechnology
Environmental Technology
Marine
Energy
Oilfield
Industry
Engineering
Second Hand Machinery
Service
The information contained in this brochure merely
serves as a non-binding description of our products
and is without guarantee.
Binding information, in particular relating to capacity
Westfalia Separator
Industry GmbH
Werner-Habig-Straße 1
59302 Oelde (Germany)
data and suitability for specific applications, can
only be provided within the framework of concrete
inquiries.
Printed on chlorine-free bleached paper
www.papp.cc
Phone +49 2522 77-0
Fax +49 2522 77-2828
[email protected]
www.westfalia-separator.com
9997-0818-010/0206 EN
Printed in Germany
Subject to modification
Westfalia Separator
Industry
Take the Best – Separate the Rest
A company of GEA Group