The separation of finely dispersed particles from liquids is a basic operation in mechanical process engineering. On an industrial scale, continuously operating decanter centrifuges are often used, whose separation principle is based on the density difference between the solid and the liquid phase due to high g-forces acting on both phases. The design of centrifuges is based on the experience on the individual manufacturer or simplified black box models, which only consider a stationary state. Neither the physical behavior of the separation process nor the sediment formation and its transport is considered. In this work, a computationally-efficient approach is proposed to simulate the separation process in decanter centrifuges. Thereby, the open-source computation software OpenFOAM was used to simulate the multiphase flow within the centrifuge. Sedimentation, consolidation of the sediment, and its transport are described by material functions which are derived from experiments. The interactions between the particles and the fluid are considered by locally defined viscosity functions. This work shows that the simulation method is suitable for describing the solid-liquid separation in a simplified test geometry of a decanter centrifuge. In addition, the influence of the rheological behavior on the flow in the test geometry can be observed for the first time.

The production of catalysts such as zeolites is a complex multiscale and multi-step process. Various material properties, such as particle size or moisture content, as well as operating parameters—e.g., temperature or amount and composition of input material flows—significantly affect the outcome of each process step, and hence determine the properties of the final product. Therefore, the design and optimization of such processes is a complex task, which can be greatly facilitated with the help of numerical simulations. This contribution presents a modeling framework for the dynamic flowsheet simulation of a zeolite production sequence consisting of four stages: precipitation in a batch reactor; concentration and washing in a block of centrifuges; formation of droplets and drying in a spray dryer; and burning organic residues in a chain of rotary kilns. Various techniques and methods were used to develop the applied models. For the synthesis in the reactor, a multistage strategy was used, comprising discrete element method simulations, data-driven surrogate modeling, and population balance modeling. The concentration and washing stage consisted of several multicompartment decanter centrifuges alternating with water mixers. The drying is described by a co–current spray dryer model developed by applying a two-dimensional population balance approach. For the rotary kilns, a multi-compartment model was used, which describes the gas–solid reaction in the counter–current solids and gas flows.

Dedicated to Prof. Dr.-Ing. Joachim Werther on the occasion of his 80th birthdayThe scale up of solid bowl centrifuges is a major challenge as the process and material behavior are complex and difficult to describe. A common approach to forecast the process behavior is to use analytical models and transfer the experience gained from the lab to the industrial scale. In this context, time-consuming and cost-intensive pilot scale experiments are necessary. This paper presents a methodology to improve the scale up process and make it more sustainable by using a numerical model that allows the real-time tracking of the process and a more reliable scale up process. For this approach, the material behavior is derived from laboratory experiments whereby the scalability is given. Here, the determination of material functions allows an accurate representation of the material behavior for solid bowl centrifuges of different scales. The focus of this paper is the detailed explanation of material related functions for the scale up of decanter centrifuges.