Industrial fluids
Kvalitatīvāks rūpnieciskais šķidrums paildzina iekārtu kalpošanas laiku un produktivitātes līmeni, kā arī samazina izmaksas. Tīrs šķidrums nozīmē arī mazāku smērvielu maiņu un mazāku ietekmi uz vidi. Alfa Laval piedāvā pārbaudītu ātrgaitas centrifūgu (stacionāro un pārvietojamo) klāstu, lai pagarinātu visu veidu darba šķidrumu kalpošanas laiku un līdz ar to arī jūsu sistēmu kalpošanas laiku neatkarīgi no tā, vai esat maza darbnīca vai liela rūpnīca.
Efektīva eļļas un cieto daļiņu noņemšana no dažāda veida šķidrumiem
- Pagarina instrumentu un šķidrumu kalpošanas laiku
- Zemas kopējās īpašumtiesību izmaksas (TCO) un mazāks dīkstāves laiks apkopes veikšanai
- Tīrāki šķidrumi palielina precizitāti
- Samazina sistēmas komponentu nodilumu, ietaupot izmaksas un palielinot produktivitāti
- Noņem gan brīvo/traipu eļļu, gan cietās daļiņas vienā operācijā - pat maza izmēra daļiņas
Pateicoties lielajam ātrumam, disku kaudzes tehnoloģijai un automātiskajai izplūdei, Alfa Laval centrbēdzes separatori ir ļoti efektīvi smalku cieto daļiņu vai šķidro piesārņotāju atdalīšanai no dažāda veida darba šķidrumiem. Tie no smērvielām noņem vairāk nekā 99% visu cieto daļiņu, kuru izmērs ir no 2 līdz 5 μm, un praktiski visu eļļu, bet ne visas piedevas. Tas arī samazina šķidrumam kaitīgo baktēriju augšanu un veicina veselīgāku darba vidi.
Cutting fluid separation
Keeping your cutting fluids free from solid and liquid contaminants prolongs tool and fluid lifetime, which means a lower total cost of ownership and less service downtime.
Wash liquid cleaning
When it comes to cleaning wash liquids, the replacement process can be costly thanks to disposal and downtime. With efficient separation, you can maximise productivity and efficiency for longer.
Centrifugal high speed separators for industrial fluids cleaning
Centrifugation is a proven, sustainable technology to get rid of tramp/free oil and/or fine particles in coolants and wash liquids. Cleaning on a regular basis significantly prolongs the service life of your fluids and, by extension, the service life of your system. Then there are the savings on fluid, filter, valve and pump replacement as well as disposal cost savings.
Working principle
During the separation process, the centrifugal force presses the heavy particles present in the service fluid outwards against the walls of the separator. These are discharged automatically from the bowl to the sludge tank. If two liquid phases are present (such as coolant and tramp oil, or neat oil and water), the centrifugal force will cause the two phases to separate. The light phase and heavy phase exit separately through different outlets of the separator.
Alfie
- Can be linked to a bypass flow, ensuring less downtime for service
- Disc stack separators provide simultaneous, three-phase separation of oil and sludge
- Designed for operator convenience
- No machinery redesign required
Emmie 2
- Installed in a bypass flow so no machinery alterations required
- Plug-and-play operation
- Requires no supervision once started
- Disc stack separator provides rapid, simultaneous and continuous three-phase separation of water and particles
AlfaPure
- Removes water, abrasive metal fines and other particles as small as 2 μm
- Plug-and-play module for easy installation
- No plant redesign required
- Disc stack technology speeds up the separation process
Quick selection guide
The Alfa Laval product guide is an easy-to-use tool to help you filter, select and quote the best solution for effective cleaning of coolants, wash liquids and lube oil. Enter the online catalogue and find your selected products and parts now. If the products are not visible for your country, please fill out the contact form.
Cleaning technologies for industrial fluids
If you clean your industrial fluids you can make substantial cost savings. But how do you determine which technology is the most efficient and represents the least overall cost for your particular application? Here we look at the four most common options – centrifugation, filtration, skimming and coalescence – to help you decide.
The four technologies in brief
- Centrifugation separates matter of different densities – both oil and particles
- Filters use different mesh sizes to capture solids only
- Skimmers use an oleophilic collecting device like a belt or a disc to collect oil
- Coalescers remove oil from industrial fluids
The best technology is the one that suits your application
- Centrifuges direct clean industrial fluid back into your process while the separated contaminant is continuously discharged. Particles are contained in the separator bowl for later disposal or are discharged automatically.
- Filters commonly capture solids in a disposable cartridge, which needs replacing regularly.
- In skimming, the oil adheres to the outside of a floating, closed-loop tube as it is drawn across the surface of the water, adjusting automatically to changing water levels.
- Coalescers can only work if the industrial fluid is almost particle free. Most often, a coalescer is used in conjunction with filters to ensure the removal of solid particles and water in one system.
Cleaning technologies compared
Industrial fluids – centrifugation
With industrial fluid centrifugation you can discard waste without the need to purchase disposables such as filter cartridges. This makes industrial fluid cleaning more convenient, cost-effective and sustainable.
Powerful, productive and cost-effective
- Removes oil and solids in one operation
- Handles even small particle sizes
- Low maintenance gives more process uptime
- Longer equipment lifetime
- Low total cost of ownership (TCO)
- Only removes loosely emulsified oils but leaves the industrial fluid emulsion intact
Centrifugation uses a force 5,000 times stronger than gravity to separate particles of different densities and continually directs clean fluid back into your process. The process releases the oil while the contaminating solids are stored separately. Centrifugation enables you to handle large cleaning volumes and can withstand a temporary high influx of oil.
Industrial fluids – filters
There are a number of questions you need to ask yourself when considering which type of industrial fluid filter you need. For example, does the process use more than 50 litres of fluid per hour? How high are the contamination levels? Is fluid contaminated with particles and oil? Can you dispose the filters in a correct way? Do you have a reliable supply chain when you need to replace a filter?
Easy to operate and install, more costly to maintain
- Relatively simple operation – few moving parts
- Low capital investment
Industrial fluid filters use cartridges of different mesh sizes to capture solid particles. Particles larger than the mesh are captured and removed from the fluid, while the smaller ones remain. When the cartridge is full, it has to be removed and replaced. The old one has to be safely discarded/disposed of.
What to consider
Although industrial fluid filters don’t require much capital investment, there are a number of factors that influence their effectiveness which may lead to a higher total cost of ownership (TCO).
- No oil removal so needs to be combined with coalescers or separators
- Need for disposables leads to higher operating costs and compliance with increasingly strict environmental regulations
- Limited performance – only captures solids larger than the mesh size (typically 10-30 µm)
- Captured particles can be released again if filter is exposed to pressure shocks at start-up/stop
- Filter needs monitoring/changing regularly to avoid clogging (particles pass through the bypass valve)
- Fluctuation/reduction in pressure when filters are contaminated
Industrial fluid – coalescers
Filters are not able to capture large amounts of oil or other liquid contamination, so if you choose a filter system to clean industrial fluids, you will have to add a coalescer module if you need to remove oil.
Extra corrosion protection
- Relatively simple operation – few moving parts
- Low capital investment (below a certain capacity)
Coalescers add an additional process to filter systems. They work by combining oil droplets so they float to the surface more readily.
What to consider
Although industrial fluid coalescers are easy to install and maintain, their effectiveness is limited which can lead to process inefficiency and higher lifetime costs.
- Cannot remove solid contamination
- Industrial fluids have to be very clean from particles to enable coalescence
- Cannot be used if special additives or surfactants are present
- Cannot cope with high amounts of free oil in the fluid
Industrial fluid skimmers – the considerations
Industrial fluid skimmers are a simple and cheap solution for removing small amounts of oil under stable conditions. They are best suited to processes where the industrial fluids are clean. They do not handle changes in properties of the oil types or the throughput-volumes very well.
- No solid contamination removal
- Cannot handle medium to high amounts of free oil in the fluid
- Removes a mixture of oil and water not just the oil
- Performance varies greatly according to oil
- Cannot be used if special additives or surfactants are present
Prolonging the life of your coolants
For the metalworking industry, coolants are a major expense. Less downtime, higher efficiency, lower operating costs and an enhanced sustainability profile are just some of the compelling reasons to switch to one of our dedicated liquid cleaning modules.
Case stories
Productivity takes off at aerospace plant thanks to AlfaPure Z3.
In the UK, AlfaPure Z3 coolant treatment systems have helped the Airbus plant at Broughton, Flintshire eliminate coolant fouling and improve productivity. Read the full story by downloading.
AlfaPure cuts coolant costs and extends tool life at Ford, Bordeaux.
An Alfa Laval high speed centrifugal separation system was installed to remove tramp oil and small particles from coolants in order for efficient re-use of coolant, giving increased tool lifetimes and a healthy working environment in the plant.
Alfa Laval wash liquid cleaning module pays for itself in one year.
Renault Cléon, France, installed an Alfa Laval separation system to clean wash liquids for engine components, removing 70 litres of tramp oil per day. This provides them with annual savings from cost related to replacement and disposal of wash liquids, and ensures efficient component washing.
High speed separators cut operating costs for French engine builder, Française de Mécanique.
Thanks to a new cleaning system incorporating Alfa Laval centrifugal separators, the wash liquids used in the production process last for seven months, compared with 2–10 days using the old cleaning system.
Nodrošiniet ilgu kalpošanas laiku
Ja pareizi rūpēsieties par savu separatoru, variet sagaidīt desmitiem gadu efektīvu rūpniecisko šķidrumu tīrīšanu. Īsāk sakot, ir jālasa rokasgrāmata un jāizmanto oriģinālās detaļas un pareizie instrumenti. Mēs piedāvājam visaptverošu detalizētu apkopes instrukciju paketi un īpašus apkopes komplektus ar oriģinālām rezerves daļām.
- Maksimāli palieliniet darbspējas laiku
- Atbalstiet ilgu darbmūžu
- Lietošanai gatavi komplekti vienkāršo apkopi un ietaupa laiku
- Samazināts pasūtījumu apstrādes laiks
- Globālie izplatīšanas centri ātrai piegādei
Profilaktiskās apkopes komplekts
Alfa Laval profilaktiskā apkope ietver starpposma apkopi (IS) vai lielo apkopi (MS), kas ir iepakota kastē ar nepieciešamajām detaļām. Apkopes intervāls ir atkarīgs no darba stundām vai noteikta laika perioda.
Mēs iesakām:
- Vienmēr ievērot separatora rokasgrāmatā sniegtos apkopes norādījumus
- Ik pēc 3 - 6 mēnešiem (2 - 4 000 stundu)* veikt starpposma apkopi
- Veikt galveno apkopi ik pēc 12-18 mēnešiem (8-12 000 stundām) atkarībā no iekārtas tipa un procesa apstākļiem*
* Rokasgrāmatā ir norādītas maksimālās prasības. Rūpniecisko šķidrumu tīrīšana parasti nav smags pielietojums, un intervāli ir nedaudz elastīgi.
Servisa komplekti un rezerves daļas
Alfa Laval centrbēdzes separators darbosies gadu desmitiem, ja par to pareizi rūpēsieties. Taču jums ir jāiepazīstas ar rokasgrāmatu un jāpārliecinās, ka izmantojat oriģinālas rezerves daļas un pareizos instrumentus. Mēs piedāvājam īpašus apkopes komplektus ar oriģinālām rezerves daļām un visaptverošu detalizētu apkopes instrukciju komplektu. Mums ir pat servisa videoieraksti par to, kā pareizi veikt separatora apkopi. Apmeklējiet produktu rokasgrāmatu, lai uzzinātu vairāk! Ja jūsu valstij paredzētie produkti nav redzami, lūdzu, aizpildiet kontaktformu.
Rokasgrāmatas rūpniecisko šķidrumu tīrīšanas separatoriem
Jaunākās šķidrumu tīrīšanas moduļa rokasgrāmatas atradīsiet šeit.
Tās ietver:
- Drošības instrukcijas
- Lietošanas instrukcijas
- Apkopes instrukcijas
- Traucējumu novēršanu
- Tehniskās specifikācijas
Lūdzu, ņemiet vērā, ka dažu produktu sērijām, kas tiek izmantotas jau daudzus gadus, var būt nelielas dizaina atšķirības.
Rokasgrāmatās ir aprakstīti visi ekspluatācijas un rūpju par jūsu ieguldījumu aspekti.
Mums ir rokasgrāmatas par:
- Alfie 200
- Alfie 500
- Emmie 2
- WSPX 403 (AlfaPure S2)
- WSPX 604 (AlfaPure S3)
- WSPX 407 (AlfaPure S7)
Ja jūsu rūpnieciskā šķidrumu separatora lietošanas instrukcija neatbilst jūsu produktam, lūdzu, sazinieties ar mums sazinieties ar mums.
Viegla uzstādīšana, ekspluatācija un apkope
Pārliecinieties paši, iepazīstoties ar mūsu servisa filmām, kas palīdzēs jums vislabāk izmantot tīrīšanas moduli.
Alfie 500 - unboxing
This video shows how your ordered Alfie will arrive. All the packages are opened and contents are shown and explained.
Alfie 500 - how to operate
This video explains how to operate the Alfie 500. You will see how to set it up and start cleaning your industrial fluids.
Alfie 500 - how to operate (by-pass)
This video explains how to operate the Alfie 500. You will see how to set it up and start cleaning in a by-pass setup.
Alfie 500 - how to operate (tank)
This video explains how to operate the Alfie 500. You will see how to set it up and start cleaning in a tank-to-tank setup.
Alfie 500 - cleaning of the bowl
This video shows how to clean the Alfie 500 in order to get accumulated solid contamination particles out of the bowl.
Emmie 2 - cleaning of the bowl
This video shows how to clean the Emmie 2 in order to get accumulated solid contamination particles out of the bowl.
Alfie 500 - exchange pump seal
This video shows how to exchange the mechanical seal on the feedpump to prevent leakage and loss of performance.
Alfie 500 - exchange of o-rings
This video shows how to exchange the O-Rings which should be done at least once a year during intermediate service.
Emmie 2 - Exchange of o-rings
This video shows how to exchange the O-Rings which should be done at least once a year during intermediate service.
Alfie 500 - exchange dampers
This video shows how you exchange the vibration dampers if it vibrates during operation or at least once a year.
Metālapstrādes šķidrumu drošas lietošanas un utilizācijas labas prakses rokasgrāmata
Rokasgrāmata attiecas uz metālapstrādes šķidrumu sagatavošanu, apkopi un iespējamo iznīcināšanu, un tā palīdz nodrošināt drošu darba vidi. To ir sagatavojusi ekspertu grupa no Apvienotās Karalistes Smērvielu asociācijas (UKLA), Metālapstrādes šķidrumu produktu uzraudzības grupas (MWFPSG) un Veselības un drošības izpildinstitūcijas (HSE), kā arī pieredzējušu darbnīcu vadītāju un medicīnas ekspertu papildus padomi.
Sazinieties ar mums, lai uzzinātu, kas jums ir vispiemērotākais
Centrifūgas viegli pārspēj citas rūpniecisko šķidrumu tīrīšanas tehnoloģijas. Ieguldījumi ir lielā mērā atkarīgi no jūsu procesa un prasībām. Ļaujiet mūsu pieredzei palīdzēt izvēlēties jūsu darbībai piemērotu tehnoloģiju.