GEA centrifuges for

industrial minerals
Processing of calcium carbonate,
kaolin and titanium dioxide
2 · RELIABLE

MINERAL PIGMENTS
are used in order to stabilize ceramics, improve the
characteristics of paper and produce paints or plastics.
GEA has developed tailor-made centrifuges for
classification, thickening and dewatering of calcium
carbonate, kaolin and titanium dioxide.
 RELIABLE · 3

Reliable
The comprehensive GEA know-how in the design,
production and process integration of centrifuges
is essential for optimum results in the recovery of
industrial minerals.

Whether processing calcium carbonate, kaolin or Whatever objectives are relevant: the solutions from
titanium dioxide: GEA centrifuges, systems and GEA mean that success can be planned. Agreed
process lines set standards for performance, service performances are attained reliably and permanently.
life as well as for economic and environmentally
reliable operation. Benefits at a glance:
• Optimum process results
Plan your success • Permanently reduced production costs
Thanks to the many years of experience and • Maximized production capacities
continuous investments in research and develop- • Protection of people and environment
ment, the company offers its customers a crucial
technological edge. The GEA global network of
test centers is available for complex trials in order
to create a reliable decision-making basis for
investments.

From initial advice, basic and detailed engineering

right through to the commissioning of the
installations, GEA offers a perfect combination
of process knowledge, sound knowledge in plant
construction, first-class products and technologies.
The result is reliable process management with
maximum availability of the centrifuges which are
used.
4 · SERVICE

More than just a centrifuge

GEA offers a comprehensive range
of services to the industry.

GEA supports its customers from the initial is developed by the process experts in close
product test in the decision-making process right cooperation with the customer.
through to 24-hour service after the centrifuges
have been installed. Thus, GEA project management offers all
services from a single source – from the
Product tests are carried out to determine how individual installation layout right through
the product can be separated most effectively to the commissioning of the installations and
and what materials which come into contact comprehensive service options. The involvement
with product have to be used. In addition, of all parties and resources means that it is
initial recommendations are also provided with always possible for customer requirements to be
regard to the design of the process, and cost met, and in many cases even exceeded, in terms
estimates are made. The optimum process design of cost and production efficiency.

Benefits at a glance: • Complete assembly and testing of the insta-

• All services from a single source lations in the ISO 9001 certified production
• Customer- and application-oriented facility
engineering • On-site assembly of certain installation types is
• Support for process development, designing also possible
the process accessories and the installation • Service network operating throughout the
layout by way of reliable scale-up world
• Reliable compliance with all agreed specifica-
tions, budgets and delivery deadlines … which provide every customer with the neces-
sary security.

PROCESS SECURITY
GEA combines top separating technology performance with
comprehensive responsibility for reliable process management.
SERVICE · 5
6 · GCC AND PCC PROCESSES

Calcium Carbonate –
Classification and Dewatering of
GCC and PCC
Decanters from GEA are used in GCC and PCC processes. The recovery of
high-purity particles extending down to the nano range meets the industry’s
highest quality standards.

Calcium carbonate is used in a broad spectrum of applications. continuous processing mode supports solid-liquid separation
Besides its use as a filler for paints and plastics, it plays an and classification by different particle sizes and liquid densities.
important role as a coater in the paper industry. The very precise classification cut enables the particle size
distribution to be adjusted so that the quality specifications are
Intelligent treatment techniques are required for classifying, always spot-on. Adding on a second classification stage has the
sorting and dewatering calcium carbonate. The product quality advantage that existing product losses can be transformed into
is determined by the particle size distribution and purity. The the desired higher quality without excessive expenditure.
decisive factor is the concentration of the valuable particles with
a size <2 µm and a dense particle distribution. A higher process Dewatering of the superfine particles to a dry substance content
flexibility must also be assured to recover different quality in excess of 70 percent subsequently ensures controlled, stable
grades and to boost the recovered yield. solids concentrations. Clarification additionally minimizes the
contaminants.
In the traditional GCC method (ground calcium carbonate),
blocks of marble are ground before being classified and Whether GCC or PCC: the result is in either case a highly
dewatered to the specifications of the intended application. pure, pasty slurry which fulfils all the demands of the paper
The PCC process configuration (precipitated calcium carbonate) manufacturer.
is exactly the opposite. Individual crystals are stimulated to grow
in a reactor by adding calcium oxide and are then dewatered. Benefits at a glance:
GEA supports both processes with customized and individually • Continuous process
configured process lines. • Support of GCC and PCC recovery
• High product purity
Very precise classification cut • High yields, less product losses
The GEA decanter series is specifically designed for the • Dry substance contents of more than 70 percent
recovery of particles in the micro and nanosize range. The
 GCC AND PCC PROCESSES · 7

Recovery of ground calcium carbonate (GCC) Production of precipitated calcium carbonate (PCC)

CaCO3
Crushed limestone
raw product

Coarse milling Calcination

Washing station Hydration

Fine milling Precipitation Utilization of PCC

Precipitated calcium
Flotation
carbonate

Hydrocyclone Thickening Dewatering

Milling Storage tanks Packaging Milling

Wet milling Filler pigment Coating pigment

Classification

Dewatering

Storage tanks
8 · KAOLIN PROCESS

Kaolin and Titanium Dioxide –

More Product of Higher Quality
Kaolin, also known as china clay, is a pigment recovered from kaolinite, a weathering
product of feldspar. It is valued as a filler and whitener in many industries. High-grade kaolin
is very much demanded by the paper industrie being an ideal luminous filler and coater in
the production of high quality paper.

Brightness, opacity, purity and gloss define the pigment quality with minimum product losses. The impact on
quality of koalin. These parameters are essentially yield and margin is substantial. A few percent more
determined by the particle size distribution. Particles make the difference n view of an anual production
smaller than 0.2 µm are irrelevant in the production of many thousand tonnes while a higher degree of
of white colour because they no longer diffract the whiteness allows to demand higher prices.
light. Particles larger than 2 µm, by contrast, negatively
impact the whiteness. Coarser particles with a diameter With a newly developed recovery process, GEA has
above 20 µm in particular must be as few as possible to also succeeded in substantially reducing the losses of
produce a good paper quality. the 2 µm fractions. The already minimal product loss
can be transformed into the desired higher quality
Optimum particle size distribution without difficulty by adding on a second classification
High-performance GEA decanters are ideal in the stage. At the same time, the manufacturer has the
process. Thanks to their accurate classification cut, the possibility to produce two different pigment qualities
particle size distribution can be configured to desired with the first and second stage.
 KAOLIN PROCESS · 9

Kaolin processing

Crusher

Blunger

Cyclones

Degritting Centrifuge

Blunger

Screens

Selective flocculation

Primary classifying
centrifuge

Blunger

Secondary classifying
centrifuge

Residue ponds Vacuum filter Evaporators Spray drier

Magnetic separators Spray drier

Bleaching and flocculation Filter presses Extruders Big bagging / ship loading
10 · TITANIUM DIOXIDE PROCESS

Titanium oxide in the chloride process The opacity as well as the optimum consistency and
Titanium dioxide has the highest opacity of the entire brilliance of the titanium dioxide heavily depends on
range of white pigments plus a very good whitening the size of the particles. The use of centrifuges from
power. These properties not only make it attractive for GEA makes it possible to classify the titanium dioxide
the production of paper. It is also of significant interest so that there is a particularly large number of superfine
for paints and lacquers, as sun blockers in sun tan particles in the quality-enhancing size of approx. 0.2 to
lotions, as a constituent of solar cells and ceramic 1 µm. Rotary brush strainers are installed upstream of
capacitors or as nano particles for self-cleaning the nozzle separators to remove the coarser fractions
surfaces. and hence protect the nozzles from possible blockage.

The chloride process has established itself worldwide Benefits at a glance:

for the recovery of titanium dioxide. This process has • Premium product quality
the advantage that the chlorine remains in the process • Higher yield – minimal product losses
circuit to a large extent and no environmentally • Continuous process
hazardous dilute acid is produced. GEA supports this • High availability of the centrifuges used
process through the integration of a special nozzle • Both separators and decanters in the product line
separator.
 TITANIUM DIOXIDE PROCESS · 11

Titanium dioxide processing

Ore deposit / coke /

nitrogen / chlorine delivery

Fluidized bed reactor Fresh gas (Oxygen)

Cooling tower Cooling water

Separation of metal
chlorides

Condensation of TiCl4 Cooling coil Pigment- and gas strainer Sludge vessel

Vanadium reduction Wet milling

Distillation Rotary brush strainer

Storage of pure TiCl4 Thickening

TiO2

Evaporator Dry milling

Super heater Packing

Burner
12 · CLASSIFYING DECANTERS

Classifying decanters –
precise right down to the nano range
Classifying decanters from GEA convince through optimal
process control in the micro and nanosize range.

Decanters from GEA used in the mineral processing sector are Depending on capacity and requirement profile, different sizes
horizontal, solids-oriented solid-wall scroll centrifuges. and drive concepts are available. In addition, the classifying
decanters convince through robustness, a long life cycle, high
In the version as classifying decanter, they take on the job of torques, user friendliness, low energy consumption and low
continuously processing the slurry so that the particle size maintenance expenditure.
distribution and purity of the product conform exactly to the
specifications.
Benefits at a glance:
The innovative technology of the classifying decanter enables an • Recovery of valuable substances
accurate classification cut. This means optimum process control • Separation of diverse particles
for the recovery of particles in the micro and nanosize range. • Separation of superfine particles and impurities
The particle size distribution can be both displaced and altered. • Displacement of the particle size distribution
Adjustment to the smallest grain sizes is also possible without • Altering the particle size distribution
difficulty. Valuable substances are recovered, undesirable • Adjustment to smallest grain sizes
superfine particles and impurities are separated reliably.

Slurry

Fine particles

Coarse particles
 DEWATERING DECANTERS · 13

Dewatering decanters for

highest dry substance
Dewatering decanters from GEA ensure
maximum solids concentrations.

Like the classifying decanters, the dewatering decanters from Their robustness and wear resistance make the dewatering
GEA also operate in continuous processing mode. These solid- decanters extremely reliable in long-term operation too.
wall scroll centrifuges are used in the mineral pro-cessing sector The decisive advantages of the centrifugal system as opposed
for dewatering suspensions. to filter press techniques are the closed and continuous
processing and the avoidance of the laborious filter handling.
Decanters operating at high speeds and high torques are Compared with evaporator technology, the energy consump-
required for dewatering fine particles. At the same time, the tion is significantly lower.
large product streams require large diameters. The centrifuges
from GEA meet these demands in every respect.
Benefits at a glance:
Due to their very high speeds, the dewatering decanters are • Maximum solids concentration
capable of producing end products with an extremely high dry • High product quality
substance. Variable drives with torque-dependent differential • High availability
speed regulation ensure constant solid concentrations, even with • Optimized drive systems
fluctuating feed concentrations. • A wide range of decanters specially designed for the
optimum dewatering of inorganic pigments

Suspension

Clarified liquid

Solids
14 · DRIVE CONCEPTS

Innovative drive concepts

for decanters

GEA summationdrive
The summationdrive always provides the full torque
across the entire regulation range. It supplies only
the power which is actually required, because the
secondary motor is operated purely as a motor, and
there are no braking effects. Accordingly, the drive
does not require any backdrive and provides savings
in terms of unnecessary conversion losses as well as
belt drives, shaft loads and construction space.

In the version used for higher differential speeds,

the drive combines the output of the primary and
secondary motor (summation) and thus minimizes
energy consumption. Conversion to the higher dif-
ferential speed range is possible without having to
replace the gear. In both drive versions, the differen-
tial speed is provided over large ranges without any
interruptions.

Differential gear drive

The differential gear drive is recommended when-
ever it is necessary to automatically regulate the
scroll speed in addition to regulating the bowl speed.
This can be achieved by means of two gears. The
secondary motor drives the central input shaft and
generates the differential speed proportionally to its
own speed. A second input shaft without any speed
is connected to the housing.

This means that the differential speed is not depen-

dent on the bowl speed. Differential gear drives are
used primarily in the lower range of the differential
speeds.
 WEAR PROTECTION · 15

Decanter wear protection –

no chance for abrasion and
corrosion
GEA uses highly resistant duplex steel and special armour-plating for all
parts which come into contact with product.

Crud treatment and recovery of organic components expose One possible solution is spray cladding, in which carbide is
decanters to extreme material strain. The low pH value of the for instance welded on to the vane of the scroll or areas in the
process (pH 2) and high operating temperature in conjunction distributor. The advantage of this solution is that the protecting
with a range of high chloride concentrations result in corrosion. material combines with the base material in the welding process.
The only way to tackle this problem is to use an extremely high
quality material. GEA therefore uses highly resistant duplex or GEA also offers the possibility of using tiles instead of or in
super-duplex stainless steels for manufacturing all components addition to carbide plating. Tiles are generally used in conjunc-
of the decanter which come into contact with product. tion with highly abrasive products. GEA also has the know-how
for cladding certain areas with ceramics in order to provide
This material is not affected by pitting, and also features higher special protection.
abrasion protection than stainless steel which is normally used.
In permanent contact with abrasive particles in metallurgy, this Depending on specific requirements, GEA offers wear and
wear protection is an essential advantage. corrosion protection in the form of
• Carbide cladding
In addition, all places at which increased levels of wear can be • Tiles
expected have to be provided with special armour-plating in • Ceramics
order to ensure permanent operation of the decanter. The most • Use of high-quality steels
suitable form of armour-plating according to the specific applica- • Rubber linings
tion is defined in close cooperation with the customer. • Coatings

GEA tackles problems posed by abrasive particles with special

armourplating for all decanter components which are at risk.
16 · ROTARY BRUSH STRAINERS

Rotary brush strainers and

wear protection
Upstream rotary brush strainers and a special coating for components
which are at risk protect the separators against clogging and abrasion.

Excessively large solid particles can clog the nozzles of the separators. This
is reliably avoided by installing a rotary brush strainer from GEA upstream.

The product is fed into the strainer insert through the inlet, and flows
through the strainer in the chamber to the discharge. The coarse solids are
retained and scraped off the interior of the strainer by the rotating brushes.
They fall into the conical base, from which they are discharged manually
from time to time or automatically through the solids discharge.

Special coating against abrasion

In order to ensure that maximum performances are permanently achieved,
the nozzle-type separators are also equipped with a special wear protection
against abrasion. This solution comprises coated wear plates as well as a
coating on the distributor bottom and the bowl bottom.

Benefits at a glance:
• Upstream rotary brush strainers prevent clogging of the nozzles
• Reliable protection against abrasion
• Maximum separation performance in the overall process
• Maximum maintenance intervals

Fine particles

Product feed

Coarse particles
 DECANTER DETAILS · 17

Decanters from GEA –

convincing right through to
the smallest detail
• GEA as a complete-range provider for a range of
Machine portfolio
600 – 350,000 l / h

• Parts which come into contact with product can be made of

Special materials
specific application-related materials, thus ensuring optimum
resistance and product-neutral properties

• Automatic system for infinitely variable adjustment of the liquid

GEA varipond®
level while the machine is running in order to adjust for product
fluctuations in the feed
• Assures maximum dry substance values and separating efficiency in
conjunction with different feed conditions, resulting in lower power
consumption
• Assures optimum conveyance of highly viscous liquids – enhances
conveyance efficiency
• Intelligent self-control

Separating zone adjustment • Assures optimum separation and clarification efficiency while the
during operation machine is running

Explosion-protected and gas- and • Can be used for instance in explosive areas or for processing
pressure tight designs available explosive or toxic products

• Drive versions tailored to meet the requirements of the specific

Six scroll drive versions
process ensure maximum clarification and dewatering efficiency as
well as cost-effectiveness of each individual application (energy
• and investment costs)
• All scroll drive versions are selected in accordance with product-
specific characteristics

• Depending on suspension and/or solids densities the bowl speed can

Adjustable bowl speeds
be adjusted by VFD

Wear protection • Better availability, lower maintenance costs

• Maximum speed, g-forces and g-volumes permit maximum

Rotor concept
throughputs and clarifying efficiency by use of product specific
cone angle
18 · GEA SEPARATORS

Nozzle-type separators for efficient

thickening and classification
Continously operating nozzle-type separators from GEA are the first choice
for efficient processing of superfine solids.

GEA nozzle-type separators discharge concentrated suspensions measurements are used for automatically carrying out adjust-
continuously via nozzles which are installed on the periphery ments to the feed capacity and the concentrate recycling. This
of the bowl. The product flows via the feed into the bowl, where achieves constant concentration of the discharged suspension.
it is separated into concentrate (underflow) and centrate (over- Fluctuations in the process results can thus be reliably excluded.
flow). The disc stack which is installed in the bowl increases the
equivalent clarification area and thus the performance of the Benefits at a glance:
separator. • All operating sizes covered
• Continuous method of operation
The size of the bowl diameter and thus the number of nozzles • With concentrate recycling before the nozzle in
are linked proportionately to the potential concentration of the order to increase the concentration
concentrate. The concentration increases in conjunction with • Sophisticated online analysis for stable process
increasing throughput, high initial concentration of the product, conditions
declining solids content in the discharge, small nozzle diameter • Direct drive for optimum energy efficiency and
and a low bowl speed. low service costs

The task is to achieve a balance between these factors and the

Product feed
equivalent clarification area as a standard measure for the clar-
ifying performance of the bowl, in order to make sure that the
remaining solid content in the concentrate permanently meets
the customer‘s requirements.

With the online analysis facility which is offered by GEA and Centrate
which is based on measurement of the concentration of the
product upstream and downstream of the nozzle-type separator, Concentrate
it is possible to adjust the clarifying performance of the centri-
fuge very precisely. The figures resulting from the concentration

GEA nozzle Separators are designed

for thickening superfine solids from
suspensions.
 DRIVE CONCEPTS · 19

Drive concept
for separators

GEA Integrated directdrive

The energy-efficient drive technology
GEA integrated directdrive ensures direct power transmission from
an integrated frequency-controlled-phase motor to the bowl – without
separate high-maintenance bearings.

Benefits at a glance:
• Improved level of effciency ensures significant energy savings
• 35 % reduced space requirement for the separator
• Exceptionally maintenance-friendly drive concept
• Water-cooled motor works considerably more quietly than an conven-
tional one
• Product feed and discharges in the bowl do not feature mechanical
seals

Direct drive system

The direct drive is an example of intelligent simplification in separating
technology. Wherever the upper limit for gear loads has been reached
or belt drives are undesirable, our separators with direct drive permit
virtually loss-free power transmission.

This boost in performance simultaneously reduces the costs of energy,

wear, maintenance and space. The required power is transmitted
directly to the bowl spindle by a 3-phase AC motor with frequency
converter control via a torsionally elastic clutch. The spindle
assembly is likewise supported by rubber-metal cushions. This
makes possible low-vibration running at high bowl speeds.

Benefits at a glance:
• Extremely space-saving design
• Avoidance of housing deformation
• High performance input
• Low maintenance requirement
20 · SEPARATOR DETAILS

Separators from GEA –

convincing right through to
the smallest detail
• GEA supplies a complete machine portfolio (capacity up to
Machine portfolio
350,000 l / h) with compatible hydraulic performance parameters /
 performance reserves – the right separator for every customer
requirement

Modular total concept • Customized solutions and delivery as required by customers

• Personnel-friendly operating of the separators and, if required,

Operating the separators
100 % remote-monitored operation possible, thus enhancing
operational reliability and availability
• Combination of maximum robust nature and reliability
• Low water consumption as no cooling necessary for the drive and
the slide ring packings

• All product contacting components can be made of special metals,

Special materials
cladded with special metals or coated resulting in optimum
resistance against corrosion

• Feed design can be adapted to product requirements

Discharge and feed design
• Clarified liquid is discharged foam-free under pressure by use of a
centripetal pump. Available discharge pressure is minimum 4 barg
which makes the need of transport pump unnecessary

• Drives are low-wear and service-friendly

Direct drive
• Use of lubricants approved for food applications
• Available in explosion-protected design and ATEX-compliant
• Special drives possible if required by customer

• Flow-optimized design (minimum flow resistance, minimum

Rotor concept
shearing forces) of all bowl parts assures optimum separating and
clarifying results with minimum product damage
• Maximum speeds (g-forces) / equivalent clarification areas achievable
   GEA SERVICE · 21

GEA Service – For your

continued success

GEA Service –
For your continued success
GEA Service offers dedicated teams of service experts. • Getting you started – Seamless support for instant
Our focus is to help our customers build, maintain, productivity and performance
and improve their performance, market presence and • Keeping it running – The cost-efficient way of
competitive edge for the entire life cycle of their plants ensuring the safety and reliability
and equipment. • Constantly improving – Sharing our knowledge
to safeguard your investment
Partnering with GEA gives you the benefit of our world- • Together with you – Enduring commitment
renowned, customer-tailored service and recommended to you and your business
spares upgrade, modernization and optimization services.
With our support you can be certain that every piece of
GEA equipment and technology will operate optimally
from day one, and for its complete lifespan, to give you
maximum return on your investment.
22 · PRODUCT DEVELOPMENT

Global test center network

Innovate, partner and prosper with GEA

Driving your future Driving solutions Driving technologies

By combining advanced in-house From new product and feasibility trials Overcoming technical barriers throughout
technology with a thorough understanding to scale-up studies, training programs the entire process chain, there’s no limit
of the processing industries, we help our and process support, we believe that our to where the GEA global network of test
customers to maximize their development services greatly benefit anyone involved centers can take your research.
results, gain more know-how and in industrial R&D, equipment selection,
discover additional opportunities for their process optimization and product
applications. development.

The GEA global network of test facilities offers teams of experts On-site trials and technical center
who work closely with their customers to optimize procedures Centrifuges are available for process trials at the operator’s
and evaluate their products, enabling them to achieve their site to assess the feasibility and profitability of individual
process and production goals. process steps and combined operations.

GEA test center Separation In co-operation with the customer, GEA also develops and
At the GEA test center of competence, customers can test both tests completely new processes. In this way, the GEA test
new and established products in a wide range of separation centers also underline the innovation strength of GEA as a
operations or perform comparative process studies with our leading international technology group.
skilled operators. Other test programs in GEA test centers
around the world can be involved to test entire manufacturing
lines.

Prosper with GEA

Book your ticket to success at

gea.com/contact
RESEARCH AND DEVELOPMENT  ·  23
We live our values.
Excellence • Passion • Integrity • Responsibility • GEA-versity

GEA is a global technology company with multi-billion euro sales operations in more than 50 countries. Founded in
1881 the company is one of the largest providers of innovative equipment and process technology. GEA is listed in the

B_CP-18-05-0007 EN © GEA Westfalia Separator Group GmbH. All rights reserved. Subject to modifications. May 1, 2018
STOXX® Europe 600 Index. In addition, the company is included in selected MSCI Global Sustainability Indexes.

GEA Germany
GEA Westfalia Separator Group GmbH
Werner-Habig-Straße 1 Tel +49 2522 77-0 [email protected]
59302 Oelde, Germany Fax +49 2522 77-2488 gea.com