SEPARATION Dr. Ir. Meika Syahbana Rusli, MSc Peralatan industri 1
Seringkali dalam industri pengolahan hasil pertanian diperlukan operasi pemisahan komponen-komponen suatu campuran menjadi fraksi-fraksinya. Fraksi-fraksi dari suatu campuran dapat berbeda satu dengan yang lainnya dalam ukuran partikel, fasa atau komposisi kimia. Peralatan industri 2
Teknik untuk pemisahan komponen-komponen suatu campuran dapat dibagi menjadi : 1. Metode pemisahan mekanis, yang biasanya berguna untuk pemisahan partikel padat atau bahan cair tetes : 2. Operasi-operasi difusinal, yang melibatkan perubahan fasa atau pemindahan bahan dari suatu fasa ke fasa lainnya. Peralatan industri 3
Metode pemisahan mekanis dibagi menjadi : 1. Pemisah campuran padatan • pemisahan campuran partikel padatan menurut ukuran dapat dilakukan pada suatu rangkaian penyaring yang memiliki lubang berukuran standar. • Pemisahan partikel padat bisa juga dilakukan dengan klasifikasi udara berdasarkan perbedaan gaya gravitasi Peralatan industri 4
2. Pemisah sistem padatan-cairan : a) b) c) Pengendapan : ¨ Gravitasi (pengental/penjernih) ¨ Gaya sentrifugal ¨ Flotasi udara ¨ Flotasi media kental ¨ Sifat magnetik Penyaringan / filtrasi : ¨ Saringan (gravitasi) ¨ Filter (vakum, tekanan atau sentrifugasi) Pengempaan / expressi ¨ Tekanan batch ¨ Tekanan kontinyu (screw, roll atau discs) Peralatan industri 5
Vibratory screeners Circular Vibratory Screeners Peralatan industri 6
These circular, vibratory separators are ideal for solids/solids and solids/liquids applications and range in size from 18” diameter (460 mm) laboratory units to 100” diameter (2, 540 mm). They handle a wide variety of feed rates and consistencies, maximize throughput by efficient screen utilization and anti-blinding devices. Multi-deck designs yield as many as six, predetermined particle sizes from 2” (50 mm) to 400 mesh (37 microns). A unique design feature, the Quick-Change Screen option, reduces screen changing from hours to minutes. Vibroscreen separators are available with ultrasonic flow enhancers as well as many accessories for maintaining performance even with difficult to scalp or classify materials. Peralatan industri 7
Multi-Deck Vibratory Classifier Kason vibratory screeners with multiple decks yield up to five precise particle classifications from 5 cm to 25 microns. Available with a variety of antiblinding devices, they handle dry, moist, lumpy, stringy and otherwise difficult-to-handle bulk material on a batch or continuous basis. They are available constructed of stainless steel to industrial or sanitary standards, in diameters from 18" to 100" (460 mm to 2540 mm) diameters. Options available for rapid screen changes, in-place cleaning, and fast, thorough washdown. Peralatan industri 8
Peralatan industri 9
Millimeters Model A B C D E F G H J K M N O P R K-18 403 506 597 696 775 607 695 784 873 105 378 445 457 102 305 K-24 371 502 616 730 845 632 745 581 975 100 441 508 610 152 413 K-30 387 527 641 758 870 667 772 886 1000 117 518 597 813 152 508 K-40 429 616 781 946 1111 810 975 1140 1305 155 657 749 1016 203 660 K-48 556 718 833 1048 1213 911 1076 1242 1407 159 806 921 1220 203 756 K-60 543 708 984 1200 1416 1013 1229 1445 1661 191 1010 1118 1524 203 914 K-72 702 1038 1290 1521 1762 1311 1563 1794 2035 235 1168 1254 1829 203 1035 K-84 749 990 1257 1524 1791 1293 1549 1916 2093 273 1473 1568 2133 254 1245 K-100 813 1080 1346 1505 1860 1372 1639 1905 2172 229 1991 2102 2540 254 1422 Peralatan industri 10
Single-Deck Vibratory Screener FLO-THRU Low-Profile High Capacity Scalper Separates at high rates in lowheadroom areas Flo-Thru Vibroscreen® separators employ two unbalanced-weight gyratory motors mounted on opposing exterior sidewalls of the unit (instead of one motor positioned beneath the screening chamber), reducing minimum height requirements significantly. This Kason innovation also enables the bottom outlet to be located directly below the top inlet, allowing material to fall vertically through the screen at high rates. Available from 18" to 84" (460 mm to 2135 mm) in diameter. Peralatan industri 11
Single-Deck Vibratory Screener Peralatan industri 12
Millimeters Model A B C D E F G H K-24 -FT 511 378 152 152 457 597 568 K-30 -FT 511 371 152 203 651 791 667 K-40 -FT 643 460 159 203 651 791 667 K-48 -FT 724 543 203 305 965 1118 924 K-60 -FT 879 635 171 203 406 965 1118 914 K-72 -FT 914 670 140 203 457 1143 1346 1067 Peralatan industri 13
Bag Dump Screening Station with Dust Collector Peralatan industri 14
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As material is gravity-fed into the unit, rotating helical paddles continuously propel the material against the cylindrical screen, and accelerate them through the apertures. On-size material then drops through the first of two discharge spouts, into a storage vessel or processing equipment. The paddles, which do not contact the screen, also serve to break-up agglomerated materials. Oversized particles unable to pass through the apertures, exit through the end of the screen cylinder and fall through a second discharge spout for discarding or re-processing. Cylindrical screens are offered in woven nylon, monofilament, stainless steel, and stainless steel wedge wire, to accommodate a wide range of materials. Available to industrial, food, dairy and pharmaceutical standards including 3 -A and BISSC. Peralatan industri 16
Vibratory Screener with clamshell Lid Allows rapid screen changes, easy washdown All Vibroscreen® separators from 30" to 84" (760 mm to 2135 mm) diameters in both single- and multideck configurations are available with Kason's exclusive "clamshell" option. The hinged lid and/or frames are released via quick-disconnect clamps and held in an open position by gas pistons, allowing rapid screen changes and easy, thorough washdown of all interior surfaces. The Clamshell Lid accepts screens with or without center tensioning construction, and accommodates screen decks with or without anti-blinding devices. Peralatan industri 17
PORTABLE BATCH SIFTER A new, lightweight Batch Sifter variant of Kason's "FLO-THRU" VIBROSCREEN separator line scalps oversize particles from small batches of bulk material being loaded into drums, blenders, other process equipment and storage vessels. The units are offered in diameters of 18, 24 and 30 in. (450, 600 and 750 mm), with a single imbalanced-weight gyratory motor, minimizing weight for easy repositioning while providing ample capacity for typical 18 Peralatan industri batch requirements
Bag Dump Screening Station Maintains quality, contains dust The Kason Bag Dump Station employs a integrally mounted vibrating separator to scalp lumps, oversize particles, paper bag pieces, string, and other foreign objects from materials dumped manually from bags, drums, boxes and other containers. Available in 24" (610 mm), 30" (760 mm), or 40" (1020 mm) diameters, the units can be fitted with integral bar magnets, self-contained dust collection systems, and high-strength decks to support containers being dumped. Outlets available for connection to any conveyor or process equipment. Peralatan industri 19
Two Stage High Capacity Screener 60 to 80% Higher capacity than single stage screeners, at low cost Peralatan industri 20
A new VIBROSCREEN® "Two-Stage RC" circular vibratory screener offers 60 to 80 percent higher capacities than conventional screeners of equal diameter. The two-stage design features an upper screen deck having a 360° annular gap at the screen's periphery. This deck is fed with more material than it can efficiently screen, with two results: 1) On-size material falling through the upper screen is funneled through a hole in the center of the lower screen to the machine's discharge outlet and 2) 2) The overflow of on-size material plus all oversize material cascade over the screen's periphery onto a second screen of equal mesh that scalps the balance of material in normal fashion. The machine boosts capacity without increasing floor space, and costs 20 to 30 percent less than conventional screeners having larger diameters and equivalent capacities. The two-stage screening hardware can be installed new or retrofit in diameters from 40 to 100" (1015 to 2540 mm) to scalp up to 70 tons per hour. Available to 3 -A, FDA, BISSC and other sanitary standards, the units can be disassembled rapidly for thorough wash down. Peralatan industri 21
ULTRA-HIGH CAPACITY IN-LINE PNEUMATIC SCREENER ALLOWS RAPID CLEANING, SCREEN CHANGES Peralatan industri 22
PRINCIPLE OF OPERATION The chambers above the top screen and below the bottom screen are connected by a central bypass chute, causing on-size material and air entering the central chamber to reach the bottom outlet via two pathways: upward through the top screen then downward through the chute; or downward hrough the bottom screen. Oversize material is ejected through a spout at the periphery of the lower screen. A tangential inlet along the horizontal centerline of the central chamber prevents material from impacting screens at 90° angles, minimizing screen damage and the breakdown of oversize foreign material into on-size contaminants. 23 Peralatan industri
Dual Screen Ultra High Capacity Screener Gently Scalps in-line with pneumatic conveying systems, at ultra high rates Peralatan industri 24
Scalpers Peralatan industri 25
n Simplicity offers a complete line of vibrating scalpers in two-bearing and four-bearing models. Designed to handle run-of-quarry or run-of-mine material, Simplicity scalpers are high-quality machines that are built to last. n A Simplicity vibrating scalper installed ahead of a crusher performs coarse sizing and provides a controlled, highcapacity flow of material. It eliminates crusher overload due to material surges. It also reduces crusher wear and minimizes production of fines by bypassing material already at or below desired size. Peralatan industri 26
Two-Bearing Peralatan industri 27
n The Simplicity Simpli-Flo heavy-duty vibrating screen serves a wide range of industries that require dependable, productive, low maintenance equipment. A wide range of sizes are available from 3' x 6' up to 8' x 20', in one, two and three-deck units. n Single piece, continuously welded decks are Huck® fastened to extra deep corner supports, and rugged steel side plates for a box-type structural strength that is highly resistant to racking. Side plates are laid out with NC equipment and drilled in matched pairs for precision fitting of deck assembly and bearing housings. Corner supports are full height for extra rigidity in the side plate area. Peralatan industri 28
Dual-Mechanism Peralatan industri 29
n Simplicity's dual-mechanism two-bearing inclined vibrating screens are the rugged machines you need for those heavy jobs. The dual 140 mm mechanism is an alternative to the 160 mm single shaft mechanism. This alternative extends bearing life on heavy-duty applications or increases speed capabilities on fine screen applications. The design isn't just tough. . . it's the toughest. n The screens are available in both two and three deck models in sizes ranging from 7' x 20' to 8' x 24'. For your next heavy-duty job, specify Simplicity dual-mechanism inclined screens. Peralatan industri 30
Four-Bearing Peralatan industri 31
he Simplicity four-bearing gyrating screen is the original mechanically vibrated screen using a counter-balanced eccentric shaft. The shaft is accurately machined to provide an exact counter-balance for the weight of the entire frame and deck structure, "building in" positive action with perfect smoothness. Simplicity four-bearing screens can be mounted by supporting the main frame from below, or suspending it by rods or cables attached to plant superstructure. With either type of mounting, positive action of the screen's counter-balanced shaft will maintain full effectiveness and minimize transfer of vibration to the supporting structure. Peralatan industri 32
High-Speed Peralatan industri 33
The Simplicity Nu-Z screen is a thoroughly field proven unit designed for efficient material separation. Its unique vibrating concept makes it ideal for a wide variety of screening applications such as dewatering, dryscreening of fine material and screening of difficult to handle materials such as chemical, fertilizer, sand, silica, slate, clay, etc. Peralatan industri 34
Horizontal Vibrating Peralatan industri 35
n Horizontal screens are designed to operate in stationary and in portable plants where load height and travel height must be held to a minimum. Simplicity horizontal screens are also ideally suited for dewatering operations. They are superior both as to capacity handled and amount of liquids that can be removed. They have done an outstanding job in dewatering coal, gravel and ores, especially in recovery of "heavy media" from the "sinkfloat" concentration processes. n Simplicity horizontal screens are built in many models and sizes, with deck styles to meet a variety of applications. Peralatan industri 36
Low-Profile Horizontal Peralatan industri 37
n Simplicity's horizontal low-profile vibrating screen is the ideal machine for your portable plant applications with the drive system built through the screen body, it gives you a compact, low-profile screen. n Speed, stroke amplitude and throw angle are easily adjusted to suit your screening requirements. The dualshaft drive gives you all the features required in a horizontal screen, plus the ease of maintenance associated with two shafts and oil lubrication. n Horizontal low-profile screens are available in two and three deck models in sizes of 5' x 14', 5' x 16', 6' x 20' and 7' x 20'. Peralatan industri 38
Centrifugal Screeners PRINCIPLE OF OPERATION Sift, scalp, de-dust, de-lump and de-water virtually any bulk solid or slurry Material is fed by gravity or pneumatically into the feed inlet and redirected into the cylindrical sifting chamber by means of a feed screw. Rotating, helical paddles within the chamber continuously propel the material against the screen, while the resultant, centrifugal force on the particles accelerates them through the apertures. These rotating paddles, which never make contact with the screen, also serve to breakup soft agglomerates. Oversized particles and trash are ejected via the oversize discharge spout. Peralatan industri 39
Direct Drive Model Peralatan industri 40
DIMENSIONS (MILLIMETERS) Model GO Motor One 1 HP (. 75 k. W) A B C D H 140 200 L 140 200 451 1340 KO One 2 HP (1. 5 k. W) 162 279 254 406 832 1708 MO One 3 HP (2. 25 k. W) 162 279 254 406 832 1708 MO Twin Two 3 HP (2. 25 k. W) W 305 463 Consult Factory Peralatan industri 41
Belt Drive Model Peralatan industri 42
DIMENSIONS (MILLIMETERS) Model GOB Motor One 1 HP (. 75 k. W) A B C D H L W 140 200 1060 959 305 KOB One 2 HP 162 279 254 406 1194 1259 463 MOB One 3 HP 162 279 254 406 1194 1259 463 YOB One 5 HP 219 343 254 406 1010 1727 521 YOB Two 5 HP Twin (1. 50 k. W) (2. 25 k. W) (3. 75 k. W) Consult Factory Peralatan industri 43
Standard Direct Drive Model MO The Centri-Sifter® centrifugal screener separates solids from solids or slurries at high rates. Rotating paddles propel on-size particles or liquids through a cylinder of woven nylon monofilament or stainless wedgewire screen. Rotating paddles break up lumps and handle difficultto-separate materials. Offered with numerous anti-blinding devices. Access door allows rapid inspection, washdown and screen changes. Available to industrial, 3 -A, FDA, and BISSC sanitary standards, and in low-profile and twin configurations. Peralatan industri 44
Twin Centri-Sifter® Separators Kason twin Centri-Sifter® models are designed for applications requiring exceptionally high capacities. These duplex units are available in a range of designs that double the capacity of single units. Twin models are equipped with a splitter to evenly divide the flow of incoming material, regardless of feed rate. Peralatan industri 45
High Temperature Clean-in-Place unit This ASME coded sanitary Centri. Sifter separator delumps and scalps fine pharmaceutical powders. It is designed to provide 300°F (149°C) temperatures and 60 psig of internal pressure required for in-place sterilization. Using special materials and finishes enables this unit to meet the specifications for pharmaceutical, biotechnical vaccine applications. Peralatan industri 46
Separator With Integral Feeder Integral feeders eliminate the need for separate feeders while reducing overhead space requirements. Powered by its own variable speed motor and drive, the unit offers independent control of material feed rates— regulated by the operator of the machine or from the control panel. The feedcontroller also lengthens screen life by preventing overloads due to surging. Peralatan industri 47
Centri-Sifter® Bag Dump Station To speed production, a pet food producer uses this combination Bag Dump Station and dust-tight Centri-Sifter screener unit with Clean-In-Place (CIP) spray heads. The unit delumps and screens in one operation, while the Bag Dump Station screens oversize material and debris. The CIP spray heads reduce cleaning time significantly. Peralatan industri 48
Quick-Clean CENTRI-SIFTER The Centri-Sifter® centrifugal sifter features a hinged end cover and three-bearing shaft that cantilevers for quick removal of internal components. External roller bearings are located at the motor end of the shaft and on a hinged cover at the discharge end for maximum support and vibration-free operation. When the end cover is hinged open, the shaft becomes a cantilever supported by a third externally mounted roller bearing located between the motorend bearing and material feed point, allowing internal components to slide freely from the opposite shaft end. Peralatan industri 49
The sifter is ideal for food, dairy and pharmaceutical applications requiring thorough wash-down, as well as general chemical applications involving frequent screen changes/inspections or runs of multiple materials with no cross contamination. Dry or moist bulk solid material is gravity-fed into the feed inlet and redirected into the cylindrical sifting chamber by means of a feed screw. In addition to sifting, scalping and dedusting of dry bulk materials, the screener can break up soft agglomerates and/or dewater moist solids or slurries. Peralatan industri 50
Small-batch, Quick-Clean CENTRI-SIFTER The Mini Centri-Sifter centrifugal sifter for screening small batches of bulk pharmaceutical materials and other contamination-sensitive products, allows rapid disassembly and thorough wash-down. Using three thumb screws, the unit's end plate, cylindrical screen and shaft-mounted paddle assembly can be removed in less than one minute, providing access to sanitize all material contact surfaces. Peralatan industri 51
Plate and frame filter press Peralatan industri 52
Features : n n Die presses the reinforced polypropylene into chamber plate featuring high intensity, light weight, anticorrosion acid and alkaline resistant, poisonless and smelless; The hydraulic device is used for pressing and releasing the chamber plates, the electrical contact pressure guage is available to automatically maintain pressure and the maximum pressure is 14 MPa; Maximum filtering pressure to be 0. 5 MPa is the best condition for cake forming; Press the button on the electrucal control board equipped with safe device to ensure safety to operators. Peralatan industri 53
n Application : Solid-liquid separation of suspensions of all kinds, prevent fruitful in a wide spectrum of industries such as coal, petrochemical, metallurgy, pharmaceutical, light industry, food processing and textile, as well as environmental protection. n Filter area : 10 -80 m 2 Peralatan industri 54
Parameter Of Plates/ frames Contents of Press¹(m 3) Thickness Foundation Length of of Size A Machine Cake(mm) Model Filter Area (m 2) B Y 10/870 -U 10 7/8 0. 132 30 1475 3180 1980 B Y 15/870 -U 15 13/14 0. 2311 30 1835 3540 2150 B Y 20/870 -U 20 17/18 0. 297 30 2075 3780 2265 B Y 25/870 -U 25 21/22 0. 363 30 2315 4020 2375 B Y 30/870 -U 30 27/28 0. 462 30 2675 4380 2550 B Y 40/870 -U 40 35/36 0. 594 30 3055 4860 2775 B Y 50/870 -U 50 45/46 0. 759 30 3755 5460 3060 B Y 60/870 -U 60 53/54 0. 8911 30 4235 5940 3285 B Y 70/870 -U 70 63/64 1. 056 30 4835 6540 3685 B Y 80/870 -U 80 71/72 1. 118 30 5315 7020 3990 B Y 90/870 -U 90 81/82 1. 353 30 5915 7620 4290 B Y 100/870 -U 100 89/90 1. 485 30 6395 8100 4535 Peralatan industri Weight (kg) 55
The Rotary Drum Filter Description The Rotary Vacuum Drum Filter belongs to the bottom feed group and is one of the oldest filters applied to the chemical process industry. Peralatan industri 56
Operational Sequence The valve has three bridge blocks: 1. Vacuum and blow zones separating bridge: This bridge cuts off the vacuum so it is slightly wider than the internal pipe port. 2. Dead zone bridge: This bridge opens to vacuum once a compartment submerges. 3. Start-up assist bridge: At start-up the upper vacuum zone is open to atmosphere and a cake may be formed only when closing the valve that controls this zone. Peralatan industri 57
The flow scheme of a Rotary Drum Filter Station Peralatan industri 58
In broad terms drum filters are suitable to the following process requirements: n Slurries with solids that do not tend to settle rapidly and will remain in a uniform suspension under gentle agitation. n Cakes which do not require long drying times to reach asymptotic moisture values. n Cakes when a single washing stage is sufficient to remove residual contaminants from the cake or yield maximum recovery of filtrate. n Filtrates that generally do not require a sharp separation between the mother and wash filtrates. Some complex valves, however, enable atmospheric purging of the sectors and internal piping to facilitate a sharp separation of filtrates. n Filtrates that are acceptable with a low quantity of fines that pass trough the filter cloth in the first few seconds of cake formation. Broadly, and depending on particle size and cloth permeability, the filtrate may contain 1000 to 5000 ppm insolubles. Peralatan industri 59
Centrifugal Decanter Peralatan industri 60
Spins the olive paste in a horizontal drum; the heavier flesh and pits goes to the outside and the water and oil is tapped off from the center. n Advantages compact machinery - one decanter can take the place of several presses semi continuous and automated limited labor n Peralatan industri 61
n n Disadvantages expensive more technical labor required may consume hot water high energy consumption pomace may end up moist greater amount of vegetable water to be disposed of reduced antioxidants due to added water subject to wear from rocks, grit Peralatan industri 62
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