Tag: Centrifuge Optimisation

Centrifuge Optimisation

Cane Sugar Processing Plant, Thailand

A major sugar producing organisation in Thailand recently commissioned a brand new sugar cane processing facility with a capacity of 15,000 tons of sugar cane/day plus its own power plant to generate 41 MW of electricity. The processing plant purchased a total of 12 vertical overdriven batch centrifuges and 5 vertical continuous type centrifuges.  

Initially they attempted to commission all the centrifuges in-house. Regrettably this led to the destruction of two units. NCD Separation Solutions Ltd was contacted by the centrifuge OEM and asked to visit site, firstly to evaluate the seriousness of the problem, then instigate an action plan to resolve all operating issues moving forward. 

Over a three week period all the centrifuges were successfully commissioned without any further operating problems. 

NCD Separation Solutions also delivered a comprehensive Operator Training package for all the centrifuge operators. This has led to plant capacity being met and a far more informed workforce.


Centrifuge Optimisation

Arabian Sugar Refinery, Bahrain

A total of 7 off batch basket sugar centrifuges and 5 off continuous sugar centrifuges, supplied by Thomas Broadbent & Sons of the UK, where installed at the brand new sugar refinery owned by Arabian Sugar of Bahrain.

As part of contractual conditions the centrifuges needed to demonstrate their ability to meet the Performance Acceptance Criteria before being fully accepted by Arabian Sugar.

NCD Separation Solutions Ltd was commissioned with the task of undertaking the Performance Acceptance Evaluations on behalf of the centrifuge supplier.

In addition to several key process performance criteria having to be met the Performance Acceptance Certificate would only be issued if the centrifuges were capable of maintaining the separation efficiency continuously for 120 hrs (5 days).

A total of three separate attempts were allowed in order to prove the performance of all the centrifuges. Failure to prove the performance acceptance criteria within the three attempts would result in the trials being deemed a failure and the Performance Acceptance Certificate would not be issued. The implication of such a failure would have serious contractual consequences between vendor and supplier.

Thankfully, it was possible to prove the efficiency of the centrifuges during the very first attempt. This therefore resulted in the centrifuge Performance Acceptance Certificate being issued.

NCD Separation Solutions Ltd was delighted with this result and pleased to have helped both the vendor and supplier to provide a highly successful, efficient and state of the art refined sugar facility.

Centrifuge Installation & Commissioning

Optimisation at Covidien UK

Following a recent overhaul of their two vertical, batch basket, filtration centrifuges, NCD Separation Solutions were invited to carryout a performance survey with a view of delivering an operator training package once the centrifuges were considered fully optimised.

The optimisation exercise for both centrifuges took approx. 5 days to complete. This not only increased production by over 10% but also improved product quality, yield, efficiency and the health and safety to the whole process.

Subsequent operator training sessions will ensure the now optimised process is maintained and operators have more confidence in making various changes to the process from time to time as they are more understanding of their actions.

Site Manager Mr Dave Hickton thanked NCD Separation Solutions for their professionalism in delivering all the various facets of the centrifuge upgrade package. He feels sure the improvement will be of significant benefit to Covidien.

Centrifuge Installation & Commissioning

Installation & Commissioning

A leading industrial chemical manufacturing organisation located in the Midlands, UK, recently purchased a large refurbished vertical batch basket filtration centrifuge with an additional Inert Gas Blanketing facility.

The company already has several batch basket centrifuges installed on site and it is hoped this latest acquisition would enhance production in its attempt to meet increased demand for one of their leading products.

NCD Separation Solutions Ltd was asked to provide assistance in the commissioning of their ‘new’ centrifuge. Following successful FAT (Factory Acceptance Test) and SAT (Site Acceptance Test) evaluations the centrifuge was ready for commissioning.

After completing dry commissioning and wet commissioning with water, the centrifuge was readied for actual product suspension. Product commissioning took several days to complete, at the end of which a fully optimised centrifuge separation system was achieved.

This latest centrifuge facility will now allow the end user to more than double their current production levels.

Centrifuge Optimisation

Centrifuge Optimisation & Operator Training

After competing against two leading centrifuge manufacturers NCD Separation Solutions were recently awarded the contract to provide Centrifuge Optimisation and an Operator Training package for one of the UK’s leading chemical companies based in the North East of England.

Initially we will carry out a Site Survey of the centrifuges in operation and its installation of 3 off horizontal batch basket filtration centrifuge. This will identify the key problem areas that are currently preventing the centrifuge stages of the operation from being anywhere near optimised.

On completion of the Site Survey we will issue a detailed Report of our findings that will identify the key areas of concern and propose a positive way forward.

Once all the centrifuges are fully Optimised NCD Separation Solutions will provided a series of in-house Operator Training sessions for all the centrifuge operators based on the findings specific to their operation.


Operator Training

Centrifuge Operator Training at GlaxoSmithKline (GSK)

Following the successful Centrifuge Optimisation program of several batch basket filtration centrifuges by NCD Separation Solutions Ltd, it was agreed they would remain on site to develop and deliver a comprehensive Training package for all plant centrifuge operatives.

The completion of the optimisation phase of the project resulted in the ideal scenario of having real meaningful before and after data. Such data formed the basis of the Operator Training. The ’live’ case study provided the basis for a training package that all the operatives could fully associate with.

Plant Manager, John Clack, said “the whole program of Site Survey, Centrifuge Optimisation and Operator Training has resulted in significant improvements in product throughput as well as a more consistent product quality. Product yield has also increased and far less batches are failing final quality checks. The comprehensive program offered by NCD Separation Solutions Ltd has been a major benefit to our companies operation and our operators”.

Centrifuge Installation & Commissioning

Centrifuge Installation & Commissioning of Vietnam sugar factory

A sugar factory in the province of Nghe An, Vietnam elected to employ the use of several new batch & continuous sugar centrifuges. The centrifuges were purchased from Thomas Broadbent based in the UK. The factory is designed to process 6,000 tonnes of sugar cane per day. Factory engineering and management support required for such a major project was supplied by a leading Australian engineering house.

NCD Separation Solutions Ltd was offered the opportunity to become part of the centrifuge Installation & Commissioning team.

Despite several issues surrounding the supply of regular volumes of sugar cane the project was eventually successfully completed by all parties, on budget and in time.

Following successful Installation and Commissioning of the centrifuges, NCD Separation Solutions remained on site to deliver a detailed Centrifuge Operator Training package.

Once operating at full capacity NCD Separation Solutions Ltd has been asked to return to site to undertake a detailed Optimisation program of the centrifuge operation.

Centrifuge Optimisation

Biodiesel plant sees benefits from Centrifuge Optimisation

An independent Centrifuge Optimisation Project at one of Europe’s largest Biodiesel plants has enabled them to produce record levels of biodiesel and pharma grade glycerine.

The optimisation exercise significantly improved the throughput & efficiency of their disc bowl, three-phase solid bowl decanter and solid bowl decanter centrifuges. This has also resulted in major operational and cost benefits being realised for the whole processing plant.

Original Problem

Following difficult plant commissioning issues the plant was struggling to meet client demands for their core product and bi-products. This resulted in them deciding to concentrate their efforts on the primary separation i.e. the centrifuges. The biodiesel plant requires key separation stages to be carried out by various types of continuous sedimentary centrifuges.

The plant was struggling to meet the plant design capacity. To achieve this it was necessary to increase the throughput to the centrifuges as well as maintaining higher levels of centrifuge ‘up time’.


With over 35 years of experience, specialising in Industrial Centrifuge separation technology, NCD Separation Solutions Ltd, acted as lead consultants for the Centrifuge Optimisation Project. They carried out an initial comprehensive Site Survey then submitted proposals for a comprehensive Process Optimisation programme.

Operator Training was also a key consideration in order to make plant operatives aware of the important parameters and how they play their part in the separation efficiency of the centrifuges. This provided them with much needed knowledge of all the centrifuge controls, capabilities and limitations as well as demonstrating the importance of maintaining a uniform feed stock.

Key Benefits

Significant cost savings were identified through the implementation of an improved control and operational philosophy. It was also possible to operate all the centrifuges, as intended, in a continuous manner with virtually no unplanned shutdowns. This has allowed the plant, as intended, to operate on a continuous basis.

From a health and safety perspective the improved operation of the centrifuge processing equipment has dramatically reduced the frequency of inspections and cleaning outs.

According to management the result of the optimisation work by NCD Separation Solutions Ltd – “has seen an amazing 30% increase in production that now allows us to not only achieve our production targets of Biodiesel, but to significantly exceed them as and when the market demands. As a general spin off from NCD’s involvement we now have a separation process that is more reliable, requires less maintenance, is operator friendly and we have a far more informed workforce”.


Centrifuge Optimisation

Centrifuge Optimisation increases output by 25%

A recent independent centrifuge optimisation project at a multinational chemical company based in the South East of England has resulted in a 25% increase in production. Optimisation of 3 off vertical batch basket filtration type centrifuges has also provided operational and other cost saving benefits upstream and downstream of the centrifuge operation.

Existing Problem – The company had to meet a significant increase in demand for its products without investing in additional plant and equipment. The solution therefore was to optimise its existing centrifuge filtration process by looking to reduce cycles times, thus increasing product throughput. The process centred around three vertical batch basket filtration centrifuges, capable of recovering upto 1200 kg/hr final cake solids. To achieve this level of throughput it was necessary to both reduce the process cycles times and increase the payload of retained product solids in each basket load.

Solution – NCD Separation Solutions Ltd acted as the independent consultants on the project and carried out an initial Site Survey, submitting proposals for a comprehensive process optimisation package. Operator Training was particularly important in making them aware of revised process requirements and providing them with knowledge of centrifuge controls, capabilities and limitations and the need to maintain strict health and safety requirements.

Key Benefits – Cost savings were also identified through using less product wash fluid leading to a corresponding reduction in effluent discharge levels hence reducing operating costs. It was also possible to operate each centrifuge continuously for much longer periods before having to clean its internal surfaces. From a Health & Safety perspective, the improved operation of the process has reduced the frequency of basket inspections and cleaning operations by 50%.

According to site management the end result is a 25% increase in production which will help satisfy escalating demand from their clients around the world.

As a general spin-off from NCD involvement they have a filtration process which requires less maintenance, is more environmentally friendly and provides healthier working conditions for company site teams.