Alfa Laval - Industrial fluids

Industrial fluids

Better quality industrial fluid extends equipment lifetime and levels of productivity, and reduces costs. Clean fluid also means fewer lubricant changes and less environmental impact. Alfa Laval has a range of proven high-speed centrifuges (fixed and mobile) to extend the service life of all kinds of service fluids and, by extension, your systems, whether you’re a small workshop or a large plant.

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Effective removal of oil and solids from different types of fluids

  • Prolongs tool and fluid lifetime
  • Low total cost of ownership (TCO) and less downtime for service
  • Cleaner cutting fluids increase precision
  • Reduces wear on system components saving costs and boosting productivity
  • Removes both free/tramp oil and solids in one operation – even small particle sizes

Due to their high speed, disc stack technology, and automatic discharge, Alfa Laval centrifugal separators are extremely efficient in removing fine solid particles or liquid contaminants from different kinds of service fluids. They remove more than 99% of all solid particles between 2 and 5 μm from a lubricant, and virtually all of the oil but none of the additives. This also reduces bacterial growth which is harmful to the fluid and contributes to a healthier working environment.

分离切削液v

将切削液与固体、液体污染物分离,可延长工具与流体使用寿命,降低总运营成本,缩短停机时间。

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清洁清洗液

当开始清洁清洗液时,由于废液及停机时间,整个更换过程会非常昂贵。将清洗液有效分离之后,您可以在更长时间里保持最高生产力和效率。

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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.

工作原理

在分离过程中,离心力把工艺流体中的重颗粒往外压向分离器壁。将这些颗粒从转鼓中自动排放到污泥罐中。如果存在两种液相(比如冷却液和浮油,或净油和水),离心力将让两种液相分离。轻相和重相通过分离器不同出口而分别排出。

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Alfie

  • 可连接到旁通流,保证缩短维修停机时间
  • 碟片式分离器同时提供油和污泥的三相分离
  • 设计便于操作员使用
  • 无需重新设计机械装置

 访问页面

 

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Emmie 2

  • 安装在旁通流中,所以不需要更换机器
  • 即插即用
  • 一旦开始不需要监督
  • 碟片式分离器提供水和颗粒的快速、同步、持续的三相分离功能。

 访问页面

 

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AlfaPure

  • 去除水、研磨的金属细粉以及小至2μm的其他颗粒
  • 即插即用模块方便安装
  • 无需重新设计设备
  • 分离片束技术提高分离速度

访问页面

 

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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.

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工业用流体清洁技术

如果清洁工业用流体,您能节省极大成本。但您如何能确定您的应用采用哪种技术最有效且总体成本最低呢?我们这里有4种最常见的选项帮您决定 —— 离心、过滤、撇油及聚结。

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简要介绍四种技术

  • 离心技术能将不同密度的物体分开,油与颗粒均可
  • 过滤器使用不同尺寸网筛仅过滤固体
  • 撇油器使用一种亲油设备如皮带或圆盘来收集油液
  • 聚结器可以去除工业用流体中的油。

最适合您的技术就是最好的技术。

  • 离心机将洁净的工业用流体导回您的工艺流程,而分离出来的污染物则继续被排出。在分离器转鼓中的颗粒等待后续处理或被自动排出。
  • 过滤器一般将过滤后的固体放在一次性套筒,需要定期更换。
  • 在撇油过程中,油液在飘过水面时粘附在浮动闭环管外,并根据水位变动自动调整。
  • 聚结器仅在工业用流体几乎没有颗粒时才起作用。大多数情况下,聚结器与多台过滤器一起使用,确保在一个系统里去除固体颗粒和水。

对比清洁技术

  Disc stack centrifuge Filter Coalescer Skimmer
分离颗粒和油

去除颗粒 部分
去除游离油 有限
资本成本
运营成本
油分离效率
颗粒分离效率 高,即使是小颗粒 高(受限于网格大小)
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离心分离

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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.

 

功能强大、生产力高、经济实惠

  • 一次性除油和固体
  • 处理即使很小的颗粒
  • 低维护水平,可延长工艺正常运行时间
  • 延长设备使用寿命
  • 总运营成本(TCO)低
  • 仅去除零散的乳化油,完整保留工业用乳液

离心技术使用比重力大5000倍的离心力来分离不同密度颗粒,持续将洁净流体导回您的工艺流程。在固体污染物被单独存储时,油被释放出来。离心技术能让您处理清洁量大及油液短期大量流入的情况。

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工业用流体-过滤器

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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.

注意事项

尽管工业用流体过滤器不要求太大资本投入,但是有一些因素会影响其效率,可能导致更高的总运营成本(TCO)。

  • 过滤器不能去除油液,因此需要配合聚结器或分离器使用。
  • 对一次性用品的需求导致更高的运营成本,同时需符合日益严格的环境法规。
  • 性能有限-只能捕获比网格大的固体(一般为10-30 µm)
  • 如果过滤器在启动或停止时受到压力冲击,所捕获的颗粒会被再次释放。
  • 过滤器需要定期监督/更换,以避免堵塞(颗粒穿过旁路阀)
  • 压力波动/下降时,过滤器被污染。
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Coalescers

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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
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Skimmers

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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

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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.

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Case stories

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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.

Airbus case story

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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.

Ford case story

 

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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.

Renault case story

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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.

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Take care of your separator correctly

Ensure a long service life

You can expect decades of efficient industrial fluid cleaning if you take care of your separator correctly. In short, it's a matter of reading the manual and using genuine parts and the right tools. We offer a comprehensive package of detailed service instructions and specific service kits with genuine spare parts.

  • Maximize uptime
  • Support long working life
  • Ready-to-use kits simplify maintenance and save time
  • Reduced order handling time
  • Global distribution centers for rapid delivery

Preventive maintenance package

Alfa Laval Preventive Maintenance includes an intermediate service (IS) or a major service (MS) packaged in a box with the parts you need. The service interval depends on running hours or a fixed period of time.

We recommend that you:

  • Always follow the service instructions in the separator manual
  • Perform an Intermediate Service every 3 - 6 months (2-4,000 hours)*
  • Perform a Major Service every 12-18 months (8-12,000 hours) depending on machine type and process conditions*

* The manual gives the maximum requirement. Industrial fluids cleaning is in general not a severe application and the intervals are somewhat flexible.

Service kits and spare parts

An Alfa Laval centrifugal separator will perform for decades if you look after it properly. But you have to familiarize yourself with the manual and make sure you use genuine spare parts and the right tools. We provide specific service kits with genuine spare parts and a comprehensive package of detailed service instructions. We even have service videos on how to properly maintain your separator. Visit the product guide to find out more! If the products are not visible for your country, please fill out the contact form.

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Manuals for industrial fluids cleaning separators

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You will find the latest manuals for your fluids cleaning module here.

They include:

  • Safety instructions
  • Operating instructions
  • Service instructions
  • Trouble-shooting
  • Technical specifications

Please note that because some product ranges has been in operation for many years there may be slight variations in design.

The manuals cover all aspects of running and taking good care of your investment.

We have manuals for:

  • Alfie 200
  • Alfie 500
  • Emmie 2
  • WSPX 403 (AlfaPure S2) 
  • WSPX 604 (AlfaPure S3) 
  • WSPX 407 (AlfaPure S7) 

If the manual for your industrial fluid separator does not correspond with your product, please contact us.

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Ease of installation, operation and maintenance

See for yourself by exploring our service films to help you get the best out of your cleaning module.

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.

 

Good Practice Guide for Safe Handling and Disposal of metalworking fluids

The guide addresses the preparation, maintenance and eventual disposal of metalworking fluids and contributes towards a safe working environment. It has been prepared by a panel of experts from the UK Lubricants Association (UKLA)Metalworking Fluid Product Stewardship Group (MWFPSG) and from the Health and Safety Executive (HSE) with additional advice from experienced workshop managers and medical experts.

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Get in touch to find out what is best for you

Centrifuges easily outperform other technologies for cleaning industrial fluids. The investment depends heavily on your process and demands. Let our expertise guide you to the right technology for your operation.

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Drops of water

Coolant cleaning

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Coolant cooling

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