GEA Westfalia Separator Industrial Fluids
Separator Spares & Equipment, LLC is an Authorized GEA Mechanical Equipment US, Inc (GEA Westfalia Separator Division) Distributor for the Gulf Coast region. We provide complete GEA Westfalia industrial fluids separator packages, spare parts, engineering support, and service.
Industrial Fluids – Increase Performance & Reduce Cost
Separator Spares and Equipment, LLC is an Authorized Distributor for GEA Mechanical Equipment US, Inc. (GEA Westfalia Separator Division) for the Gulf Coast region. We provide complete GEA Westfalia separator packages for industrial fluids, metalworking fluids, and cutting fluids applications.
Separators from GEA Westfalia Separators are the right choice for treating liquids or liquid mixtures with a low solids content. Centrifugal separation technology with separators nowadays performs critical functions in solid-liquid separation and solid-liquid-liquid separation. Applications range from the recycling of metalworking lubricants or industrial wash liquids to treating oil-based fluids such as lube, hydraulic, or waste oils.
GEA Westfalia separators are designed especially for liquid-based applications. They use centrifugal force to separate solids from liquids. They are equally as effective at separating liquid mixtures simultaneously as removing solids.
Separator Designs:
- Manual Cleaning (Solid-Wall) separators for clarifying and separating liquids with a low solids content. Solids are removed manually.
- Self-Cleaning Disk Separators for clarification and separation processes. Solids ejection takes place automatically in the form of partial or
total ejections.
GEA Westfalia Separators for industrial fluids have been designed to separate cooling lubricants, cutting fluids, washing liquids, oil-water mixtures, industrial fluids, lube oil, metalworking fluids, fuel oil, waste oil, etc. The separator of the enclosed design is equipped with an oil-level sight glass and driven by a 3-phase AC motor. Power is transferred to the bowl spindle via a flat belt. Depending on the GEA Westfalia Separator, the hood of the separator might be hinged, and all bearings are splash-lubricated from a central oil bath.
Most metalworking operations utilize a coolant to remove the heat generated in the process. Fluid coolants are widely used since they lubricate the contact surface between the tool and the workpiece, inhibit corrosion, and wash away swarf fines from the work area. They are prolonging the life of the tools and improving the quality of work. By extending the useful lifetime of metalworking fluids, you reduce consumption and maintenance costs. By keeping them constantly purified, you also reduce wear on machines and tooling.
Separator Spares & Equipment can help you choose the most economical systems for your industrial fluids, metalworking fluids, and cutting fluids applications.
For the treatment of fluids in Industrial Applications, the GEA Westfalia Separators are designed for the separation of:
Diesel Oil
Hydraulic Oil
Lube Oil
Metalworking Coolant Emulsions
Oily Water
Rolling, Cutting, & Grinding Oil
Washing Liquids
Waste Oil & Oily Waste Water
Lube Oil
Continuous treatment of lube oil is recommended to remove contaminants, such as water and particles of dirt or metal, which could cause corrosion, blockages, and system malfunctions. GEA Westfalia separators are perfect for this continuous treatment process and can remove metal particles down to 1 μm.
Hydraulic Oil
Continuous treatment of hydraulic oil is recommended to remove contaminants, such as water and particles of dirt or metal, which could cause corrosion, blockages, and system malfunctions. GEA Westfalia separators are perfect for this continuous treatment process and can remove metal particles down to 1 μm.
Metalworking Coolant Emulsions
Operating fluids like coolant emulsions or coolant oils must be regularly rid of solid impurities and water. Early and efficient action reliably avoids machine downtime and unhygienic production conditions. GEA Westfalia realizes the treatment of operating fluids in bypass to the circulatory system.
Neat Oil Coolants
The primary contaminants in neat oils are solid particles, water, and other oils. The solids include metallic and other fines originating from tools, carbon, and oxidation products resulting from repeated heating. Neat oil coolants must be either clarified or purified.
Rolling, Cutting, and Grinding Oil
Continuous treatment of rolling, cutting, and grinding oil is recommended to remove contaminants, such as water and dirt or metal particles, that could cause corrosion, blockages, and system malfunctions. GEA Westfalia separators are perfect for this continuous treatment process and can remove metal particles down to 1 μm.
Tramp Oil Separation
Circulating water-based coolants tend to pick up traces of hydraulic, lubricating, and other oils. The presence of this oil is undesirable because it tends to hold very fine particles in suspension and carry them back to the work area. It impairs the coolant properties of the working fluid. It encourages the growth of bacteria that precipitate iron and also gives rise to unpleasant odors.
Washing Liquids
Certain surface treatment processes in the metal-processing industry require thorough cleaning with washing liquids beforehand. To maintain the optimum cleaning effect and ensure continuity of production, entrained particles and tramp oils must be separated out early. GEA Westfalia separators can handle this job.
Waste Oil & Oily Waste Water
Industrial sectors that work with large numbers of machines will need to store, transport, and dispose of large amounts of waste oil, which increases with every oil change. Disposal of this waste oil is associated with significant costs. As an alternative, waste oil can be converted into a valuable resource using GEA’s centrifuges. The treated oil can be used as a high calorific value secondary fuel in certain sectors of industry or as a base oil for the production of lubricants. This not only saves valuable resources but also cuts costs.
What are benefits of cleaning lubricants with separators?
Separators from GEA Westfalia increase the service life of operating materials, reduce unplanned machine downtimes, promote hygienic production conditions and often pay off in less than one year.
Cooling lubricants need to be rid of impurities and tramp oils on a regular basis. The sooner and more reliably this happens, the more assuredly machine downtimes and unhygienic production conditions can be avoided. GEA Westfalia makes safe and problem-free cleaning possible in the bypass to the circulation system. Disk separators are integrated into the production and ensure smooth operational procedures thanks to early partial flow cleaning. This extends the service life of the cooling lubricants used four or fivefold. This is just one of the reasons for the very short amortization period.
Benefits of using Disc Separator:
- Less machine downtime
- Longer service life of the machines
- Improved surface quality
- Less scrap
- Improved working conditions thanks to the minimization of health risks (e.g., skin irritation or respiratory ailments)
- Continuous production / Fewer bath changes
Tramp oils shorten tool life considerably. GEA Westfalia separators reduce the tramp oil fraction to less than 1 % and extend the service life of the tools by a factor of up to 5.
How does GEA Westfalia separators provide a cost reduction in industrial fluids treatment?
Service life extensions of the liquids save procurement and disposal costs- Efficient production process thanks to shorter set-up times
- Longer service life of the machines, tools, and bearings
- Greater availability of the tools, machines, and bearings increases the productivity of the manufacturing processes
- Less scrap in the production thanks to improved surfaces and lubrication properties
What are the methods for cleaning cutting fluids?
Common Cleaning Processes
Filtration:
Cutting fluid filters typically use paper bands of various 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 paper band is used up, it must be removed, safely disposed of, and then replaced with a new filter. Keep in mind that filters don’t remove oil, which means they need to be combined with coalescers or separators—otherwise, you’ll end up with the rapid growth of bacteria and fungi.
Skimming:
Oil skimmers are designed to remove oil floating on the cutting fluid’s surface. While there are many different types of skimmers, they work in the same way: floating oil adheres to a skimming medium such as a mop, rope, disk, tube, or belt. The medium is then passed through a machine that wipes it clean and collects the oil. Oil skimmers are simple, low-cost solutions for removing small
amounts of oil under stable conditions. But they don’t handle emulsified oil, changes in oil properties, or throughput volumes very well, and performance varies significantly depending on the oil used.
Coalescence:
Coalescers are used to perform coalescence, which is the process of causing small liquid droplets to form larger droplets. The larger droplets are then drained away gravitationally. Coalescers are easy to install and maintain, and the capital investment is low. However, their effectiveness and capacity are limited, which can lead to process inefficiency and higher lifetime costs. Solid contaminants are not removed, and coalescers can’t be used if certain additives or surfactants are present.
Centrifugation:
High-speed centrifugal separators use centrifugal force to separate tramp oil and solid contaminants from cutting fluids. Particles present in the cutting fluid are pressed against the walls of the separator by centrifugal force. The particles can be discharged automatically from the bowl to the sludge tank. The centrifugal force also causes unwanted oil to separate from the cutting fluid. The cutting fluid is sent back into the machining or metalworking process while the unwanted oil is continuously discharged. The separation is a continuous process—unlike filtration, which requires frequent filter media replacement and high maintenance.
Centrifugation is the future of fluid management. A high-speed centrifugal separator offers the lowest Total Cost of Ownership (TCO) of all cutting fluid cleaning processes and typically pays for itself after a few years. It’s simple to install and maintain, and your only operating expense is the cost of electricity.
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