The MK-8 & MK-12 Sludge Centrifuges is of robust design to recover the palm oil present in the sludge

water from the clarifying plant.

This Sludge Centrifuges is unique piece of machine of smaller in physical size but with higher operating capacity. The MK sludge Centrifuges differs
from the traditional Star Bowl Design. MK sludge Centrifuges is of Dish Bowl type with 12 or 14 nozzles. The rotation speed of the separator is
being maintained at 1500 r.p.m and capable of achieving higher capacity of 8000 or 12000 liters per hour of sludge and maintining the normal oil
loss. All this area possible with the new concept and design.

The Dish Bowl is easily balanced by mill personnel compare to one star bowl to be maintained by the specialist with special equipment. There of
many advantages of this design:
- Higher capacity in term of power to space and weight ratio
- Balancing of the dish bowl by specialist Is not required
- Less vibration/ less maintenance cost
- Low capital cost per machine
- Increase productivity
- Easy to operate
-
SPECIFICATION DATA
INSTALLATION/ SHIPPING
MK- 8
Model : MK- 8 (2ND) A - 1240 mm
Capacity : 8.000 l/h B - 340 mm
No. of Nozzles : 12 (Tungsten Carbide/Hexaloy) C - 1400 mm
Motor : 15KW 3 Phase 4 Pole F/mt D - 700 mm
Fluid Coupling : 11 KSD E - 690 mm
Rotor Speed : 1500 rpm F - 500 mm
Transmission : V-belt G - 1200 mm
Bearing : SKF/FAG H - 27 mm
Rotor material : 6mm Stainless Steel 304 Weight - 1,700 kgs
Casing/ housing : Cast Iron to Grade 20 Volume - 2.80 m3
Media Parts : Stainless Steel 304

MK- 12
Model : MK- 12 (2ND) A - 1680 mm H - 30 mm
Capacity : 12.000 – 14.000 l/h B - 1460 mm I - 400 mm
No. of Nozzles : 14 (Tungsten Carbide/Hexaloy) C - 1730 mm J - 275 mm
Motor : 22KW 3 Phase 4 Pole F/mt D - 980 mm K - 80 mm
Fluid Coupling : 12 KSD E - 880 mm L - 22 mm
Rotor Speed : 1500 rpm F - 600 mm M - 452 mm
Transmission : V-belt G - 1250 mm N - 1430 mm
Bearing : SKF/FAG Weight - 2,400 kgs
Rotor material : 8mm Stainless Steel 304 Volume - 4.60 m3
Casing/ housing : Cast Iron to Grade 20
Media Parts : Stainless Steel 304

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MK Sludge Centrifuges Manual
List of Content Page
1. GENERAL DATA .................................................................................................. 1

2. GENERAL TECHNICAL REQUIREMENTS

Erection Of Equipment ........................................................................................... 2
Process Requirements ............................................................................................. 2

3. TECHNICAL DATA
Working Data ......................................................................................................... 3
Product Data ........................................................................................................... 3
Machine Data .......................................................................................................... 3
Speed Of Rotary Bowl ............................................................................................ 3
Minimum Passage of piping ............................................................................... 3

4. DESCRIPTION
Description ............................................................................................................. 4
Schematic Drawing ................................................................................................. 5
Drawing .................................................................................................................. 6
Operation ................................................................................................................ 7

5. OPERATON
Capacity .................................................................................................................. 8
Drawing .................................................................................................................. 8
Preparation For Operating ....................................................................................... 9
Starting ................................................................................................................... 10
Stopping.................................................................................................................. 11

6. MAINTENANCE
Purpose of Maintenance .......................................................................................... 11
Long Term Maintenance ......................................................................................... 12
Roller Bearing With Taper Bore ............................................................................. 13
Table Maintenance .................................................................................................. 14
Mounting and Tensioning of V- Belts..................................................................... 15
Assembly Of Rotary Bowl (See Also Page 13)....................................................... 15

7. PERFORMANCE DATA ....................................................................................... 15

Drawing .................................................................................................................. 16

8. DRAWING
Parts Description List MK ...................................................................................... 17
Main Drawing ......................................................................................................... 18
Certificate of Grant of a Patent ............................................................................... 19

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1. GENERAL DATA

Client :
Location :
Purpose : Reclaimed of palm oil from oily sludge
Year of construction :
Serial No :

1
2. GENERAL TECHNICAL REQUIREMENTS

ERECTION OF EQUIPMENT

Erection and assembly of apparatus must be done according to the drawings.

Erection must further be in accordance with further engineering data given in order to meet the
requirements applying for the entire palm oil extraction process.

The centrifuges should be set perfectly level and free from vibration. Equipment should be well
accessible for inspection and Maintenance purposes.

PROCESS REQUIREMENT
1. Feed tank to Sludge Centrifuges
Volume - 5m3 (1 to 2 units)
- 10m3 (3 units)
- 15m3( 4 units)
Head - 6 to 7 meter
2. Maintain constants feed, do not starve the Sludge Centrifuges
3. Oil content in the underflow should not more than 12%
4. Static cold water supply pressure @ 8 meter head of water to gland packing

2
3. TECHNICAL DATA

Working Data : 380-415 V/ 50 Hz,or

420-440 V/ 60 Hz (Option)
Water :
Hot water temperature : approx. 90oC
Static hot water supply pressure : 8 meter head of water

Product data
Product to be treated : Oily Sludge
Inlet temperature : 95oC
Static supply pressure : equal to 6m height difference

Machine data : 8000 liter/h at 1,9mm Nozzle (MK-8)

Capacity : 10000 liter/h at 1,7mm Nozzle (MK-12)

Speed of rotary bowl : n = 1500 rpm

Motor : TEFC squirrel cage type
Motor Power : 15 KW (MK-8)/ 22 KW (MK-12)
Speed of 50 cycles : 1500 rpm
Transmission : V- Belts

Minimum Passage of piping

Hot water Supply : D= 40mm
Flat Sludge : D= 100mm
Recovered oil discharge : D= 25mm
Colling water supply : D= 15mm
Non-oily sludge discharge : D= 150mm

Weight : Approx. 1700kg (MK-8)

Approx. 2400kg (MK-12)

Ambient Temperature : 35-40oC

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4. DESCRIPTION

The Sludge Centrifuges has been specially designed to serve the purpose of reclaimed the palm oil
present in the sludge water from the clarifying plant.

Sand and other impurities in the sludge water are apt to set up heavy wear on the centrifuge.
Therefore the MACHINE is made of exceptionally high grade materials.

Owing to the Simplicity of its design, the centrifuges requires a minimum of upkeep, while the
various component parts can be replaced quickly and without any difficulty.

The MACHINE consist of th following parts:

- A bottom section and top section
- A bowl housing
- A bowl

The bottom section is fitted with flanges serving the purpose of securing the centrifuges to
foundation as well as with a flange connection for the waste drain pipe.

The top section is mounted on the bottom section by means a flange connection. An inspection
cover on the top section permits access to the nozzles. An arrow on the top section indicates the
direction of rotation of the bowl.

THE BOWL MUST NEVER ROTATE AGAINST THE DIRECTION INDICATED BY THE
ARROW !!!

Within the top and the buttom sections are two dish shaped section of stainless steel plate which,
together with the wearing strip from the bowl housing and which the bowl rotates. The ball
bearings are supported in the bowl housing and have bearing cover to keep out dust.

The DISH- SHAPED bowl has to shaft journals, one which is hollow to permit the supply of the
heated oily sludge. The other serves to purpose of driving the disc bowl. The free end can be made
to carry a rope or belt pully, as required.

The points of the disc bowl are littled with the nozzle holders, which retain the nozzles, through
which the non-oily sludge water can escape. The position of these holders is fitted (by menas of a
pin) in such a manner as to make the direction of jetting opposite to the direction or rotation of the
disc bowl.

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NEVER CHANGE POSITION !!!

5
6
Operation

In the sludge centrifuges, whose basic construction is shown on page 6, the heated oil sludge is fed
under pressure by means of a fees pipe B to the Center of the disc shaped rotary bowl.

The oily sludge coming from the clarification plant contains part from water, sand and other
contaminations, the palm oil be recoverd.

In the oily sludge coming from the clarification palntcontaints part from water, sand and other
contaminations, the palm oil recovered.

In the entirely filled dish bowl the oily sludge will be accelerated as well as radially as a result of the
centrifugal force set up. The particles making up the will also be accelerated. The extent of
acceleration on the specific gravity of the particle concerned.

Water and sand particles for example will be subjected to more acceleration than those containing oil.

Consequently the heavier particles will be flung to the outer tips of the entirely filled bowl where they
are discharged through the nozzle (non-oily sludge) to the bowl housing and frame. From the
complete and free discharged of the non-oily sludge should be enabled via discharge E and a sloping
(non-shut table) pipe.

The light particles containing oil will, however, remain more or less in the center of the dish bowl and
are discharged freely through oil-discharge pipe C.

The length of this pipe should not exceed 2m.

7
5. OPERATION

Capacity Setting

The capacity of the sludge centrifuges can be adjusted by replacing the fitted nozzles (PN 44) by nozzles
whose bore is either larger or smaller.

When replacing the nozzles (PN 44) make sure that the lead ring (PN 45) are fitted again
(see drawing page 8)

8
Preparing for Operation

When the centrifuge is started up for the first time, the packing of the shaft seal should be fitted
loosely enough for the dish bowl to be rotated by hand. Every time prior to starting the centrifuges it
is necessary to check whether the nozzles (PN 44) are not cloggy.

Proceed as follows:
(See drawing pga 9 & Main Drawing)
1. Close oil discharge C and oily-sludge supply B.
2. Open hot water supply A and fill bowl (PN 16).
3. Remove inspection cover (PN 40) and check whether ALL nozzles operate even jets- rotate bowl
(PN 16) by hand.

IF NOT
4. Clear nozzles bores (PN 44) if the required result is not obtained.
5. Loosen nut (PN 48) by menas of the wrench supplied. Remove the nozzle holder (PN 49) and
clean nozzle (PN 44)

Make sure that C-ring (PN 46) is in holder (PN 49) and that is does not drop into centrifuges.

IF THERE IS TOO MUCH DIRT IN BOWL PN 16

6. Remove all nozzle holder (PN 49) (refers to item 5) and flush bowl with hot water and clean
nozzles (PN 44)
7. Refit inspection cover PN 40 and unit will be ready for operation.

Note: Make sure that Female Nut (PN 48) are tightened properly so that the seal between nozzle
holder (PN 49) an O- Ring (PN 46) ia absolutely leak proof.

9
Starting

Do not start unit prior having followed up the instructions as given on page 10
Starting point is:
The supply of oily sludge and make- up water is warranted throughout the period of operation.
Valve A, B, C, and D are closed.

1. Open water supply D.

Shut water supply D to check packing so far as to allow a small quantity of sludge water handle
will be considerably smaller, because much sludge water will then be displaced by fresh water.
2. Open water supply A fully an fill bowl.
3. DO not start centrifuges until the bowl has been completely filled. Check the directon of
rotation (refer to allow on top section).

Note: Under no circumstances may the centrifuge be operate with an empty of partly filled
bowl, since it will bring the bowl out of balance. So, supply A must always be fully open,
when starting operation.

4. Open oil discharge fully.

5. Open oily sludge supply B gradually and close water supply A slowly, so that the rotating bowl
remains entirely filled when the oily sludge supply is displacing the water from the dish bowl.
The implies: water supply A must never be closed completely until sludge supply B is full
open.

6. To ensure the maximum effect, valve C shoul be adjusted is such a manner that out flowing oil
contains approx. 40% residual water.

During operation, check at regular times wheter:

1. The oil flows off constantly at C.
2. The non- oily sludge flows of constantly at E.
3. Clean water trickles from packing.
4. Centrifugs runs smoothly.

IF NOT:

Stop centrifuges immediately and check whether one or more nozzles are clogged (Refer
pages 13 and 16)

10
Stopping ( see page 10)

Proceed as follows to stop centrifuge:

1. Open hot water supply A fully.

2. Oily sludge supply B is closed

Leave centrifuges in operation until there is no more sludge in the bowl. Discharge E will
discharge clean water.

3. Stop machine and shut water supply A at the time so the bowl will empty itself as it comes to
a stand still.

This will keep any deposit of dirt from settling in the bowl.

4. Close water supply D and oil discharge C

Every time prior to starting the centrifuges, it is necessary to check whether the zozzles are
not cloggy.

6. MAINTENANCE

Purpose of Maintenance

A production plant derives its value from the productive potential it posseses.

The maintenance procedure described belows has the object of preserving this potential.

All operations activities involved should have one thing in common: regularity!

To achieve this goal in actual practice. The necessary operation for maintenance and lubrication
are set on in maintenance schedule and/or corresponding drawing.

Explanation

The lubricant to be used is designated by a lubricant number (no) that refers to the table of
recommended lubricants. In certain cases reference is made to accompanying instructions.

11
 The following abbreviations are used:

R ind = Spare parts indication (see also page 18)

i. fr = Inspection frequency
Lubr fr = Lubricating frequency
D = Daily or after 10 operating hours
W = Once a week or after 60 operating hours
1/2M = Twice a month or after 125 operating hours
M = Once a month or after 250 operating hours
3M = Every 3 month or after 750 operating hours
1/2J = Every 6 month or after 1500 operating hours
J =Once a year or after 3000 operating hours

Long term maintenance

The maximum period covered by the schedules for preventing maintenance is 12 months. In the
longer run certain maintenance or overhaul operations may prove necessary because plant
components have aged or attained the limit of their working life.

They will provide the data required for the revormal and installation of component and so enable the
customer’s own maintenance staff the perfom overhauls jobs without outside assistance.

Some types overhaul work, however may require specialized skill. You can always contact the
manufactur. Which can provide field technical assistance through separate arrangement.

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Roller bearing with taper bore

Fitting instruction

The double- row roller bearings with taper bore used must be mounted on the shaft with a fairly tight
fit.

This fit is not determined by the shat tolerance but by the extent to which the bearing is forced onto
the tapered adaptor sleeve by tightening the relevant nul.

Prior to mounting, it is essential that any grease present on the mating faces of bearing, adapter sleeve
and shaft be removed with a clean both.

To check whether the bearing has been mounted with a correct force fit, one can measure the
reduction in redial clearance, the bearing endplay and/or the axial displacement of the bearing
involved.

To measure the reduction in clearance, one should work from the original radial bearing clearance
and screw the nut onto the conical adaptor sleeve to a point within the minimum an maximum limits
specified for the reduction in clearance of the bearing involved (refer to the table below).

Table according to SKF

Bore diameter Reduction Axial movement mm Minimum endplay
D In Radial Taper Taper Of mounted bearing
mm Clearance 1.12 1.12 With initial bearing
mm mm
More than Up to Min Max Min Max Min Max normal C3 C4
110 120 0.0050 0.0070 0.75 1.1 1.9 2.75 0.050 0.065 0.100

After mounting, the bearings outer ring must be able to move to and from without encountering too
much resistance.

NOTE: Do not force the bearing beyond the limit specified, in view of the strength of the inner ring.

13
ITEM I LUBRICANT DRAWING CAT PART WORK TO BE DONE
NO.
Fr. Fr. No.

21 J - - Sealing Rings Check for wear and replace if necessary

11 - J 0 Bearing Clean and fill space in housing between rollers for ½ to ¾ with new
Grease (in order to be able to remove bearing, a disassembly nut is
included in the supply). Also refer to assembly instruction on page 19

13 J - - Felt Ring Chech for wear and replace if necessary

4 W - - Packing in Check for excessive leaking (refer to page 10) Replace if necesary
Stuffing Box

45 W - - Nozzle Holders Check for the wear and replace if necessary

NOTE : For replacing or refitting holders
See instruction on page 10 (point 5)

48 D - - Spray Nozzles Check prior to start up whether these are clear (refer instruction on page
10)
Check for wear and replace if necessary

52 W - - Vee Belt Check for wear and tension (refer to mounting instruction) Replace if
necessary

W - - Wearing Parts Check for wear and replace in necessary

- - - Assembly See page 22

Instruction

W - - Whole Apparatys General check up

114
 How to put and tension V-belt

1. Belts should be mounted slack, for which purpose one og the pulley shafts must be adjustable
provided with a lensioning roller.
2. When bringing V-belts in position never force them over heedge of the pulley, as this may
demage the inlays and considerably shorten the working life.
3. As a rule, the belts must be given so muchlension that they can still be twisted 90 o halfway
between the two pulleys. Check belts regularly for proper tension.
4. The pulleys must be exactly in line.
5. Never use any belt grease or other anti-sip agents an keep belts as clean as possible. Check belts
regulary for wear and damage.
6. Do not use both new an use belts on one and the same transmission. If one or more belts need
replacing, replace the complete set. Keep spare belts in a dry, cool, and dark place.

Assembly of rotary bowl ( seealso page 13)

1. When fitting or refitting, check that the clearance between bearing and housing is in accordance with
specification, ( fit additional washers, if so required). During operation, the clearance specified will
be reduced 7mm.

N.B. In any case there should be a minimum positive clearance of 2mm between bearng and
housing.

2. When fitting or refitting, fill bearings with grease 9see also page 18) through grease cup.
3. Fit/ refit with liquid packing which is resistant to water and oil of 90oC
4. When fitting or refitting, make sure that one opening of the feed pipe is at the bottom.
5. Se page 13 for fitting or refitting of bearings.

7. PERFORMANCE DATA

Oil Loss:

Underflow <12%

< 1% Oil Loss On Wet Basis

< 14% Oil Loss On Dry Basis

15
1
 2
16
PARTS DESCRIPTION LIST FOR MK HIGH CAPACITYSLUDGE CENTRIFUGE

ITEM QTY DESCRIPTION MATERIAL

1 1 PC OIL DRAINS VALVE
2 1 PC INLET CAST IRON
3 1 PC JOINT RING
4 1 PC GASKET
5 1 PC INLET PIPE STAINLESS STEEL
6 1 SET STUFFING BOX CAST BRONZE
7 4 PC BOLT AND NUT HIGH TENSILE STEEL
8 1 PC PACKING BUSH STAINLESS STEEL
9,13,36 3 PCS OIL SEAL 100 X 130 X 12
10 8 PCS BOLT FOR BEARING COVER HIGH TENSILE STEEL
11 2 PCS SPHERICAL BEARING 22224 EK + SLEEVE SKF/ FAG
12 2 PCS GREASE NIPPLE ¼”
14 24 PCS STUD C/W NUT MILD STEEL
15 2 PCS JOURNAL WEARING RING STAINLESS STEEL
16 1 UNIT ROTOR (DISH BOWL) STAINLESS STEEL
17 1 PC JOURNAL HOLLOW (SLUDGE INLET) CAST STEEL
18 1 PC CASING- UPPER CAST IRON
19 1 PC CASING- LOWER CAST IRON
20 1 PC JOURNAL SOLID CAST STEEL
21,22 2 PCS SPACER RING- INNER MILD STEEL
23 2 PCS BEARING SLEEVE AHX 3124
24 16 PCS ALLEN CAP SCREW FOR DISH END HIGH TENSILE STEEL
25 1 SET GLAND PICKING TEFLON
26 1 PC GLAND CAST BRONZE
27 1 PC GLAND NUT CAST BRONZE
28 1 PC HANDLE
29 1 PC INTERMEDIATE PARTS CAST IRON
30 2 PC BEARING HOUSING CAST IRON
31 1 PC RECOVERY PIPE STAINLESS STEEL
32 12 PCS LOCKING PLATE STAINLESS STEEL
33 2 PCS GASKET
34 1 PC COVER (BEARING HOUSING) CAST IRON
35 2 PCS LOCK NUT (KM 23)
35 A 2 PCS LOCK WASHER MB 23
37 1 PC KEY MILD STEEL
38 8 PCS CSK SCREW STAINLESS STEEL
39 1 SET DISH END STAINLESS STEEL
40 A 1 PC TOP COVER CAST IRON
40 B 1 PC INSPECTION COVER STAINLESS STEEL
41 1 SET WEARING STRIPE STAINLESS STEEL
42A 1 SET WEARINGBASE LINER 70MM STAINLESS STEEL
42B 1 SET WEARING LINER 50MM
43 12/14 PCS CAP NUT STAINLESS STEEL
44 12/14 PCS NOZZLE TUNGSTEN CARBIDE
45 12/14 PCS LEAD RING TEPLON
46 12/14 PCS O RING (2ND) RUBBER
47 12/14 PCS MALE NUT (2ND) STAINLESS STEEL
48 12/14 PCS FEMALE NUT (2ND) STAINLESS STEEL
49 12/14 PCS NOZZLE HOLDER (2ND) STAINLESS STEEL

17
3
ITEM QTY DESCRIPTION MATERIAL
50 2 PCS PULLEY 4 SPB C/IRON
51 4 PCS SPB V-BELTS
52 1 PC FLUID COUPLING
53 1 PC DRIVE PROTECTION COVER M/STEEL
54 1 PC ELECTRO MOTOR
55 1 PC ½” BALL VALVE
56 1 PC 1” BALL VALVE
57 1 PC 1 ½” BALL VALVE
58 1 PC 4” BALL VALVE

4
18
19
18
 20
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