Prezentacija ACO Separatori Masti ENG

Haustechnik
Grease separators
Advanced training
contact: cbauer@aco-online.de
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Content
1. Basics
reasons (regulations, standards)
function
components
2. Dimensioning
regulations
calculation example
3. Product range
ground installation
free standing – full disposal
free standing - partial disposal
4. Installation
ventilation, filling device
sampling pot, remote control,
suction pipe
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1. BASICS
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Basics
S
y
s
t
1.2
e
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Basics
Waste water containing grease can cause…
…pipe obstruction. …formation of corrosion and …negative effect on treatment

noxious stench. plants.
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Basics
Grease separator plants have to be used if

animal and organic fats and oils have to be
retained.
This applies to commercial and industrial
establishments, where animal and organic fats
occur…
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Basics -
Regulations
Grease separators pursuant to EN 1825

(Germany = DIN EN 1825 - United Kingdom = BS EN 1825
Other national standards

EN 1825 – Part 1 EN 1825 – Part 2
(Example DIN 4040-100)
Manufacturing principles Dimensioning and
Installation, operation
and testing of installing of
and maintenance of
grease separators grease separators
grease separators
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Basics –
operating conditions
EN 1825 – Part 2, chapter 4 recommends the usage of grease

separators in…
• restaurants
• hotels
• canteens
• butcheries
• students‘ refectories
• grill kitchens
• slaughterhouses
• sausages production
• oil mills
• margarine factories
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Basics –
…but what about…
• block of flats ?
• fairs ?
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Basics –
EN 1825 – part 2, chapter 4 points out that grease separators may

have no satisfying effect when used in…
• dairies
• cheese dairies
• fish industry (!)
• „pure“ dish washing
factories
• colour industry
Wastewater treatment
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Function
Grease separator - functional principle
Grease
Sludge
Precondition: The separator has to be filled with water. Otherwise no separation effect can be guaranteed!
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2. Construction Principles
According to EN 1825,
Part 1
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Components
Functional diagram of grease separator

according to EN 1825, part 1
Grease storage capacity min. 40 l x NS

Grease surface 0.25 m2 x NS
Inlet Outlet
Grease layer
Separation compartment
Inlet Outlet
baffle baffle
Imaginary sludge trap
Capacity = 100 l x NS Capacity of separation compartment is

dependent on hydraulic test.
In the case of meat processing plants Maximum permissible hydrocarbons
Capacity = 200 l x NS in the outlet: „less than 25 mg/l“
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Nominal Size – Determination of main dimensions
Nominal Size Sludge trap Separation Separation Grease storage

volume compartment compartment volume
(volume in litres) (minimum surface (minimum volume in (minimum volume in
area in m2) m3) m3)
NS NS x 100 0,25 x NS 0,24 x NS 0,04 x NS

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Material selection
Stainless Steel Polyethylene Reinforced Concrete
- easy handling - permanently highly

- no fire risk - low heat conduction loadable statically and
- high temperature - high resistance to dynamically
resistance chemical influences - highes shape stability
- hygenic material - disposal-friendly surface towards inside and
- absolute UV resistance - easy after-treatment outside
locally - nearly any installation depths
Use esclusively for Use for free-standing Use esclusively for

free-standing installation and ground installation ground installation
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Material selection
Sealant
„Only sealant made from rubber (elastomeric material) must be

used.“
„Cement mortar must not be used as sealant.“
(EN 1825-1, Chapter 5.2.6)

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Identification
Type Plate
Content:
-EN 1825
-Nominal Size (NS)
-Separator capacity (in litres or m3)
-Sludge trap capacity (in litres or m3)
-Grease storage volume (in litres or m3)
-Maximum height of grease layer (in mm)
-Year of production
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3. Dimensioning according
to EN 1825, part 2
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Dimensioning (EN 1825)
Types of dimensioning according to EN 1825
-per kitchen equipment
-based on meals per day
-based on number of slaughtered animals

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Dimensioning based on meals per day:

(example values see „Red book“, page 187 )
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Dimensioning based on meals per day:

(example values see „Red book“, page 187 )
Meals per Consumpt/meal F=sporadic load

day factor Waste water qty.
200 x 100 l x 5 = 100,000 l
100,000 litres = 3.0864 l/s (max. waste water inflow

QS=
9 oper.hrs.x 3.600 sec. to separator)
NS = QS x fd x ft x fr
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fd = density of ft = temperature of fr = cleaning agents

waste water water
fd = 1 (for density until 0,94 g/cm3) ft = 1 (temperature until 60° C) fr = 1 (no agents)
fd = 1,5 (for density over 0,94 g/cm3) ft = 1,3 (temperature over 60° C) fr = 1,3 (agents)
fr = 1,5 (hospitals)
In „normal“ kitchens Depends normally on Could be even higher in

(restaurants, hotels etc.) always character of dish washer. hopitals, has to checked
assume density 0,94. together with planning
offices.
NS = 3.0864 x 1 x 1.3 x 1.3 = NS 5.22 NS 7
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Dimensioning based on number of slaughtered animals:

(example values see „Red book, page 190)
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Dimensioning based on number of slaughtered animals:

(example values see „Red book, page 190)
Sausage Unit-specific water F=sporadic load

quantity per kg
production sausage production
factor Waste water qty.
200 x 15 l x 35 = 105,000 l
105000 litres = 3.645 l/s (max. waste water inflow

QS=
8 oper.hrs.x3.600 sec. to separator)
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fd = density of ft = temperature of fr = cleaning agents

waste water water
fd = 1 (for density until 0,94 g/cm3) ft = 1 (temperature until 60° C) fr = 1 (no agents)
fd = 1,5 (for density over 0,94 g/cm3) ft = 1,3 (temperature over 60° C) fr = 1,3 (agents)
fr = 1,5 (hospitals)
In „normal“ kitchens Depends normally on Could be even higher in

(restaurants, hotels etc.) always character of dish washer. hopitals, has to checked
assume density 0,94. together with planning
offices.
Double-sized
NS = 3.645 x 1 x 1.0 x 1.3 = NS 4.74 NS 7 sludge trap!
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Dimensioning per kitchen equipment (example see Red book, page

183)
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Dimensioning per kitchen equipment (see Red book, page 183)

Equipment Number qi l/s (n x qi) Simultaneity Grey water
factor Zi (n) Qs
Boiler outlet 25 mm 10 1 10 l/s 0.20 2
Boiler outlet 50 mm 15 2 30 l/s 0.20 6
Tilting boiler outlet 70 mm 4 1 4 l/s 0.21 0.84
Tilting boiler 100 mm 5 3 15 l/s 0.20 3
Wash basin without odour seal, 50 mm 8 1.5 12 l/s 0.20 2.4
Dishwasher 6 2 12 l/s 0.30 3.6
Tilting frying pan 4 1 4 l/s 0.21 0.84
High-pressure cleaner 2 2 4 l/s 0.31 1.24
Vegetable wash units 3 2 6 l/s 0.25 1.5
Outlet valve DN 20 8 1 8 l/s 0.20 1.6
Outlet valve DN 25 6 1.7 10.2 l/s 0.20 2.04
Sum Qs 25.06 l/s

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Dimensioning per kitchen equipment:
NS = 25.06 x 1.0 x 1.0 x 1.3 = NS 37.59 NS 40
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Dimensioning according to EN 1825 vs. dimensioning according to DIN 4040
Grease layer
Grease layer
Separation compartment
Sludge
trap Separation compartment
Imaginary sludge trap
Grease separator Grease separator

according to DIN 4040 according to EN 1825
(old German standard)
Haustechnik
…which means:
Dimensioning according to EN 1825 = Choose separator according to EN 1825
Dimensioning according to DIN 4040 = Choose separator according to DIN 4040
…but:
Dimensioning according to EN 1825 = Never choose separator according to DIN 4040!
Dimensioning accordint to DIN 4040 = Never choose separator according to EN 1825!

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3. PRODUCT RANGE
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Product range
Two possibilities
Free standing
Ground installation installation
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GROUND INSTALLATION
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Product range
Ground installation - properties
• Separator is installed outside a building in the ground

• Load class A,B or D possible
• NS 1 – 10 (made from polyethylene)
• NS 1- 40 (made from reinforced concrete)
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Product range
Ground installation – example
Kitchen facilities
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Product range
Ground installation – product series ECO FPI
• separator made from polyethylene

• cover made from concrete
• available in NS 1 – 10
• load class B or D
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Product range
ECO-FPI NG 4
„
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Product range
ECO-FPI NG 4
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Product range
ECO-FPI NG 4
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Product range
ECO-FPI NG 4
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Product range
ECO-FPI NG 4 with sampling shaft

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Product range
ECO-FPI NG 4 with direct suction

pipe R
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Product range
Ground installation – product series LIPUMAX/LIPUSED
• separator made from reinforced concrete

• cover made from concrete
• available in NS 1 – 25 (LIPUMAX)
• available in NS 20 – 40 (LIPUSED)
• selectively available with inner coating (polyethylene)
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Product range
FREE STANDING
INSTALLATION
- FULL DISPOSAL
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Product range
Free standing installation - properties
• separator is installed inside a building, it stands free

inside a cellar room (or something similar)
• made from polyethylene or stainless steel
• in round or oval shape
• available in NS 1 – 10 (oval shape)
• available in NS 1 – 20 (round shape)
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Product range
Free standing installation - example
Kitchen facilities
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Product range
Free standing installation – product series

Material stainless steel Material polyethylene
dn 1 LIPUREX-O/-OD ECO-JET-O/-OD
N a eg Basic version:
no at
e is s standard design
re no LIPUREX-R/-RD ECO-JET-R/-RD
u v is Extension stage 1:
ci ne
e sa tx with direct disposal
B e ECO-JET-G/-GD
Extension stage 2:
P with direct disposal, high-pressure
cleaning and manual control
r 3/
2 Extension stage 3:
LIPURAT-OS/-OA HYDROJET-OS/-OA
o se
ga with direct disposal, high-pressure
g ts LIPURAT-RS/-RA HYDROJET-RS/-RA cleaning and automatic control
r no
is
a ne LIPURAT-OSE/-OAE HYDROJET-OSE/-OAE
tx
m E
m Legend:
s
t -O : oval shape -S : plus high-pressure cleaning and
-R : round shape manual control
r -G : separated chambers -A : plus high-pressure cleaning and
u -D : plus direct suction pipe automatic control
k -E : plus disposal pump
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Product range
Basic version
Standard design
Advantages
low purchase price
easy bringing in and assembly
no wear and tear parts
LIPUREX®-O
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Product range
Extension stage 1 Direct disposal
With direct disposal
Advantages
Higher comfort thanks to suction appliance
No odour nuisance during disposal process
Trouble-free handling
No wear and tear parts

LIPUREX®-OD
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Product range
Extension stage 2
With direct disposal, high-pressure
inner cleaning and manual control Option Suction pipe
High pressure cleaning
Disposal pump
Advantages
Hydro-mechanic inner cleaning
by means of high-pressure pump
Suction or pumping, crushing and

cleaning in one working process
Even following disposal, opening is

not required
LIPURAT®-OS
Haustechnik
Product range
Extension stage 3
With direct disposal, high-
pressure inner cleaning and Option Suction pipe
High pressure cleaning
automatic control
Advantages Remote control Switch box

Fully automatic programme
control
Easy operation possible

via remote control
Optimum system for a

problem-free disposal
LIPURAT®-OA
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Product range
FREE STANDING
INSTALLATION
- PARTIAL DISPOSAL
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Product range
Function of separator with partial disposal
Inlet
90 % of total volume is Outlet
...not removed
No grease deposits

...thanks to short stay in
...separator
Disposal without
...interrupting operation
...and without suction
...vehicle Grease
Sediments
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Product range
Partial disposal
Stainless steel
Lipatomat
Haustechnik
Product range
Installation of separator with partial disposal
1 Grease separator LIPATOR NG 4

Connection to sewer 2 Sampling device
3 Lifting plant
4 Grease collecting container
5 Sediments collecting container
6 Ventilation
7 Ventilation
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4. INSTALLATION
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INSTALLATION
Ventilation:
1. Inlet and outlet have to be adequately
aerated!
2. Ventilation to be taken above the roof
3. All connecting cables exceeding 5 m

have to be separately aerated
4. If the length of the inlet pipe exceeds

10 m and there is no separate venti-
lated connecting cable available, a
ventilation pipe has to be provided to
the inlet pipe directly in front of the
separator plant!
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INSTALLATION
Prevention of
grease deposit:
1. A thermal insulation may be ne-
cessary in the case of inlet pipes
led through cool cellar rooms!
2. A heating may be necessary in

the case of inlet pipes led through
building parts exposed to frost,
as e.g. underground garages!
3. The temperature of the heating

should be adjustable via a
thermostat.
4. In the case of heated rooms and

frostfree laid cables, no additional
measures are required!
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Installation as per
DIN V 4040 part 2
Inlet:
1. Transition into horizontal pipes
has to be performed by two
45 º bends!
2. The intermediate section must be

at least 250 mm long!
3. Then, a calm region has to be

provided, the length of which
should be at least 10 times the
nominal width of the inlet pipe!
4. Inlet pipes must have a minimum

slope of 2 % (1:50)!
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INSTALLATION
wrong
KPMG Munich
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INSTALLATION
right
AGFA Munich
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INSTALLATION
Emptying:
1. Unless stipulated otherwise, grease
separator and sludge trap should be
emptied, cleaned and re-filled with fresh
water at least once a month, preferably,
however, fortnightly!
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INSTALLATION
Emptying:
Haustechnik
INSTALLATION
Sampling:
1. Behind the separator, a sampling
possibility has to be provided to
check the waste water values!
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INSTALLATION
Lifting plant:
1. Grease separator plant, the static
water level of which lies beyond
the backflow level, have to be
drained via a following lifting plant!
2. A twin lifting plant has to be

installed in the case of industrial
and commercial areas!
Haustechnik
INSTALLATION
Backflow loop:
1. The pipe bottom of the backflow
loop has to be led above the
backflow level!

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Waste water containing grease can cause…

…pipe obstruction. …formation of corrosion and …negative effect on treatment

Grease separator plants have to be used if

Grease separators pursuant to EN 1825

Other national standards

EN 1825 – Part 2, chapter 4 recommends the usage of grease

…but what about…

EN 1825 – part 2, chapter 4 points out that grease separators may

Grease separator - functional principle

Functional diagram of grease separator

Grease storage capacity min. 40 l x NS

Imaginary sludge trap

Capacity = 100 l x NS Capacity of separation compartment is

Nominal Size – Determination of main dimensions

Nominal Size Sludge trap Separation Separation Grease storage

NS NS x 100 0,25 x NS 0,24 x NS 0,04 x NS

Stainless Steel Polyethylene Reinforced Concrete

- easy handling - permanently highly

Use esclusively for Use for free-standing Use esclusively for

„Only sealant made from rubber (elastomeric material) must be

„Cement mortar must not be used as sealant.“

(EN 1825-1, Chapter 5.2.6)

Dimensioning (EN 1825)

Types of dimensioning according to EN 1825

-per kitchen equipment

-based on meals per day

-based on number of slaughtered animals

Dimensioning (EN 1825)

Dimensioning based on meals per day:

Dimensioning (EN 1825)

Dimensioning based on meals per day:

Meals per Consumpt/meal F=sporadic load

200 x 100 l x 5 = 100,000 l

100,000 litres = 3.0864 l/s (max. waste water inflow

Dimensioning (EN 1825)

fd = density of ft = temperature of fr = cleaning agents

In „normal“ kitchens Depends normally on Could be even higher in

Dimensioning (EN 1825)

Dimensioning based on number of slaughtered animals:

Dimensioning (EN 1825)

Dimensioning based on number of slaughtered animals:

Sausage Unit-specific water F=sporadic load

105000 litres = 3.645 l/s (max. waste water inflow

Dimensioning (EN 1825)

fd = density of ft = temperature of fr = cleaning agents

In „normal“ kitchens Depends normally on Could be even higher in

Dimensioning (EN 1825)

Dimensioning per kitchen equipment (example see Red book, page

Dimensioning (EN 1825)

Dimensioning per kitchen equipment (see Red book, page 183)

Boiler outlet 50 mm 15 2 30 l/s 0.20 6

Tilting boiler outlet 70 mm 4 1 4 l/s 0.21 0.84

Tilting boiler 100 mm 5 3 15 l/s 0.20 3

Wash basin without odour seal, 50 mm 8 1.5 12 l/s 0.20 2.4

Dishwasher 6 2 12 l/s 0.30 3.6

Tilting frying pan 4 1 4 l/s 0.21 0.84

High-pressure cleaner 2 2 4 l/s 0.31 1.24

Vegetable wash units 3 2 6 l/s 0.25 1.5

Outlet valve DN 20 8 1 8 l/s 0.20 1.6

Outlet valve DN 25 6 1.7 10.2 l/s 0.20 2.04

Sum Qs 25.06 l/s