Figure 1—Decanter (closed-bowl) centrifuge. Figure 2—Screen (open-bowl) centrifuge.

Gear Drives
USED IN CENTRIFUGE APPLICATIONS
STEFANIE BURNS AND CHRIS MAYR, SUMITOMO DRIVE TECHNOLOGIES

Sumitomo Drive Technologies may Sumitomo is only one of many that ments) that is transferred to the smaller
not have the centrifuges that Kevin make a gear drive suitable for centri- end of the bowl with a conveyor. Inside,
Costner is promoting in the Gulf Oil fuges. We offer two different designs the product under process is mixed with
Spill (Ed.’s note: The film actor’s company, of centrifuge gear drives that will liquid and solids, e.g., saltwater, muddy
Ocean Therapy Solutions, has developed a break away solids from liquids, i.e.—a water or oil and water (it just has to be
device—the V20 Centrifuge—that pur- decanter (closed-bowl design) and a mixed weights).
portedly can separate oil from water to a screen centrifuge (open-basket design). The liquid runs via centrifugal force
purity level of 99.9 percent.) However, we The design preference is dependent on at high rotational speed of the bowl
do provide centrifuge drives that will do the OEM’s equipment design. But for towards the larger diameter, and the
just that. How do these drives work? It either type, you will need a gear drive solids are pushed to the smaller diam-
can be as simple or complex as you like to operate the conveyor within the eter of the bowl. In this tapered area,
it to be. Centrifuges use a cylindrical centrifuge. the solids slowly come out of the liquid
motion to force the solids away from Decanter centrifuge (Fig. 1). and are dried before being disposed.
the liquid. This concept is being used Decanters are closed-bowl type appli- The gearbox is creating differential or
in the Gulf BP oil spill to separate oil cations providing a housing and bowl relative speed between the conveyor and
from seawater. that operate at different speeds. the bowl. Through this relative speed,
The marketing information pro- A decanter needs a bowl with a the solid transportation works and we
vided about these applications is very completely closed drum. Inside this are able to separate the liquid from the
limited, and the user generally does not bowl is a worm conveyor, with both solid. The gearbox rotates together with
have an in-depth understanding, even the drum and the conveyor driven by the bowl and is driven by a belt drive
among engineers, and therefore take a gearbox. The bowl is connected to from the main motor. The bowl operates
information as presented at face value. the gearbox housing and the conveyor at the same speed as the gearbox hous-
In order to make better purchasing is connected to the output shaft of the ing, while the input shaft connected to
decisions about centrifuge applications, gearbox. It is called a decanter because the conveyor is operating at a different
one must understand the concept of the liquid pours out as if from a wine speed, creating centrifugal force.
centrifuges and the drives that operate decanter; and in the other side there is Screen centrifuge (Fig. 2). Screen
this equipment. a solid discharge (similar to wine sedi- centrifuges have an open bowl, or what
22 powertransmissionengineering august 2010 www.powertransmission.com
we call a screen basket. The bowl itself mass of the bowl and the conveyor. • n1 = rotational speed of high
has holes. The basic function is the Selection of gearbox. Now that you speed shaft
same—the screen basket (or bowl) is realize you need a gearbox, you must • n2 = rotational speed of slow-
fixed to the gearbox housing and the first obtain from OEMs the follow- speed shaft and conveyor
conveyor belt drive is fixed to the out- ing information in order to select the • n3 = rotational speed of gearbox
put shaft—both operating at different proper one: housing and bowl
speeds to create the centrifugal force. • n2–n3 = relative speed between
The bottom line: What is centrifugal 1. Torque (T2) slow-speed shaft with conveyor
force? Quoting Schwarz, “This is the • This is the torque needed for and gearbox housing with bowl
most obvious parameter to use when the conveyor. • n3–n1 = relative speed between
considering the actions of a centrifuge. 2. Rotational Speed (n3) gearbox housing and high-speed
The maximum centrifugal acceleration • Rotational speed of the bowl. shaft
developed inside a centrifuge is a func- 3. Relative Speed (n2 – n3) • (n3–n1)/(n2–n3) = relation
tion of its radius and angular rota- • Speed between the conveyor between relative speeds
tional speed. More commonly, the term and the bowl. (= ratio i of the gearbox)
G-Force (G-Value) is used instead of 4. Is the conveyor faster or slower • –i = slow-speed shaft and con
acceleration. The G-Force is defined as than the bowl? veyor are faster than bowl
the multiple of the gravitational con- • A gearbox can do either. This • +i = slow-speed shaft and conveyor
stant that is obtained in the centrifuge. is usually a design preference are slower than bowl
The centrifugal acceleration (G-Force) from the OEM (centrifuge • T2 = torque at slow-speed shaft
will increase with the bowl diameter manufacturer). and conveyor
and the bowl speed.” (Ref.1). 5. Lubrication System Example—Table 1. Here is a selec-
Some manufacturers differentiate • Grease Lubricated tion diagram that shows the available
themselves by offering smaller-diame- • Oil Bath Lubricated torque over the differential speed for
ter machines, claiming they will achieve * Closed System without Oil a certain gearbox size (619 ZS model)
the same flow rates as larger-size diam- Reservoir and ratio (25:1). It shows the maximum
eters. While the flow rates may be * Open System with Oil torque (8,000Nm) and maximum-
achievable, it is highly unlikely that Reservoir input, relative speed (2,000 rpm), as
the same separation performance will • Oil Circular well as the maximum bowl speed (3,500
result. The diameter is key when look- • Oil Once-Through rpm). If we divide the maximum-input
ing for the capacity of conveying solids 6. Draft Design relative speed by the ratio (2,000/25),
to provide greater suspension volume • A draft design is usually pro- we are then able to produce up to a
for settling out solids. (Ref.1). vided from the OEM in order 70-rpm differential speed on the output
for the gearbox manufacturer to side. This diagram is limited by the
Purpose of a gearbox in a centrifuge suggest a proper size and type. mechanical strength at the maximum
application. Following is the required informa- torque and by the rated life of the
tion to calculate the proper gearbox: eccentric bearing (in this case, service
Typical continued

Application:
Table 1—Selection diagram—available torque over the differential speed
Tconveyor = 5,000 Nm for gearbox size (619 ZS model) and ratio (25:1).
nconveyor = 2,525 rpm
nbowl = 2,500 rpm

1. Centrifuge without gearbox:

Pconveyor = 5,000 x 2,525 / 9,550
= 1322 kW

2. Centrifuge with gearbox:

Relative speed = nconveyor – nbowl
= 2,525 – 2,500
= 25 rpm
Pconveyor = 5,000 x 25 / 9,550
= 13.09 kW

The centrifuge gearbox allows run-

ning the centrifuge with the practicable
power requirement. The main power
portion is the energy in the rotating
www.powertransmission.com august 2010 powertransmissionengineering 23
factor = 1.0) in that it has a B10 life turns at the bowl speed. The output can be designed to fit into all applica-
of 8,000 hours. If we continuously run shaft of the centrifuge reducer is con- tions.
the machine at 40 rpm and a little over nected to the conveyor and transmits Sumitomo offers four different main
5,000 Nm, then we have a rated life of the torque that is needed for the solids types of drives available that meet users’
approximately 8,000 hours. This is the transport. The input shaft can be locked specifications for centrifuges:
philosophy behind selecting the correct by a torque arm or driven by a back- ZS is a single-stage cyclo drive
product. drive motor to provide the necessary centrifuge reducer for most applications
Sumitomo’s centrifuge drives—Table 2. relative speed. when the conveyor turns faster than the
Sumitomo offers a variety of gear- The flexible lubrication system bowl.
boxes that are used in both decanter allows grease lubrication as well as The ZSPN and ZSPV are both
and screen centrifuges. The balanced oil lubrication—depending on a user’s double-stage centrifuge drives with a
housing is connected with the bowl and requirements. Mounting dimensions cyclo drive stage and a planetary stage
for higher ratios. ZSPN provides the
Table 2—Sumitomo drives for users’ specifications for centrifuges. conveyor slower than the bowl (posi-
tive ratio); ZSPV provides the conveyor
Rotating
Type Cyclo Planetary Stage Shaft Ratio Direction faster than the bowl (negative ratio).
Input/Output The ZSPR is a very special double-
stage centrifuge drive with a cyclo drive
ZS X 1 3 - Opposite
stage and a differential planetary stage.
ZSPV X X 2 3 - Opposite This version allows variable relative
ZSPN X X 2 3 + Same speed over the full control range of the
Same/ motor with either a slower or faster
ZSPR X X 2 4 +/-
Opposite conveyor.
Same/ Also available is the purely planetary
ZSP X 2 or 3 3 +/- ZSP as a double- or triple-stage design.
Opposite
4 This type is mainly used for applica-
Centrifuge Gearbox Selection
tions with high bowl speed and high
differential speed.
(1) One Motor, One Gearbox: What is a “cyclo” drive stage?
Bowl drive through belt on gearbox. Input shaft of gearbox with torque arm Sumitomo’s cyclo drives are cycloidal
(n1 = 0) reducers intended for gear drive appli-
Features: cations. The cyclo’s epicycloidal design
Very simple and cheap solution
Constant solids volume has advantages superior to speed reduc-
Relative speed regulation by changing gear ratio or bowl speed only. ers using common involute tooth gears,
in that cyclo components operate in
(2) Two Motors, One Gearbox:
compression, not in shear. Unlike gear
Bowl drive through belt from main motor to gearbox casing. teeth with limited contact points, a
Input shaft of gearbox connected with “backdrive” motor through belt drive or
alternative inline connection with coupling (n1 < n3) cyclo has two-thirds of its reduction
Features:
components in contact at all times. This
Cost effective solution for relative speed regulation design enables cyclo speed reducers and
Fluctuating solids volume
Relative speed regulation by changing the control motor speed gear motors to withstand shock loads
exceeding 500% of their ratings while
(3) Two Motors, Two Gearboxes: providing exceptional performance,
Bowl driven through belt drive on primary gearbox. Input shaft of primary gearbox
is connected with output shaft of secondary gearbox. Primary and secondary reliability and long life in the most
gearboxes are both driven by main motor through different belt drives. Input shaft severe applications (Fig. 4 and Table 3).
of secondary gearbox is connected with control motor.

Features:
Automatically adapted and extremely precise solution for relative speed Conclusion
regulation Centrifuges have been used in oil
Regulation as function of the fluctuating solids content in the bowl
Relative speed regulation by changing the control motor speed fields since the early 1950s. More recent-
ly, their role in the oil field has expand-
(4) Two Motors, One Differential Gearbox: ed to include environmental cleanup.
Bowl drive through belt from main motor to gearbox casing. Central input shaft of
differential gearbox connected with control motor. Hollow input shaft of differential
Unfortunately, processing through a cen-
gearbox connected torque arm. trifuge alone will not solve the disaster
Features: in the Gulf. This is only a small portion
Recommended whenever necessary to regulate the conveyor speed as well as
the bowl speed
of the oil separation process and will
Regulation as function of the fluctuating solids content in the bowl require further treatment.
Relative speed regulation by changing the control motor speed
Relative speed is independent from the bowl speed. BP has already purchased over 30
centrifuge drives to clean up the oil spill
Figure 3—Centrifuge gearbox selection.
in the Gulf. (Officials) say skimmer ves-
24 powertransmissionengineering august 2010 www.powertransmission.com
sels will pump oily water onto a barge
where the centrifuges can process a total
of 600,000 gallons a day, separating the
gunk from the water.
Centrifuges are a technology that
will continue to improve, develop and
be used in all types of applications
that require separation of liquid from
solids.

References:
1. Schwarz, Nils. “Selecting the Right
Centrifuge—The Jargon Demystified,”
Whitepaper.
2. Mayr, Chris. “Sumitomo Centrifuge
Gearboxes—Training,” June, 2010.
Sumitomo (SHI) Cyclo Drive,
Germany GmbH.

Figure 4—Torque range in relation to type at ratio 60:1.

Table 3—Selection of gearbox type.

ZS ZSPV ZSPN ZXPR ZSP
Torque Range 3 2 2 2 1
Shock Overload 3 2 2 2 1
Lubrication 3 2 2 2 2
Bowl Speed 2 2 2 2 3
Relative Speed 1 2 2 2 3
Speed Variation 1 2 2 3 2
Diameter 1 1 1 1 3
Weight 2 1 1 1 3
Cost 3 2 2 1 1
19 16 16 16 19
* 1 = Good, 2 = Better, 3 = Best
** Sumitomo is the only centrifuge gearbox manufacturer who supplies a complete range of ALL possible types of
centrifuge gearboxes.

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