A decanter centrifuge, or horizontal solid-bowl centrifuge, is a mechanism used to dewater spent grains. A decanter is one type of centrifuge among perhaps 30 or more manufactured worldwide. The machine's function is to separate - or literally decant - liquids from solids in the ethanol-making process. A typical 40-mmgy ethanol plant would install four, sometimes five, decanters.
Sharples, a company purchased by Alfa Laval several years ago, arguably supplied more decanters to first-generation U.S. ethanol plants than any other manufacturer of the era. In fact, many of the used and reconditioned decanters available today are Sharples machines. Known for lasting durability - but not necessarily great efficiency by modern standards - it is not uncommon to find robust Sharples decanters in use today that were originally manufactured in the early 1970s.
The Leading OEMs:
While several international companies manufacture new decanter centrifuges, the U.S. ethanol industry is supplied principally by three original equipment manufacturers, or OEMs: Westfalia Separator, Inc., with sales offices in Northvale, N.J., Alfa Laval, with sales offices in both Oak Brook, Ill., and Richmond, Va., and Flottweg Separation Technology, of Florence, Ky.
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Used, Reconditioned Sales & Service:
The decanter aftermarket is made up of several small companies that sell used and reconditioned machines and also service existing machines for producers.
Bensenville, Ill.-based Aaron Equipment, a third-generation family-owned business, is one of the largest dealers of new, used and reconditioned process equipment in the world and the largest international dealer of used and reconditioned centrifuges. Aaron Equipment has been selling used centrifuges, dryers, evaporators, stand-by generators, seed tanks, fermentation tanks and other process equipment to the ethanol industry since the early 1980s.
Over the last decade, Aaron Equipment has supplied many of the used and reconditioned Sharples centrifuges used in the ethanol industry today. The company remains concentrated on supplying used and reconditioned Sharples centrifuges with "state-of-the-art, new drive and control systems" that meet industry standards. In addition, the company has been involved in selling surplus parts and equipment from ethanol plants.
Roemer Machine of Davenport, Iowa, is a service provider that ordinarily rebuilds decanters purchased from Aaron Equipment's inventory. Roemer Machine is arguably the ethanol industry's most experienced decanter reconditioning and rebuilding service provider, with 34 years in the business. Producers say the company has impeccable quality standards and has earned one of the best reputations for machine repair in the ethanol industry. In fact, some of the repair procedures and specifications the company pioneered are today's industry standards.
"Service is the name of our game," Roemer Machine shop supervisor Carl Stark told EPM. "About 70 percent of our business is in the ethanol industry."
Jenkins Centrifuge, of North Kansas City, Mo., is a broker and small OEM that offers ethanol producers reconditioned decanters, as well as decanter rebuilding and repair services. Owner Doc Jenkins has a team of 27 employees primarily dedicated to rebuilding decanters. However, due to demands from its customers, Jenkins Centrifuge began manufacturing its own make of decanters (largely for the meat-packing and rendering industry) in 1990. Jenkins told EPM his company sells about four or five new decanters a year.
In addition, Kyte Centrifuge Sales & Consulting (KCS & C), of New Bern, N.C. is a small broker that offers the ethanol industry used and reconditioned decanters and decanter parts. KCS & C, operated by Ken Kyte, sells reconditioned centrifuges and offers testing services, process recommendations, troubleshooting, inspections, reconditioning assistance, parts location assistance, appraisals and centrifuge disposal.
Cost, Materials & Engineering:
While decanters are not particularly substantial in size, the machines are highly engineered and, as a result, quite expensive. Purchased new, the leading models range from $250,000 to $400,000 apiece, according to two industry sources.
According to Aaron Equipment owner Alan Cohen, decanter centrifuges, both new and used, are costly because an extensive amount of engineering goes into the equipment's design; the raw materials used to manufacture the equipment are very expensive (e.g., stainless steel centrifugal castings and carbide composite wear protection), and the manufacturing process entails a great deal of high-tolerance machining.
For this reason, Aaron Equipment, Roemer Centrifuge, Jenkins Centrifuge, KCS & C and other dealers source, supply and sometimes recondition used decanter centrifuges, offering models from the leading manufacturers at reduced costs, they told EPM.
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