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Predicting the separation performance of decanter centrifuges is challenging due to dynamic events within the apparatus. Current methods for designing decanter centrifuges rely on simplified models, often leading to inaccuracies. Consequently, manufacturers must perform time‐intensive pilot scale experiments to derive their own correction factors. Growing computing power sparks interest in alternative modeling strategies. Grey box models (GBM) combine mechanistic white box models (WBM) and data‐driven black box models (BBM), with the optimal structure (parallel or serial) varying by application. For modeling decanter centrifuges, we propose a serial GBM that comprises an artificial neural network that outputs unknown material parameters into a first‐principle multi‐compartment model. Comparing this approach to alternative data‐driven modeling strategies (pure BBM, parallel GBM), we conclude that the serial GBM excels in terms of extrapolation, prediction ability, and transparency while also enabling a better comprehension of the separation process. [ABSTRACT FROM AUTHOR]

High production rates and the constant expansion of production capacities for lithium-ion batteries will lead to large quantities of production waste in the future. The desired achievement of a circular economy presupposes that such rejects could be recovered. This paper presents a two-staged process route that allows one to recover graphite and conductive carbon black from already coated negative electrode foils in a water-based and function-preserving manner, and it makes it directly usable as a particle suspension for coating new negative electrodes. In a first step, coating residues, which accumulate in production (as offcuts or rejects for example), are decoated in an aqueous ultrasonic bath. The ultrasonic bath also serves as a pre-thickener. As a result, high mass concentrations of active material can already be achieved in the water after the first process step. Water is then removed from the negative electrode suspension in a subsequent step by applying dynamic cross-flow filtration. With this unit operation, it is possible to concentrate the slurry residue to a solid content similar to that of the new electrode slurries used for coatings. An important criterion for the direct utilization of production waste is that the particle properties are affected as little as possible so that the suspension can be used directly for coating new films. This work presents the individual recycling process steps and their influence on the particle and slurry properties. The aim is to assess whether the recyclate is suitable for a coating of new negative electrodes and thus also for manufacturing batteries from 100% recycled material. [ABSTRACT FROM AUTHOR]

The solid volume fraction of a slurry requiring solid–liquid separation often fluctuates in industrial cake filtration processes. For low solid volume fractions, particle segregation arises, resulting in an inhomogeneous filter cake structure. Particle segregation has significant impacts on cake formation such as a longer cake formation time compared to homogeneous cakes. This work addresses the impact of this effect on vibration compaction, which is an alternative deliquoring method applying oscillatory shears to the filter cake. The dewatering results of homogeneous and segregated cakes made of the same material with a broad particle size distribution are compared. Although cake deliquoring is achievable despite particle segregation, vibration compaction is more effective for homogeneous cakes. The reason is that no particle size homogenization within segregated cakes occurs due to oscillatory shear, as particle size analyses indicate. The particle size measurements of cakes before and after vibration compaction reveal that the material's particle size distribution is preserved despite vibration application. Vibration compaction achieves higher deliquoring than the common compaction method by squeezing, as elastic recovery effects after squeezing lead to the reabsorbing of liquid, already expressed and stored in the filter cloth. This demonstrates that vibration compaction is a real alternative for cake deliquoring. [ABSTRACT FROM AUTHOR]

Solid–liquid separation plays a decisive role in various industrial applications particularly in the treatment and purification of suspensions. Solid bowl centrifuges, such as the decanter centrifuge, are commonly employed in these processes as they operate continuously and enable high throughputs with short processing times. However, predicting the separation performance of solid bowl centrifuges proves to be challenging due to dynamic phenomena within the apparatus, such as particle settling, sediment build-up, consolidation and sediment transport. In practice, design considerations and the dimensioning of the apparatus rely on analytical models and the manufacturer's expertise. Computational Fluid Dynamics (CFD) offers a way to deepen our understanding of these devices by allowing detailed examination of flow phenomena and their influence on the separation processes. This study utilizes the open-source software OpenFOAM to simulate multiphase flow in a laboratory-scale decanter centrifuge, solving individual transport equations for each particle size class. The basis is the characterization of the material through targeted laboratory experiments to derive material functions that describe the hindered settling and the sediment consolidation. Furthermore, experiments on a laboratory decanter served as validation. The results demonstrate the solver's capability to replicate clarification and classification within the apparatus. Furthermore, the solver supports the definition of geometries tailored to specific separation tasks. This research demonstrates the potential of CFD for a better understanding of complex centrifuge processes and for optimizing their design to improve performance. [ABSTRACT FROM AUTHOR]

If fine and compressible particle systems need to be separated, the ground layer compaction caused by the compacting of the filter cake leads to high flow resistances. Thin‐film filtration is a suitable method to avoid the limiting effect of the filter cakes. Gas‐impermeable filter membranes prevent shrinkage cracking, which can occur during demoisturing of the filter cakes. Titanium dioxide and baker's yeast are used as model particle systems, which are present in different concentrations and are filtered with track‐etched membranes in different particle‐to‐pore size ratios. The parameters determined during the investigation are the residual moisture, the specific solid mass, and the completeness of the discharge. Filtration causes progressive blocking of the membrane pores, resulting in filter medium resistances that are increased by up to a factor of 175. Metabolism of yeast can cause bubbles to accumulate on the membrane and decreasing the free filter area. Without regeneration the specific solid mass flow rate is reduced by 61 % for titanium dioxide and by 13 % for yeast under ideal conditions of this experimental study. [ABSTRACT FROM AUTHOR]

Solid–liquid separation is a fundamental operation in process engineering and thus an important part of many process chains in the preparation of slurries in the chemical industry and other parts of the industrial environment. For the separation of micron-sized particles which, due to their size, do not settle or settle very slowly in the earth's gravity field, centrifuges are often used. The preferred choice are often decanter centrifuges because they work continuously and stabilize the process against product fluctuations due to their adjustment possibilities. The design of the apparatus is complex: The main components of the apparatus are the cylindrical-conical bowl, which rotates at a high speed, and a screw located inside the bowl, which rotates in the same direction at a low differential speed to transport the separated solids out of the apparatus. Geometrical properties of the apparatus, as well as the adjustable operating parameters, such as rotational speed or differential speed, have a significant influence on the separation. In practice, analytical models and the experience of the manufacturers form the basis for the design. Characteristics of the disperse phase, interactions with the liquid, as well as the influence of the flow on the separation, are not taken into account. As a consequence, the transfer to industrial scale always requires a large number of pilot-scale experiments, which are time-consuming and expensive. Due to the increasing computational power, computational fluid dynamics (CFD) provides one possibility to minimize the experimental effort in centrifuge design. In this work, the open-source software OpenFOAM is used to simulate the multi-phase flow in a laboratory decanter centrifuge. For validation, experiments were carried out on a laboratory scale and the main operating parameters, such as speed, differential speed, and volume flow rate, were varied. The simulation results show a good agreement with the experimental data. Furthermore, the numerical investigations show the influence of the flow on the separation of the particles. To evaluate the transportability of a material, the transport efficiency was introduced as a dimensionless parameter. In addition, the simulation allows the consideration of the individual velocity components, making it possible to generate an impression of the complex three-dimensional flow in the apparatus for the first time. [ABSTRACT FROM AUTHOR]

Filter cake compaction is a common method for mechanical deliquoring of compressible filter cakes. In addition to the conventional squeezing compaction method, applying oscillatory shear to filter cakes at low pressure is an alternative compaction process in cake filtration. While basic differences in terms of compaction success have already been identified for various materials, a systematic analysis of the influence of material properties on compaction behavior under oscillatory shear is missing. The present work addresses the influence of particle size distribution and increasing particle agglomeration on the compaction success of oscillatory shear to further clarify the process knowledge and applicability. The compressibility achieved by this technique was investigated for calcium carbonate materials with various particle size distributions. The results show that the compaction potential increases from 17.3% for the coarsest material ( x 50 , 3  = 23.5 μm) to 26.6% for the finest material ( x 50 , 3  = 2.3 μm) with decreasing mean particle size. The more widely distributed material exhibits a higher compaction potential of 21.7% compared to 18.4% for the narrowly distributed material. Increasing particle agglomeration to improve the slurry filterability does not affect the achievable compaction states of the material by vibration compaction at sufficiently high energy input. [ABSTRACT FROM AUTHOR]

The scale up of solid bowl centrifuges is a major challenge as the process and material behavior are complex and difficult to describe. A common approach to forecast the process behavior is to use analytical models and transfer the experience gained from the lab to the industrial scale. In this context, time‐consuming and cost‐intensive pilot scale experiments are necessary. This paper presents a methodology to improve the scale up process and make it more sustainable by using a numerical model that allows the real‐time tracking of the process and a more reliable scale up process. For this approach, the material behavior is derived from laboratory experiments whereby the scalability is given. Here, the determination of material functions allows an accurate representation of the material behavior for solid bowl centrifuges of different scales. The focus of this paper is the detailed explanation of material related functions for the scale up of decanter centrifuges. [ABSTRACT FROM AUTHOR]

This document is a correction notice for a published paper titled "Iron Ore Tailings Dewatering: Measurement of Adhesion and Cohesion for Filter Press Operation." The authors have made two corrections to the paper. Firstly, Figure 7 has been replaced with a new graph. Secondly, the word "mm" in a specific paragraph has been replaced with the word "cm." The authors and the Editorial Office apologize for any inconvenience caused and assure readers that the scientific conclusions of the original article remain unaffected. [Extracted from the article]