Advanced analytical model of a disc stack centrifuge to enhance the understanding of its industrial application in an API recovery facility

This study aims to advance the understanding of biosuspension separation in a three-outlet disc stack centrifuge through a model-based approach. A steady-state model of the centrifuge is developed in which a suspension is separated into three outlet streams. This model considers both liquid and particle separation within two separation zones. Furthermore, the applicability of the model is evaluated in an industrial setting. The model is developed using systematic modelling methods within Process Systems Engineering (PSE). It is formulated through macroscopic balances expressed in radial coordinates, considering the appropriate boundary conditions. The analytical trajectory of particles is implemented to describe the particle separation within the two separation zones. Validation of the model predictions against historical production data demonstrates the model's accuracy, evidenced by a low Normalized Root Mean Squared Error (NRMSE) score of 0.131 in predicting the supernatant flow rate. Furthermore, the model’s applicability is demonstrated through the analysis of separation performance and the discharge process, thereby enhancing process understanding without interfering with production.