Separator insert, separator and separator insert replacement method

Abstract

The present invention relates to a method of operating a separator which reduces cross-contamination when processing a product, the separator being provided with a separator insert (II, III) as a pre-assembled replaceable unit for insertion into a stator unit (4a, 4b) on a frame (I) or housing (68) of the separator, the separator insert (II, III) comprising at least i. a rotor (2, 65) rotatable about an axis of rotation (D) provided with a drum (3, 66) and a drum wall, ii.. a separating means preferably arranged on the drum (3), iii. at least one product supply line and two product discharge lines, and iv. the contact area of ​​the separator insert with the product is partly or completely made of plastic. A method of operating the separator comprises the steps of: a) providing a separator with a first separator insert (II, III) mounted in a frame (I) or housing; b) introducing an initial product to be separated into the separator; c) discharging first and second product streams (LP, HP) separated from the product mixture out of the separator through two separate product discharge lines during the separation operation of the separator; d) stopping the separation operation and draining any residual liquid remaining in the drum; and e) replacing the empty, contaminated separator insert (II, III) from the separator frame or housing with an unused separator insert.

Description

[Technical field]

[0001] The present invention relates to a separator insert for a separator according to the preamble of claim 1, to a separator with such a separator insert and to a method for replacing said separator insert. [Background technology]

[0002] The separator defined in this specification is used to separate a free-flowing suspension as starting product into phases of different density in a centrifugal field. Steam sterilization of the separators used is necessary for a wide variety of applications. A relatively "small" steam sterilizable separator with a disk pack introduced on the market by the Applicant has a capacity of 6000 m 2 The separator CSC 6 has a fairly clean surface. However, in laboratory conditions, this machine is still relatively large.

[0003] Known separators with disc packs, which are commercially available, are driven by a spindle, which is driven by a motor, either directly or via a gearbox. Furthermore, known machines are made of stainless steel. For these reasons, filters are now used very frequently in laboratories instead of centrifuges. Steam sterilization (SIP - Sterilization In Place) is not necessary for separators with disc packs and disposable plastic parts (disposable technology - one-time use of pre-qualified plastic parts). The separators may be particularly suitable for use in the biotechnology field.

[0004] A separator for separating a flowable product into different phases is known from WO 2014 / 000829, which comprises a rotatable drum with a lower drum part and an upper drum part and means arranged on the drum for treating a suspension in a centrifugal field of solids or for separating a heavy solid phase from a light phase in a centrifugal field, in which one the lower drum part, the upper drum part, the washing means, some or all of the following elements consist of plastic or a plastic composite material.

[0005] In this way, parts of the drum, or preferably the entire drum, preferably together with the feed and discharge systems or areas, can be configured for disposable use, which is of particular interest and advantage in relation to the processing of pharmaceutical products such as fermentation broths, since after being run to process a corresponding product batch, the entire drum can be replaced without the need for cleaning of the parts of the drum that come into contact with the product, preferably during continuous operation during the processing of the product batch.

[0006] This separator is therefore highly advantageous, particularly from a hygienic point of view. In order to achieve a physical separation between the disposable drum and the drive, a contact-free connection between the drive and the drum is advantageous.

[0007] A further development is shown in the general German Patent Publication 10 2017 128 027, in which the bearing devices are configured as magnetic bearing devices, one of which is preferably also used as a drive device for rotating a drum which is held in suspension during operation. This makes it advantageous to configure the separator with a disposable separator insert since no mechanical parts are required to rotate and support the drum and the separator insert is very easy to replace. The present invention also takes advantage of these advantages. Summary of the Invention [Problem to be solved by the invention]

[0008] Against this background, the object of the present invention is to optimize the replacement of the separator insert and to make its subsequent disposal as simple as possible. In particular, the separator insert can be used or configured as a disposable element, so that the separation process becomes easily controllable. [Means for solving the problem]

[0009] The present invention solves this problem by means of a method having the features of claim 1. The present method of operating a separator is intended to achieve a reduction in cross-contamination during product processing.

[0010] To this end, the separator insert is used as a preassembled, replaceable unit within the separator. At the same time, the replaceable separator insert is disposed of in a simple and uncomplicated manner as part of the method. In particular, the method contemplates that the separator insert and any residual liquid contained therein can be separated and disposed of.

[0011] In a first variant, the separator insert is provided for insertion into a stator unit on the frame of the separator. In this variant, the separator insert can comprise both a rotatably mounted drum and a housing that is stationary during the separation operation as a preassembled replaceable unit.

[0012] In a second variant, the separator insert can be configured as a rotor with a rotatably mounted drum, preferably with integrated separating means, in particular a separating disk pack, which is inserted into the separator housing. It is preferred and advantageous that the entire supply and discharge system, i.e. all supply and discharge lines, are at least partially or completely part of the separator insert, so that hermetically sealed supply and discharge lines are ensured relative to the separator housing. In contrast to the previous variant, the housing of this variant remains partly in the separator when the separator insert is replaced. The disadvantage compared to the first variant is that the sealing between the rotating and non-rotating parts is more complex. Examples of such sealing and corresponding axially arranged supply and discharge systems are known, for example, from EP 2 864 053. In the case of supply lines from below, so-called mechanical seals can be used, which allow the replacement of the separator insert. Such seals are known, for example, from WO 2020 / 120358.

[0013] In both of the above variants, the separator insert has at least the following characteristics: i. A rotor rotatable about an axis of rotation comprising a drum and a drum wall, which in a preferred embodiment may have a closed wall in a central region of the drum.

[0014] In the context of the present invention, the intermediate range is preferably defined as the range of 20%-80% of the axial extension length of the drum. ii. A separating means preferably located within the drum (3).

[0015] A disc pack consisting of separating discs can be used as the separating means. iii. At least one product supply line and two product discharge lines from the separator insert.

[0016] Advantageously, in order to further reduce cross-contamination, a separate wastewater discharge line can be provided, which in the context of the present invention is preferably not allocated to the discharge system. iv. Here, the product contact area of ​​the separator insert is partly or completely made of plastic.

[0017] In its function for single use, the use of plastic for the separator insert is ideal for subsequent disposal of the separator insert or at least the area that contacts the product. This is advantageous in the processing of various products in pharmacy, radioactive tracer analysis and biotechnology, e.g. in the extraction of phytotoxic substances, where contamination must be kept to a minimum even when changing the separator insert.

[0018] The method according to the present invention comprises at least the following steps: a) providing a separator having a first separator insert (II) mounted in a frame (I) or housing;

[0019] This first separator insert is replaced after use with a second separator insert that is preferably uncontaminated and otherwise identical, however, it is also possible that the separator insert, and preferably the separation means of the separator insert, vary depending on the separation task. b) introducing into a separator the starting products to be separated; c) discharging first and second product streams separated from the product mixture during a separating operation of the separator through two separate product discharge lines from the separator;

[0020] Hereinafter, the separation operation will also be referred to as the "operation" for short. The products are separated according to density in the centrifugal field of the separator. d) stopping the separation operation and draining any residual liquid remaining in the drum;

[0021] When the separation operation is stopped or halted, any residual liquid remaining in the drum is preferably allowed to drain by gravity. The drum is allowed to move slightly when the separation action is stopped, but gravity takes precedence and determines the emptying direction.

[0022] If a separate drain discharge line is used, it is preferably located along the bottom surface of the separator insert so that the separator insert is emptied as completely as possible.

[0023] If step d is carried out with a separator insert in which the housing and rotor are combined into a pre-assembled unit, the drain discharge line may be arranged so that both the drum and the housing drain residual liquid via the drain discharge line. For this purpose, one or more drain discharge lines may also be provided. e) replacing the empty, contaminated separator insert from the separator frame or housing with an unused separator insert;

[0024] The empty, contaminated separator insert can then be disposed of without any residual liquid.When processing particularly problematic products, such as hazardous substances of different hazard classes, it is desirable to immediately package the separator insert in a contamination-proof packaging. It is impractical to drain the residual liquid when the separator insert is dismantled, and increased safety standards are required.

[0025] In a particularly preferred embodiment of the invention, the processing of the starting product, e.g. a suspension, is carried out by a separator having a frame and a separator insert replaceably arranged on said frame, the separator insert being configured to separate the flowable suspension in the centrifugal field into at least two flowable phases of different densities and to form a preassembled replaceable unit which is inserted into a stator unit on the frame of the separator, the separator comprising at least a housing configured like a container which is stationary during operation and closed except for a number of openings, a rotor rotatable about a rotation axis together with a drum arranged in said housing and having one or more openings, a separating means preferably arranged in the drum, and a rotor with the drum. and at least two rotor units for a magnetic bearing device at two axially spaced positions of the rotor, the rotor with the drum being held in a suspended state within the housing during operation, rotatably mounted and rotatable within the housing during operation, further spaced receivers with stator units of the magnetic bearing device are formed on the frame, between which a housing of a separator insert is held non-rotatably and the rotor is maintained rotatable, the relative positions of the spaced receivers with stator units of the bearing device can be changed to allow the separator insert to be replaced, and the housing and receivers are provided with corresponding positive locking means to hold the housing non-rotatably on the receivers.

[0026] By "in operation" it is meant during the centrifugation process when the rotor is spinning.

[0027] According to claim 1 it is possible to make a separator with a disposable module with the disposable parts "drum" and "housing", while at least the frame and parts of the bearings and drive can be reused. By changing the position, the corresponding positive locking means can be engaged and disengaged to exchange the separator insert.

[0028] The present invention allows for the manufacture of separators that can use disposable separator inserts, desirably constructed so that all product contact components are made of plastic or other non-magnetic materials that can be discarded after a single use. This eliminates the need for cleaning after use. In this way, the machine and its operation can be significantly cheaper. The magnets can be recycled if desired.

[0029] It is simple and safe to have spaced receptacles for the bearing arrangement on the frame between which the separator insert can be inserted so as to be rotatably fixed.

[0030] It is also provided that the separator insert can be attached to the frame in a positive and non-positive manner so as to prevent rotation.

[0031] According to a particularly simple variant, the receiving part and the housing can have corresponding pins and recesses as corresponding positive locking means to hold the housing on the receiving part against rotation. It is particularly simple if the receiving part and the pin each extend axially.

[0032] It is also possible that the position of the receivers, in particular on the bracket, can be adjusted so that the separator insert can be replaced. For this purpose, the relative distance between the receivers is adjustable, but one or both receivers can also be hinged, swivelled, rotated or displaced so that the separator insert can be placed between them. Preferably, according to one variant, the relative vertical spacing of the receivers can be adjusted together with the stator unit of the bearing arrangement in such a way that the separator insert can be replaced, thereby allowing the corresponding positive locking means to be adjusted into or out of engagement.

[0033] This allows for quick and easy replacement of the separator insert after processing a batch.

[0034] According to a first particularly simple variant, only one of the two receiving parts can be arranged in an adjustable manner, in particular in a height-adjustable manner, on the frame, in particular on the bracket, and the other receiving part can be arranged in a fixed position on the frame, in particular on the bracket, or it is possible for both receiving parts to be arranged in an adjustable manner, in particular in a height-adjustable manner, on the frame, in particular on the bracket.

[0035] Further advantageous embodiments of the method are the subject matter of the dependent claims.

[0036] As mentioned above, the separator insert can be provided with an additional drain discharge line for draining residual liquid remaining in the drum in step d. In particular, this is provided in addition to the feed and drain system of the separator insert, which does not require additional bypasses or control elements, as opposed to emptying via the bottom feed.

[0037] Draining the residual liquid remaining in the drum in step d includes collecting the residual liquid outside the separator insert in a collection container, preferably a drain bag. In this way, the residual liquid can be preferably transferred from the airtight environment of the separator insert to the similarly contaminant-free airtight environment of the collection container immediately prior to replacement. The contents of the collection container can be determined by weighing the empty and filled containers, so that the weight of the residual liquid can be determined very precisely. In the case of hazardous substances, e.g. phytotoxins or radionuclides, various national regulations may require a precise determination of the residual amount.

[0038] Residual liquid remaining in the drum can also be drained in step d via the product feed line as an alternative to the drain discharge line. If the product feed line is part of the replaceable separator insert, it can also be replaced automatically. If part of the product feed line or part of the feed system with the product contact surface is part of the housing, this part is preferably constructed to be replaceable so that it can be discarded together with the separator insert. However, this may require an additional disassembly step.

[0039] The product supply line or a downstream line element connected thereto, desirably a hose or pipe, may comprise a changeover valve between the retentate collecting container and the product output container, where the changeover valve is actuated during draining in step d. The control unit can implement both the operating sequence of the described method and the actuation of the changeover valve as well as any other components for actuating the separator, e.g. a peristaltic pump.

[0040] In one variant of the invention, the separator insert can be configured as an exchangeable, rotatably mounted rotor with a feed system and a discharge system integrated in the separator housing, the introduction of the starting product in step b and the discharge of the residual liquid in step d are carried out via a product feed line of the feed system, and prior to the discharge of the residual liquid in step d, the inlet element connected to the product feed line is replaced by a discharge element equipped with a collection container.

[0041] Advantageously, the central closed wall area of ​​the drum extends over 20%-80% of the axial extension length of the drum.

[0042] In particular in the first variant in which the separator insert comprises a housing and a rotor, it is advantageous if at least one product discharge line, in particular the product discharge line of the heavy product stream, is connected to a pump, such as a peristaltic pump, in particular a peristaltic squeeze pump, which is used to regulate the pressure in the product discharge line, so that, for example by reducing the flow rate, the pump can generate a pressure corresponding to the product discharge of the heavy phase in the separator insert configured as a gripper.

[0043] During the drainage in step d, the pump can be switched off or operated at reduced pressure compared to step c, so that the residual liquid can be drained by gravity. Alternatively, the product discharge line can also have a control element for reducing the pressure, preferably a valve, particularly preferably a stop valve, which ensures drainage via the wastewater discharge line. Alternatively or additionally, the residual liquid can also be drained via this wastewater discharge line under negative pressure.

[0044] Furthermore, residual liquid can be advantageously drained from both the drum and the housing in step d. This is particularly true for the first variant in which the housing and the drum are part of the separator insert.

[0045] The removal of the contaminated first separator insert in step e for replacement with a new second separator insert can be advantageously performed by changing the relative position of the receiver with the stator unit of the bearing arrangement.

[0046] An advantageous and simple method for exchanging the first separator insert of the separator for the second separator insert in step e is preferably carried out in particular using the following steps: a) providing a separator having a first separator insert mounted in a frame; b) adjusting the relative positions of the receiving parts, in particular the relative distance between the receiving parts, and releasing the positive lock between the frame and the separator insert, and removing the first separator insert from the receiving part; c) disposing a second separator insert (before, during, or after steps a and b); d) inserting another second separator insert into one of the receptacles and engaging corresponding positive locking means on one end of the housing and one of the receptacles; e) adjusting the relative positions, in particular the relative distances, of the receivers until the opposite housing ends of the separator insert and the corresponding positive locking means on the two receivers engage each other in a rotationally fixed manner.

[0047] During the separating operation of the separator, the discharge of the first and second product streams separated from the product mixture through two separate product discharge lines from the separator can advantageously be carried out in such a way that there is no connection between the product supply system and the product discharge system outside the separator insert, thereby ensuring an airtight and contamination-free discharge of the streams of the product supply system and the discharge system.

[0048] Furthermore, the first and second product streams separated from the product mixture during the separation operation of the separator can be discharged from the separator via two separate product discharge lines in such a way that there is no connection between the product discharge system and a waste discharge system outside the separator insert, the waste discharge system preferably comprising said waste discharge line and, optionally, additional pipe or hose lines connected to said waste discharge line outside the separator insert and said collection container.

[0049] Furthermore, when the separator stops separating action in step d, the residual liquid is preferably drained from the separator so that there is no connection between the product supply system and the drainage system outside the separator insert.

[0050] This means that the product supply system and / or the product discharge system are hermetically sealed from the drainage system, preventing cross contamination.

[0051] Alternatively, customers can partially return individual wastewater streams (light or heavy phase) in the range of 10%-90% to the starter tank (fermentor) (not shown) to retain certain auxiliary materials within the system.

[0052] The drain discharge line comprises a nozzle formed on the housing such that the medium contacting the surface of the product is leak-tight, and a pipe or hose line preferably airtightly connected to the nozzle for draining residual liquid into a collection container. The nozzle projects outwardly from the housing. Preferably, said nozzle projects from an adjacent outer wall of said housing.

[0053] The housing preferably has a product supply having a supply line as well as first and second product discharges, and the waste water discharge line is preferably arranged as a separate line opposite the product supply and product discharges.

[0054] The supply line can have a supply nozzle that protrudes into the interior of the housing, which creates a height difference between the supply opening and the drainage outlet opening, so that it is not necessary to close the product supply to drain the residual liquid.

[0055] The hose or pipeline may have sterile connections at the ends.

[0056] The product feed system advantageously comprises a pump, preferably a centrifugal pump, the product contact elements of which are preferably replaced after the shutdown of step d.

[0057] The product supply system, the product discharge system and the water drain system preferably comprise replaceable systems, in particular hoses or pipes attached to or on the product supply line, the product discharge line and / or the water drain line.

[0058] Advantageously, the flow rate of the product feed or a physical measurement equivalent to the flow rate can be determined to control the pump output, in particular by a measurement without contact with the medium.

[0059] The pump and flow meter can be placed in the riser of the product delivery system for optimal measurement.

[0060] The heavy phase discharge of the product discharge system can have a pump, preferably a peristaltic pump, which after the shutdown in step d remains part of the separator while the line elements connected to the pump are replaced.

[0061] The heavy phase discharge may have a flow meter and / or pressure sensor to adjust the pressure at the heavy phase discharge based on the speed of the pump, with at least the flow meter located along the riser.

[0062] The container for temporarily storing the light phase is advantageously placed at the light phase drain.

[0063] An optical sensor for quality control can be suitably placed in the drain of the light phase, preferably in a hydrodynamic manner behind the container.

[0064] The pump may also be located at the light phase drain, preferably downstream of the tank.

[0065] The pump output can be controlled by measuring the filling level of the container, preferably by means of a filling level measuring device.

[0066] The amount of residual liquid drained in step d can also be measured, inter alia for balancing reasons.

[0067] Advantageously, in steps b and c, a protective gas, preferably nitrogen or an inert gas, can be introduced into the separator insert through one or more connection nozzles arranged separately from the product supply and discharge on the housing of the separator insert.

[0068] Furthermore, advantageously, prior to step b, the separator insert can be evacuated of air through the connecting piece and, for example, filled with an inert gas.

[0069] Finally, in order to accelerate and ensure the completion of the emptying step, gas can be introduced into the separator insert via the connecting piece when the separator insert is emptied according to step c.

[0070] Below are further advantageous embodiments which relate in particular to the first variant of the separator insert according to the invention.

[0071] It is also particularly advantageous and simple in construction if one or both of the receiving parts is arranged slidably on the frame, in particular on a bracket.

[0072] It is also advantageous if, when inserting the separator insert into one or both of the receiving parts, one or more axially extending hoses are guided on the separator insert via respective through-openings in the respective receiving parts.

[0073] It is preferred, as it is simple and practical, that the rotor units are arranged at the two axial ends of the drum, and the two corresponding stator units are formed on the frame of the separator, thus forming magnetic bearing devices at both axial ends of the drum.

[0074] It is particularly advantageous here that the functionally required position of the stator unit and the rotor unit relative to one another is ensured mechanically according to the invention, which applies in particular to the exact axial and radial centering of the stator unit and the rotor unit, which are located coaxially one inside the other.

[0075] The invention also provides a separator insert for separating a fluid suspension in a centrifugal field into at least two fluid phases of different densities, which separator insert forms a preassembled and replaceable unit inserted into a stator unit on a frame of a separator and comprises at least: a housing that is stationary during operation and configured like a closed container except for one or more openings, a rotor arranged inside the housing and rotatable about its axis of rotation and having a drum with one or more openings, a separating means arranged in the drum, at least two rotor units for magnetic bearing devices at two axially spaced positions of the drum, by means of which the rotor with the drum is held in a suspended state and rotatably mounted and set in a rotating state in the housing during operation, the housing comprising positive locking means for holding the housing against rotation on the support. This separator insert is suitable as a replaceable module for a frame, in particular for a separator whose receiving part forms the support.

[0076] According to an advantageous variant, at least one of the two magnetic bearing devices preferably also represents a rotary drive for the drum, which drive is also suitable for driving the drum at a freely adjustable speed or a freely selectable direction of rotation. One or both magnetic bearing devices preferably act as radial and axial bearings and keep the rotor suspended within and away from the container during operation.

[0077] The rotor unit and the stator unit together form a magnetic bearing unit, which can be used to support the drum axially and radially and keep it suspended.

[0078] According to a further advantageous and constructionally particularly easy to implement variant, the further opening of the drum is furthermore configured as a free radial outlet for the second phase of the flowable phase flowing from the drum into the housing, from which it can be discharged.It can also be advantageous and simple to provide a catch ring chamber in the housing associated with the free outlet with a discharge from the housing.

[0079] According to another advantageous variant, which is particularly easy to implement from the standpoint of construction, it is also possible, however, for a further opening of the drum for discharging the further flowable phase from the drum to be formed as a paring disc.The paring disc then advantageously has a drainage pipe which is formed coaxially to the feed pipe and which is guided coaxially from the drum to the feed pipe through an opening in the first axial boundary wall of the housing.

[0080] In order to better control the separation process, i.e. to be able to control or regulate the separation process, it may also be provided that downstream of the first pairing disk and / or the second pairing disk, on the flow side, i.e. in each case on the discharge side, a control valve controllable by the control device is connected.

[0081] The control valve can preferably be configured as a pinch valve, which acts on the hose line from the outside, but can also be installed in the hose line and thus be replaced after step d with a contamination separator insert as a disposable version.

[0082] It is also preferred that a disc pack is arranged in the drum as a separating means and that a pairing disc is arranged in a space-saving and simple arrangement, i.e. in the area often required for fastening the drive spindle, below the distributor and below the disc pack, which pairing disc is used to discharge the first flowable phase from the drum.

[0083] It is preferred, as this is a simple and safe construction, that rotor units for the magnetic bearing device are arranged at the two axial ends of the drum and that the supply pipe and the drain pipe of the first pairing disk each pass axially through one of these two rotor units.

[0084] It is particularly advantageous and practical to configure the separator insert as a preassembled unit, in particular because all of its contact elements with the product are made of plastic or other non-magnetic material and can be replaced as a whole and completely discarded after use, so that cleaning and, if necessary, steam sterilization of the separator insert is no longer necessary.

[0085] The respective bearing arrangement serves, in addition to the radial bearing, also the axial bearing of the drum and / or the rotary drive and can act permanently and / or electromagnetically.

[0086] The supply line or the pairing disk shaft which surrounds the supply line on its outer periphery is preferably inserted in a sealed manner into the housing or formed integrally with the housing.

[0087] The drum may be monoconical or biconical. Additionally or alternatively, it may have one or more cylindrical sections. It may also be composed of several parts, in particular an upper part and a lower part, which are preferably joined together after installation of the internal components and their assembly (e.g. by gluing or welding). Similarly, the housing may be composed of several parts, in particular an upper part and a lower part, which are preferably joined together after installation of the internal components - in particular the rotor - and their assembly (e.g. by gluing or welding).

[0088] The drains can have nozzles on the outside of the housing, which are sealed to the periphery of the housing to allow easy connection of hoses etc. Alternatively, the hoses can be pre-assembled onto the nozzles, completely sealed and sterile if desired. The nozzles can, for example, extend radially, tangentially or at an angle to the radial direction.

[0089] After manufacture, the entire separator insert can also be provided as a sealed unit to prevent the ingress of impurities. For this purpose, the nozzle at the opening of the housing can be sealed and removably closed. For example, a hose section can be arranged on the nozzle, which has an openable connector by means of which the separator insert can be connected to other elements of the supply and discharge system, such as a bag or a tank or a hose or a pipeline.

[0090] These separators are suitable for variable speed operation, even at relatively high speeds, and can also be used for single-shot processing, e.g., centrifuging product batches of fluid fermentation broth as a suspension, e.g., from 100 L to several thousand, e.g., 4000 L, into different phases and then discarded. A particular advantage here is that all product-contacting components of the separator can be assembled, operated and disposed of as a prefabricated and sterile unit. This prefabricated unit consists of at least the rotor with drum, the separating disk, the inlet distributor and the rotor magnet or rotor unit, as well as the housing with the inlet and outlet. Furthermore, the unit may also contain inlet and outlet lines (hoses etc.) as well as measuring equipment or other components in contact with the product. These are intended for a single use and are disposed of together with the separator unit after use.

[0091] Finally, it is also advantageous for the housing to only have openings for the supply pipes and the discharge and to be otherwise hermetically sealed. For this purpose, it is provided that the supply pipes and the discharge protrude outwardly from the housing like nozzles, which are connected to the housing in a sealed manner or are formed integrally with it. [Brief description of the drawings]

[0092] In the following, the present invention will be described in more detail with reference to the drawings using exemplary embodiments, but further advantageous variants and embodiments will also be described. It is emphasized that the exemplary embodiments described below are not intended to be exhaustive of the present invention, but variants and equivalents not shown are also possible and are included in the scope of the claims. [Figure 1] FIG. 2 is a schematic diagram of a replaceable first separator insert of the separator and a schematic diagram of the separator's supply and discharge system and control unit. [Diagram 2] 1 is a schematic diagram of a replaceable second separator insert of the separator, and a schematic diagram of the separator's feed and discharge system and control unit. [Diagram 3] As in FIG. 1, a schematic diagram of a separator with a reusable frame and a replaceable separator insert is shown, which here is similar to FIG. 1, on which a hose section is arranged. [Figure 4] FIG. 4 shows a perspective view of the replaceable separator insert from FIG. 1 and FIG. 3, on which the hose section is arranged. [Diagram 5] 5A-5C show three successive steps in inserting the replaceable separator insert of FIG. 4 into the frame of FIG. 3. [Figure 6] 5A-5C show three successive steps in inserting the replaceable separator insert of FIG. 4 into the frame of FIG. 3. [Figure 7] 5A-5C show three successive steps in inserting the replaceable separator insert of FIG. 4 into the frame of FIG. 3. [Figure 8] 8 is a perspective view of a variation of the separator and separator insert of FIGS. 1-7 as a further exemplary embodiment. FIG. [Figure 9] 1 is a schematic diagram of an installation for carrying out the method according to the invention; [Figure 10] FIG. 4 shows a perspective view of a separator insert according to a modification of FIGS. 1 to 3 with an integrated drain pipe; [Figure 11] 1 shows another embodiment variant with the rotor as a separator insert and the housing as a fixed, non-replaceable element of the separator. [Figure 12] 1 shows another embodiment variant of the separator insert, which implements a variant of the separator insert having at least one connecting piece on its housing for the supply or exhaust of gas. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0093] 1 to 12 show a separator with a plurality of reusable frames I and with exchangeable separator inserts II for centrifugation. The method according to the invention can in particular be realized by the variant of the embodiment of figures 9 to 12, in which a waste water discharge line 120 is provided.

[0094] In principle, the separator insert can also be constructed similarly to FIG. 1 or FIG. 2 and can optionally be supplemented with a drainage discharge line, not shown.

[0095] The separator insert II is preferably configured as a preassembled unit, in particular as a disposable separator insert that can be replaced or substituted as a whole, configured as a preassembled unit, the unit II being made entirely or mainly of plastic or plastic composite material.

[0096] The separator insert (without elements 4a, 5a) is shown separately by way of example in Figures 1 and 2. The separator insert is discarded after processing a product batch and replaced by a new separator insert II.

[0097] According to figures 1 and 2, the separator insert II of the separator comprises a housing 1 and a rotor 2 which is inserted in the housing 1 and which can rotate relative to the housing 1 during operation. The rotor 2 has an axis of rotation D which can be aligned vertically in accordance with the structure of the frame I. However, the axis of rotation can also be arranged differently in space, provided that the frame is also correspondingly configured.

[0098] The rotor 2 of the separator insert II has a rotatable drum 3. The rotor 2 is rotatably mounted by magnetic bearing devices 4, 5 at two points spaced apart in the direction of the rotation axis. Preferably, the rotor 2 or the drum 3 is rotatably mounted at both ends in the axial direction. The separator insert II has rotor units 4b, 5b of the magnetic bearing devices 4, 5. Meanwhile, the stator units 4a, 5a of the magnetic bearing devices 4, 5 are arranged on the frame I-1.

[0099] The magnetic bearing devices 4,5 preferably act radially and axially to suspend the rotatably mounted rotor 2 within the housing 1 and maintain it at a distance therefrom.

[0100] Such separators with easily replaceable separator inserts are useful and advantageous in that they allow, during product processing, to exclude with a very high degree of certainty that impurities are not introduced into the product (the fluid suspension or its phases) during the centrifugation process, or when cleaning and disinfecting the separator is very time-consuming or not possible at all.

[0101] The frame I has a bracket I-1, which is mounted on a carriage I-2 with rollers I-3, but this is not necessary. Receiving portions I-4 and I-5 can be formed on the bracket I-1, which serve to receive and hold the separator insert II, even during operation. Preferably, a first axial end of the separator insert II protrudes from below toward the upper receiving portion I-4, and a lower end of the separator insert II protrudes from above into or toward another receiving portion I-5, and the separator insert II is held non-rotatably on the bracket I-1 and thus on the frame I.

[0102] One or both of the receiving parts I-4 and / or I-5 can be arranged laterally on the frame I, in particular on the bracket I-1. According to one variant, for example, it is provided that the lower receiving part I-5 is configured to be fixed on the bracket I-1. It is then advantageous if the further upper receiving part I-4 is configured height-adjustable on the bracket I-1.

[0103] In this case, it is advantageous if the bracket I-1 has a vertical extension / length such that the separator insert can be fixed by both height-adjustable receiving parts I-4, I-5 in a first position in the height-adjustable receiving part I-4 and exchanged in the other upper position.

[0104] Advantageously, the receivers I-4 and I-5 with the stator units 4a, 5a on the frame I can be moved axially away from and towards each other in order to change the separator insert II, i.e. to allow the old separator insert II to be removed from the frame I and replaced by a new one. This can be realised, for example, by rails on the brackets and slides on the height-adjustable receivers which can be moved and locked in the sliding position.

[0105] Thus, the relative distance between the receiving parts I-4 and I-5 and the stator units 4a, 4b of the magnetic bearing devices 4, 5 can be adjusted so that the separator insert II can be replaced.

[0106] The respective stator units 4a, 5a of the two drive and magnetic bearing devices 4, 5 can be arranged in respective receivers I-4 and I-5. The control and power electronics therefor can be arranged inside or on top of the frame I, for example bracket I-1.

[0107] Corresponding positive locking means may be formed on the receiving parts I-4 and I-5 and on the housing 1 of the separator insert II, which does not rotate during operation, so that the separator insert II can be inserted in a rotationally fixed manner into the stator units 4a, 5a. The upper and lower stator units 4a, 5a, respectively, may have aligned axes.

[0108] According to a particularly simple variant, the housing 1 and the receiving part I-4 or I-5 with the stator unit 4a, 5a are provided with projections (e.g. pins or webs) and recesses (e.g. holes) as corresponding positive locking means for non-rotatably holding the housing 1 on the stator unit and thus on the frame II. Corresponding positive locking means can also be formed directly on the frame II.

[0109] The position of these corresponding positive locking means also defines the functionally required position of the stator units 4a, 5a and rotor units 4b, 5b relative to one another. This serves in particular for precise centering of the stator and rotor units 4a, 5a, 4b, 5b, which are coaxially located one inside the other. Additionally, a retaining force can be exerted axially (from above and below) by the receivers on the housing, so that the housing is retained force-lockingly.

[0110] According to FIG. 3 to FIG. 7, the above measures are implemented as follows, for example.

[0111] The receiving parts I-4 and I-5 with the stator units 4a, 5a of the frame I each have several pins 41a projecting in the axial direction, and each separator insert II can have a corresponding blind hole in the housing 1, for example extending in the axial direction, as a recess 42 or 41b.

[0112] In this case, the receiving part I-4 having the stator unit 4a has a pin 41 (not visible here) protruding in the axial direction or here vertically downward, the separator insert II has a corresponding blind hole-shaped recess 42 (not visible here) vertically upward, the lower receiving part I-5 having the lower stator unit 5a has a corresponding pin 41a (not visible here) protruding in the axial direction or here vertically upward, and the separator insert II has a corresponding blind hole-shaped recess (not visible here) axially downward. By way of example only, four pins 41a and recesses 41b are arranged distributed over the corners of an imaginary polygon, in particular a square, and are formed in the upper and lower parts of the receiving parts I-4, I-5 and the housing 1 of the separator insert II.

[0113] 1-7, the corresponding positive locking means 41a, 41b and 42 are arranged distributed circumferentially around the separator insert II. However, instead of several positive locking means, it is also possible that only one positive locking means is provided.

[0114] However, the corresponding positive locking means may also be arranged asymmetrically so that the separator insert can only be used in a single orientation.

[0115] The stator units 4a, 5a each have openings, in particular through openings 43, to accommodate lines such as hoses 44, 45 connected at the top and / or bottom to the separator insert II.

[0116] One or both receiving parts I-4 and I-5 are configured so as to be vertically adjustable. One of the two receiving parts I-4 or I-5 can therefore also be fixed to the frame I. It is therefore also conceivable that one of the two receiving parts I-4 or I-5, for example the lower side, is formed on a wall of the frame I and is not adjustable. It then suffices to configure the frame I in such a way that each other receiving part I-4 or I-5 is adjustable, in particular arranged and / or configured on the frame I so as to be vertically height-adjustable.

[0117] This is also evident from the interaction of FIGS. FIG. 5 shows the frame I before the separator insert II is inserted.

[0118] The two stator units 4a, 5a are moved away from each other so that the respective separator inserts together with the stator units 4a, 5a (Figures 5, 6) can be lifted axially between the two receivers, and the separator insert II is then placed in / on the lower receiver I-5 (Figures 6 and 7) so that the corresponding positive locking means - here 41, 42 - engage with each other.

[0119] Furthermore, the hose 45 at the lower end of the housing 1 is guided downwards through the lower through-opening 43 and thus axially through the associated stator unit 5a (FIG. 6). The upper receiving part I-4 is lowered (FIG. 7) until the positive locking means of the upper receiving part I-4 and the housing 1-41, 42- of the separator I engage firmly with each other. The upper hose 44 of the housing 1 is guided through the through-opening 43 of the upper receiving part I-4.

[0120] The separator insert II is fixed non-rotatably on the frame I. The centrifugation process for processing a product batch in the centrifuge field can then be started. After the intended batch has been processed, the upper separator unit is lifted upwards again until the separator unit is lifted out of the frame I and replaced with a new one.

[0121] Further structures of an exemplary preferred separator insert II are described in more detail below with reference to Figures 1 and 2, as well as the structure of the separator's drive and bearing systems, the separator's control system, and the separator's supply and discharge systems, without the invention being limited thereto, and in particular the supply and discharge lines can also be realized in different ways on the separator insert II.

[0122] Firstly, the rotor unit 4b, 5b can be configured essentially as an inner ring of magnets, in particular permanent magnets, and the reusable stator unit 4a, 5a can be configured essentially as an outer ring, which stator unit 4a, 5a is used for the axial and radial mounting of the rotor 2 (e.g. at the top) or alternatively also for the rotational drive (e.g. at the bottom).

[0123] As part of the separator drive, the rotor units 4b and / or 5b therefore also form part of the rotation system or rotor, in other words the rotor of the drive is part of the centrifuge drum.

[0124] Thus, one or both of the magnetic bearing devices 4, 5 are preferably also used as a drive device for rotating the rotor 2 together with the drum 3 within the housing 1. In this case, each magnetic bearing device forms a combined magnetic bearing and drive device. The magnetic bearing devices 4, 5 may be configured as axial and / or radial bearings, where the magnetic bearing devices 4, 5 support the ends of the drum 3 in axial and radial directions which generally interact during operation, keeping the drum 3 floating and rotating during operation.

[0125] The magnetic bearing devices 4, 5 can have the same or almost the same basic configuration. In particular, only one of the two magnetic bearing devices 4, 5 can be used as a drive device. Thus, the corresponding components of the magnetic bearing devices 4, 5 are formed on the separator insert II, i.e. on the rotor 2 thereof, and on other corresponding parts on the frame I. One or both stator units 4a, 5a are electrically connected to control and power electronics for controlling the electromagnetic components of the magnetic bearing devices.

[0126] Each magnetic bearing device 4, 5 may for example operate according to a combined electromagnetic and permanent magnetic principle of operation.

[0127] Preferably, at least a magnetic bearing device 5 acting axially downwards serves to keep the rotor 2 axially suspended in the housing 1 by levitation. For example, one or more first permanent magnets can be provided on the underside of the rotor and further electromagnets can be provided in a receiver on the frame, coaxially surrounding the permanent magnets. The rotor can be driven electromagnetically. However, drive via rotating permanent magnets can also be realised.

[0128] Such bearings and drives are used, for example, by Levitronix to drive centrifugal pumps (EP 2 273 124). They can also be used in the context of this specification. For example, a first motor "bottom" from Levitronix can be used as drive, which also supports the drum radially and axially magnetically. In addition, a second motor from Levitronix, identical in structure except for, for example, its control system during operation, can be provided, which supports the rotor 2 radially and axially at its head as a magnetic bearing device 4.

[0129] The rotor speed can be variably adjusted with the aid of a control device 37 (see FIG. 1 or FIG. 2) or a separate control device for the magnetic bearing devices 4, 5. The direction of rotation of the rotor 2 can also be specified and changed in this way.

[0130] During operation, the rotor 2 rotates and remains axially suspended and radially centered. Preferably, the rotor 2 with the drum 3 operates at a speed between 1,000 revolutions per minute and possibly up to 20,000 revolutions per minute, desirably between 5000 and 10,000 revolutions per minute. The centrifugal forces resulting from the rotation separate the suspension being treated into phases LP, HP of different densities and different fluidities, as described above, leading to their discharge as explained in more detail below. As the product batch is treated in a continuous operation, the phases separated from the suspension are completely discharged from the drum during operation.

[0131] This makes it very possible to create separator inserts and housings for separators that are configured for total disposable use, which is of particular interest and advantage in the processing of pharmaceutical products such as fermentation broths, since the separator insert can be replaced in its entirety, so that during the processing of a product batch, no cleaning of the drum in which the corresponding product batch is processed, preferably in continuous operation, needs to be carried out after the operation. Incidentally, individual elements such as magnets are appropriately recycled (see also DE 10 2017 128 027).

[0132] The housing 1 is preferably made from a plastic or plastic composite material and may be cylindrical, having a cylindrical outer casing at the ends of which are formed two radially extending boundary walls 6, 7 (cover and base).

[0133] This drum 3 is used to centrifuge the fluid suspension S in a centrifugal field into at least two phases LP, HP of different density, for example a lighter liquid phase and a heavy solid phase or a heavy liquid phase.

[0134] In the preferred configuration, the rotor 2 and its drum 3 have a vertical axis of rotation D, but the housing 1 and rotor 2 can also be arranged differently in space. The following description refers to the vertical arrangement shown in Figure 3. In the case of a different orientation in space, the arrangement changes according to the new orientation. Furthermore, one or both outlets (not yet described) can also be arranged differently.

[0135] The rotor 2 of the separator with the drum 3 preferably consists exclusively of plastic or plastic composite material.

[0136] The drum 3 is preferably at least in part cylindrical and / or conical, as are the other elements of the rotor 2 and the housing 1 (with the exception of the elements of the magnetic bearing devices 4, 5).

[0137] The housing 1 is configured like a container and is advantageously hermetically sealed except for a few openings / open areas (described below). According to figures 1 and 2, in this example each of the two axial boundary walls 6, 7 located at the top and bottom of the container 1 is formed with one of the openings.

[0138] One of the openings - the first, here the axially upper boundary wall 6 - enables or serves to feed 8 the suspension to be separated in the centrifugal field through the housing 1 into the drum 3 into at least two phases of different densities LP and HP according to Figures 1 and 2. Here, the first phase is the light phase LP and the second phase, which is denser than the first phase, is the heavy phase HP.

[0139] A second opening in the second, here axially lower boundary wall 7 allows or serves to drain the second heavy phase HP directly from the drum 3 through the housing 1 . The drum 3 also has an opening which is assigned to the opening of the housing.

[0140] A supply pipe 12 for the suspension to be processed extends into an upper opening 12a at one axial end of the drum 3. The supply pipe 12 passes through the housing 1, in particular one of its, here the axially upper boundary wall 6. On the outer periphery, the supply pipe 12 is sealed towards the housing 1 according to FIG. 1 and is inserted into the housing 1, for example by welding or gluing, or is additionally constructed integrally with the housing as a plastic injection molded part. The housing 1 may also be made of plastic. One end of the supply pipe 12 projects outward from the top of the housing 1 and extends into the drum 3 through the upper boundary wall 6 without touching the drum 3.

[0141] According to FIG. 1 (but also FIG. 2), the supply pipe 12 passes through the housing 1 and one of the magnetic bearing devices 4 concentrically about the axis of rotation of the rotor 2, then extends further inside the housing 1 into the rotatable drum 3 and terminates at the other end of the drum 3 - the outlet free end.

[0142] According to Figures 1 and 2, the feed pipe 12 opens into the drum 3 in a distributor 13 which in each case is rotatable together with the drum 3. The distributor 13 has a tubular distributor shaft 14 and a distributor leg 15. In the distributor leg 15 one or more distributor channels 16 are formed. A separating disk stack, in this case a conical separating disk 17, can be arranged on the distributor 13. The distributor 13 and the separating disk 17 are preferably made of plastic.

[0143] Furthermore, according to both FIG. 1 and FIG. 2, a first pairing disk 33 is used to discharge the heavy phase HP of the two phases HP and LP from the drum 3 . A paring disc shaft or central drain pipe 34 passes through the second axial boundary wall 7 (see Figures 1 and 2).

[0144] According to one possible - but not essential - configuration, the drum 3 has at least two cylindrical portions 18, 19 of different diameters. Adjacent the cylindrical portions 18, 19, one or more conical transition regions may be formed on the drum 3. Also, the drum 3 may have a single or double conical configuration inside its central axial region (not shown here).

[0145] As shown, the drum 3 can have a lower cylindrical section 20 of smaller diameter, on which the rotor unit 5b of the lower magnetic bearing device is formed, merging into a conical section 20a, which then merges, for example, into a cylindrical section 19 of larger diameter, which then merges again into a conical section 18a, which then merges into an upper cylindrical section 18 of smaller diameter, on which the rotor unit 4b of the upper magnetic bearing device 4 is formed. The separator inserts of FIG. 1 and FIG. 2 differ with regard to the evacuation of the lighter phase.

[0146] The openings (which may be provided on the drum 3 so as to be distributed circumferentially and in each case several openings may be provided on the drum 3) serve as radial or tangential outlets 21 of the light phase LP from the drum 3 according to Fig. 1. The openings in the outer casing of the housing then allow or serve as drainage 10 of the lighter product phase LP formed during centrifugation and discharged from the drum 3 according to the exemplary embodiment of Fig. 1.

[0147] The first outlet 21 on the radius ro of the drum 3 is configured in particular as a "nozzle-like" opening in the outer casing of the drum 3. The outlet 21 is also configured as a so-called "free" drain from the drum 3. The first outlet 21 is used to discharge the lighter phase LP. The outlet can be configured so that the light phase exits radially or alternatively so that the light phase exits tangentially to the direction of rotation of the drum, thus contributing to the drive of the rotor and to the reduction of the drive energy.

[0148] This phase emerging from the drum 3 is collected in the housing 1 in a catch chamber 23 at the upper side of the housing 1. This catch chamber 23 is configured in such a way that the phase trapped therein is directed towards the drain 10 of the catch chamber 23. This can be achieved by locating the drain 10 at the lowest point of the catch chamber 23. The catch chambers 23 open radially inwards towards the rotating drum 3 and are spaced such that liquid sprayed from each outlet 21 is sprayed only into the associated catch chamber 23 which is at essentially the same axial level during centrifugation.

[0149] A chamber 25, not used for draining the phases, can optionally be formed below the capture chamber 23. This chamber 25 can optionally have a leakage drain (not shown here). Leaks can flow out freely. However, if the chamber 25 has a negative pressure connection for connecting a device generating negative pressure, the leakage can also be extracted by negative pressure.

[0150] The first capture chamber 23 and the chamber 25 are here conical in shape and can be separated from each other by a first wall 26 which starts from the outer casing of the housing 1, extends conically inward and upward and terminates radially in front of the drum 3 at an internal distance from the housing 1.

[0151] Preferably, at the lowest point of the capture chamber, the product phase LP leaves the housing 1 through a drain 10. A nozzle can be provided on the outside of the housing 1 in the region of the drain 10 to allow easy connection of pipes, hoses etc.

[0152] The nozzle is either formed directly on the housing 1 or attached to the housing by adhesive. The nozzle is also preferably made of plastic. The housing 1 may consist of several plastic parts that are sealed together, for example by gluing or welding.

[0153] As a (here second) outlet for the heavier phase HP from the drum (through the housing 1) a first pairing disc 33 is provided according to figures 1 and 2, which extends essentially radially and merges into a drainage pipe 34 which runs axially as a pairing disc shaft and which passes through the axially lower boundary wall 7 of the housing 1. The pairing disc 33 has an outside diameter ru, where ru>ro applies. The inlet opening 33a of the pairing disc 33 is therefore on a larger diameter or radius ru than the outlet 21 for the light phase LP on radius ro. This allows the pairing disc 33 to be used to discharge the heavy phase HP against the light phase LP from the drum 3. The pairing disc 33 is stationary during operation of the separator and has its outer edge immersed in the heavy phase HP which rotates within the drum 3.

[0154] The phase HP is pumped inwards through channels in the pairing disk 33. Thus, the pairing disk 33 acts like a centripetal pump to pump the phase HP.

[0155] The pairing disc 33 can be arranged in a simple and compact manner in the drum 3 below the distributor 14 and below the disc pack 17. The radius ru corresponds to the immersion depth of the pairing disc 33.

[0156] One end of the drain pipe 34 does not touch the drum 3 but is pulled out of the housing 1 downward from the drum and passes through the lower boundary wall 7. The drain pipe 34 can be formed integrally with the housing 1 or can be inserted in a sealed state. A hose or the like can be connected to the drain pipe as a drain part 35.

[0157] The drain pipe passes through the housing 1 and the lower magnetic bearing device 5 concentrically about the axis of rotation D of the rotor 2 and then extends axially further inside the housing 1 into the pairing disc 33 .

[0158] It can be provided that a controllable, in particular an electrically controllable, control valve 36 is inserted in the outlet for the heavy phase HP, in particular in the drain 35 for the heavy phase HP. The control valve 36 can be used to throttle the volumetric flow rate of the heavy phase HP in the drain 35 and to increase the immersion depth of the associated pairing disk. The control valve 36 is preferably provided with a control device 37. The control valve 36 is preferably connected to the control device 37 by wireless or wires.

[0159] A control device 37 may also be configured and provided for controlling the magnetic bearing devices 4, 5 and the drive device. Also according to FIG. 2, the light phase LP is ejected via the pairing disc.

[0160] For this purpose, in the upper region of the drum 3 a pairing disk 22 is provided, the inlet opening 22a of which can be located at a radius ru smaller than the inlet radius ru of the first - lower - pairing disk 33 for the heavy phase.

[0161] The shaft of this pairing disc 22 can surround the supply pipe 8 like the outer drain pipe 24 and can be rigidly connected to the housing 1 instead of the supply pipe 8 or can be formed integrally with the housing. The drain pipes 24, 34 of the two pairing discs 22, 33 are therefore led out of the drum 3 at both ends of the housing according to Fig. 2. They are also led out of the housing 1 at the opposite end of the housing. The drain pipes 24, 34 can be inserted in a sealed manner into the housing 1. But they can also be made in one piece from plastic. The supply pipe 12 can be connected to the upper end of the paring disc shaft 24. A radial or tangential connecting piece 24a can lead out of the paring disc shaft 24. A drain 40 for releasing the light phase can be connected to the connecting piece 24a, which can lead, for example, to a tank of a bag or the like. The ends of the pipes 12 and 34 can thus also be configured as nozzles for connecting hoses or the like (Fig. 2, but also Fig. 1).

[0162] A controllable, in particular an electrically controllable, control valve 39 may also be provided, which is installed at the drain 40 for the light phase LP. The control valve 39 can be used to vary the volumetric flow rate of the light phase LP, in particular to throttle it more or less and thus vary the immersion depth of the second pairing disc 22. The control valve 39 can also be controlled by the control device 37, as it is connected to the control device 37 wirelessly or by wire.

[0163] Each pairing disk 22, 33 is in each case a cylindrical, essentially radially aligned disk, provided with several, for example one to six, channels, which are stationary during operation and have channels such that a kind of centripetal pump is formed. The outer edge of each pairing disk 22 or 33 is immersed in the phase LP or HP rotating in the separator. The respective phase LP, HP is directed inwards through the channels in the pairing disk, and the rotation speed of the respective phase LP, HP is converted into a pressure. In this way, each pairing disk 22, 33 replaces a drainage pump for the respective phase LP, HP, and thus the pairing disks each function as a centripetal pump. The pairing disks are made of plastic.

[0164] In theory, a third pairing disk could also be provided, which could be used to eject a further phase. The operation of the separator according to FIGS. 1 and 2 will now be briefly explained.

[0165] Firstly, each separator is equipped with its dual-use or reusable parts. This includes the drive unit 4a of the magnetic bearing device, the stator unit 5a as well as the frame I. This also includes the control device 37. The separator insert II is then provided and mounted on the frame I. For this purpose, only the stator units 4a and 5a need to be moved separately. The separator insert is then inserted with a secure fit and the stator units are moved towards each other. This ensures that the housing is held safely against rotation. Concomitantly, a hose is connected to a nozzle that leads to a tank or bag. Each separator insert of figures 1 and 2 can therefore preferably also have at least a hose and a nozzle that can be connected to other lines (not shown here) and containers such as bags, tanks, pumps, etc.

[0166] Then, after connecting pipes, hoses, etc., the suspension is pumped into a rotating drum (inlet 8) where it is centrifuged into a light phase LP and a heavy phase HP. The more dense heavy phase HP flows radially outwards within the drum 3 in the separation chamber, where it leaves the drum on a radius ru through channels in the stationary pairing disc 33.

[0167] The lighter phase LP flows radially inwards in the drum 3 in the separation chamber and rises upwards through a channel 38 on the shaft of the distributor, where it leaves the drum at a radius ro according to Figures 1 and 2. The control valves 36, 39 can be used to easily influence the separation process, thus achieving an optimization of the separation process.

[0168] The main application of the method according to the invention for operating a separator is cell separation in the pharmaceutical industry. The performance range is intended for processing broths from fermenters of the order of 100 L to 4000 L and for laboratory use.

[0169] Other industrial sectors in which separators are used include chemical, pharmaceutical, dairy technology, renewable raw materials, oil and gas, beverage technology and mineral oils.

[0170] The separator shown allows the production of a separator insert in which all elements in contact with the product are preferably made of plastic or other non-magnetic material, and which can preferably be discarded after a single use or put into a recycling process. This eliminates the need for cleaning after use. The separator and its operation can therefore be implemented cost-effectively.

[0171] Figure 8 shows a modification of the separator insert II of figures 1 to 7 in a second embodiment variant, where similar features are given similar reference numbers. A special feature of this second embodiment variant is that the positive locking means 41a and the corresponding positive locking means 41b provided on the frame I are provided only on one side between the frame I and the separator insert II, thereby allowing axial and torsional locking of the separator insert II to the frame I. Among other things, this reduces the complexity of the construction.

[0172] Use of a modular centrifuge with replaceable separator inserts as shown in Figures 1-8 ensures internal sterility, i.e., a sterile flow path within the centrifuge. Preferably, other replaceable components can be used in the separator with a product feed, discharge system and drainage system, comprising a separator insert, a feed system, a discharge system and a product feed and discharge system and a drainage system, providing a sterile flow path for the suspension being fed and the separated light and heavy phases.

[0173] Although mentioned purely by way of example, the pump for the supplied suspension, the hose lines for the supply, the hose lines for the light and heavy phases, the receiving container for the heavy phase may be interchangeable sterile elements suitable for isolating a single product batch or a limited number of product batches. The hose for the liquid drainage and the container for the liquid drainage are also interchangeable sterile elements.

[0174] All these elements are connected to each other with sterile connectors, allowing easy and at the same time sterile replacement of the elements. The product supply system, the product discharge system and the waste discharge system of the separator are described in more detail below with reference to Figure 9:

[0175] For example, a single-use centrifugal pump 101 can be used for the supply. This has the advantage that it is smaller than an equivalent peristaltic pump of the same comparable flow rate. The pump delivers a fixed volume depending on its speed and the existing back pressure.

[0176] The flow meter 102, which is also placed in the feed line between the pump 101 and the separator insert II, preferably works according to a non-contact measurement principle, for example the ultrasonic transit time difference method, which means that the flow meter can simply be pushed onto the feed line without touching the product.

[0177] Therefore, it can always be reused, whereas the supply hose is one-time use. The measurement signal from the flow meter is used to adjust the speed of the supply pump. In this way, the controller can set the speed of the supply pump so that a preselected set point for the supply volume corresponds to the measured actual value. The pump and flow meter are placed in a rising supply line, so that the line is always filled with liquid, which results in a more stable measurement of the flow meter 102.

[0178] In the discharge line for the heavy phase is placed a pump 110 and a flow meter 111. The pump and flow meter are placed in the upward discharge line to ensure that the line is always filled with liquid, which results in a more stable reading of the flow meter 111.

[0179] The drain pump 110 is preferably configured as a peristaltic pump. One advantage of a peristaltic pump is that it only contacts the outside of the drain hose and does not directly contact the product. Alternatively, valves can be used to control flow, either acting outside the hose or as a single use type within the hose.

[0180] Therefore, peristaltic pumps can always be reused. The drain hose, on the other hand, is a one-time use product. Another advantage of peristaltic pumps is that they deliver a defined volume depending on the speed. Unlike centrifugal pumps, peristaltic pumps can be used as throttles, i.e. they can generate pressure in the heavy phase drain, the level of this pressure can be regulated by the control system. The pressure sensors required for this can be provided in each or preferably all hose lines (not shown in the drawings).

[0181] The light phase discharge line is provided with a container 105 which serves as a buffer container. The current light phase filling level in the buffer container is determined by a filling level measuring device 104 and passed on to the control system. Alternatively, the filling level can also be quantified by means of a load cell. Alternatively, the filling level can also be monitored by a limit switch, in which case the pump control options are reduced.

[0182] The light phase can be introduced from the separator insert II into the container 105 on the upper side (above the forming liquid level) or into the container 105 on the lower side (below the forming liquid level). For products prone to foaming, the upper inlet proves to be the best choice. The outlet of the container 105 is connected to a descending drain hose, which is guided via an optical sensor 106 and a peristaltic pump 107.

[0183] With the aid of the measurement signal from the filling level measuring device 104 the pump speed is optimally adjusted so that the container 105 is never completely full or completely empty. In this way the drain hose is always filled, which results in a stable signal from the optical sensor 106. This can also be achieved by arranging two limit switches to monitor the minimum and maximum levels.

[0184] The signal from the optical sensor 106 is used to evaluate the quality of the light phase. Here, for example, the amount of remaining trub and suspended solids can be evaluated. The pump 107 can be configured as a centrifugal pump or as a peristaltic pump. The volume of the container 105 must be selected such that the residence time of the light phase in the container is long enough for the air bubbles to separate from the liquid. With the help of the measurements from the filling level measuring device 104, the conveying rate of the pump 107 can be set in such a way that a constant filling level is maintained approximately in the middle of the container 105.

[0185] A drain hose line connected to the drain discharge of the separator insert II leads to a container 109 equipped with a filling level measuring device 108. This determines the amount of drain discharged. Drain is essentially generated when the drum is stopped at the end of the batch process and emptied via this drain. It is also possible to determine the mass, for example using a load cell. Limit switches can also be used here. All the above variants are preferably of a non-invasive construction. This allows the filling level of the heavy phase in the container 109 to be determined and regulated in the same way as the light phase.

[0186] All of the hose lines in Figure 9 for the supply and exhaust lines into and out of the separator system then lead to a sterile connection 112. Not shown in Figure 9 is the frame that holds the separator insert and drive.

[0187] The product supply system PZS, the product discharge system PAS consisting of the heavy and light phase product discharges, and the drainage system PS shown in FIG. 9 are separated from one another outside the separator insert and are therefore hermetically sealed.

[0188] The filling level measuring device 108 or 104 can be arranged, for example, as an ultrasonic sensor element in the bottom region of the container 105 / 109. The ultrasonic sensor element emits a signal which is reflected at the liquid boundary. By means of a time measurement, the filling level can be determined.

[0189] Figure 10 shows a modification of the first variant of the separator insert II of figures 1 to 8 for connection to the drainage system of figure 9. The separator insert II has a drainage discharge line 120, which is located in the base area 121 of the separator insert and has liquid drains 122 and 123 both from the drum and from the housing. The remaining parts can be of the same construction as the variants of the previous embodiment.

[0190] 11 shows a second variant of a separator insert III operable as part of the method of the invention. This separator insert III has a bottom feed into the disc stack 67 via a feed line 61 and a distributor 70. The product feed line 61 runs from the base of the housing 68 into the interior of the rotor 65 and is equipped with a feed nozzle 73 opening into a distribution chamber 78 of a holding device 77 for the disc stack 67. The holding device 77 can have a longitudinal axis parallel to the rotation axis of the rotor 65. One or more distribution channels 70 run from the distribution chamber 78 and allow for a radial transfer of the starting product fed into the separation area of ​​the rotor 65.

[0191] The product discharge 62 of the light phase is carried out as in figures 1 to 10. The product discharge 63 of the heavy phase is discharged through a channel in a separation disk 69, here as a separation disk in the closing wall of the end of the disk pack, and finally by a gripper 64 through a product line of the product discharge 63. In the separation disk, a separation takes place between the heavy and light phase, the heavy phase being led around the outside of the disk and the light phase being led to the inside of the disk and discharged. However, this is only one of many possible variants of the product discharge for the heavy phase.

[0192] The separator insert III can be configured such that the rotor 65, in particular the drum 66 and the disk stack 67, can be removed from the housing 68. In this variant, it is recommended that the rotor, in particular the drum, is emptied of residual liquid before the rotor is removed as part of the method. In this case, this can be done via the supply line 61.

[0193] It is then recommended to also replace the supply line 61 when the separator insert III is replaced, so that subsequent batches are not exposed to cross contamination. The supply line can therefore be attached to the housing in a replaceable and medium-tight manner, using a seal not presented, for example a sealing sleeve.

[0194] FIG. 11 can be modified in many ways, but in particular shows that the method according to the invention can also be applied to a separator configured as a separator unit III in which only the rotor with its product feed and discharge lines is replaceable. The housing 68 can be opened, for example by forming part of the housing as a cover (not shown), for which purpose it is preferable to remove at least the upper receiving part from the cover.

[0195] In FIG. 11, the residual liquid is discharged via a drain discharge line 120 into a collection container 74 via a line element 71 connected to the drain discharge line, in particular a discharge element in the form of an attached or plugged hose. The feed line 61, in particular the feed nozzle 73, is connected to a feed element 72 which is connected to a container 75 with a suspension of the starting product. This line element can be equipped with a changeover valve, not shown, which switches between the two containers 75, for example to supply a demulsifier which improves the suspension. Alternatively, the valve can be closed and the line element can be replaced with a container.

[0196] Furthermore, the feed element can have a pump, for example a hose squeeze pump, in which only the feed element comes into contact with the starting product.

[0197] FIG. 12 shows a further variant of the separator insert II, which can be operated as part of the method according to the invention. This separator insert II has at least one connecting piece 76 on its housing 1. The separator insert can be filled with an inert gas through this connecting piece before the product to be separated enters the separator insert. In this way the product to be separated can be prevented from coming into contact with air and oxygen. A second connecting piece 76 can be provided on the housing 1, which is provided for evacuating gas from the separator insert, so that the separator insert can be flushed with an inert gas.

[0198] Gas can also be extracted from the sealed separator insert via the connecting piece 76 so that a negative pressure is created within the separator insert, which not only reduces contact with residual oxygen but also reduces the frictional forces of the rotating drum 66, which now rotates in a lower density atmosphere.

[0199] Alternatively, in addition to the inert gas, a compressed gas, e.g., compressed air, can also be introduced through one or more of the gas connection pieces 76, which further facilitates evacuating the housing via a drain line. [Explanation of symbols]

[0200] List of References Frame I Bracket I-1 Carriage I-2 Lola I-3 Receiving part I-4, I-5 Separator Insert II Housing 1 Rotor 2 Drums 3 Magnetic bearing device 4,5 Stator unit 4a, 5a Rotor unit 4b,5b Radial boundary walls 6,7 Supply section 8 Drainage section 10 Supply Pipe 12 Opening 12a distributor 13 Distributor shaft 14 Distributor leg 15 Distribution Channel 16 Separation disc 17 Cylindrical part 18, 19, 20 Cone section 18a, 20a exit 21 Pairing Disk 22 Inlet opening 22a Capture ring chamber 23 Drainage pipes 24 Connecting piece 24a room 25 Cone Wall 26 Pairing Disk 33 Inlet opening 33a Drain pipe 34 Drainage section 35 Control valves 36 Control device 37 Channel 38 Control Valves 39 Drainage section 40 Pin 41a Recess 41b Recess 42 Through opening 43 Hose 44,45 Pump 101 flow meter 102 Filling level measuring device 104 Container 105 Optical Sensor 106 Peristaltic Pump 107 Filling level measuring device 108 Container 109 Pump 110 flow meter 111 Sterile Connections 112 Wastewater discharge pipe 120 Base Area 121 Drainage section 122 Drainage section 123 Separator Insert III Supply Line 61 Product discharge section (light phase) 62 Product discharge (heavy phase) 63 Gripper 64 Rotor 65 Drums 66 Disk Stack 67 Housing 68 Separation disc 69 distributor 70 Line elements 71 Supply Factor 72 Supply nozzle 73 Recovery container 74 Container 75 Connecting piece 76 Holding device 77 Distribution room 78 Rotation axis D Suspension S Phase LP, HP radius ro, ru PAS Product Discharge System PZS Product Delivery System DS Drainage System

Claims

1. A method of operating a separator for reducing secondary pollution in the treatment of a product, comprising: The separator is provided with separator inserts (II, III) as pre-assembled replaceable units for insertion into the stator units (4a, 4b) on the frame (I) or housing (68) of the separator. The separator inserts (II, III) include at least: i. A rotor (2, 65) rotatable about a rotating shaft (D) having a drum (3, 66) and a drum wall; ii. Separating means preferably disposed within the drum (3); iii. At least one product supply line and two product discharge lines; iv. The contact area of the separator insert with the product is made of plastic, either partially or completely. In the method of operating the separator, a) Providing a separator with a first separator insert (II, III) mounted within the frame (I) or housing; b) Introducing the starting product to be separated into the separator; c) During the separation operation of the separator, discharging the first and second product streams (LP, HP) separated from the product mixture out of the separator through two separate product discharge lines; d) Stopping the separation operation and draining the residual liquid remaining in the drum; e) Replacing the emptied and contaminated separator insert (II, III) with an unused separator insert from the frame or housing of the separator.

2. The method according to claim 1, wherein the drum wall has a closed wall configuration in the central region of the drum (3, 66).

3. The method according to claim 1 or 2, wherein the separator insert (II) is provided with a further drain line (120) for draining the residual liquid remaining in the drum (3) in step d.

4. The method according to claim 1 or 2, wherein the residual liquid outside the separator insert (II, III) is collected in a collection container (109), preferably a drainage bag, to drain the residual liquid remaining in the drum (3, 66) in step d.

5. The method according to claim 1 or 2, wherein in step d, the residual liquid remaining in the drum (3) is emptied by draining it through the product supply line (61).

6. A product supply line (61) or a downstream line element connected to the product supply line, preferably a hose or a pipe, has a switching valve for switching between a residual liquid collection container and a product output container, where the switching valve operates in the drain during step d, according to the method of claim 5.

7. An exchangeable and rotatably mounted rotor (65) is formed within the housing (68) of the separator, and the introduction of the starting product (S) in step b and the discharge of the residual liquid in step d are carried out via the product supply line (61). Before the discharge of the residual liquid in step d, the supply element connected to the product supply line (61) and the discharge element with a collection container are exchanged, according to the method of claim 5.

8. The central region of the drum wall extends over 20% - 80% of the axial extension length of the drum (3, 66), according to the method of claim 2.

9. At least one product discharge line (10, 62, 63), especially the product discharge line for a heavy product stream, is connected to a pump (110), where the pump (110) is used to adjust the pressure of the product discharge line, according to the method of claim 1 or 2.

10. The pump (110) is switched during discharge in step d, or operates in a decompressed state compared to step c, or the product discharge line (10, 62, 63) or the line element connected thereto has an adjustment element for reducing the pressure and / or flow rate, and the adjustment element is preferably a valve, especially preferably a shut-off valve, according to the method of claim 9.

11. The separator insert (II) is configured to separate a fluid suspension (S) as the starting product in a centrifugal separation field into at least two fluid phases (LP, HP) of different densities, and forms a pre-assembled exchangeable unit for insertion into a stator unit on the frame of the separator, at least i. a housing (1) configured like a container that stops during the separation operation and is closed except for one or more openings, ii. a rotor (2) arranged inside the housing (1) and having a drum (3) with one or more openings and being rotatable around a rotation axis (D), iii. preferably, separation means arranged on the drum (3), iv. At least two rotor units (4, 5) for magnetic bearing devices (4b, 5b) at two axially spaced positions of a rotor (2) provided with a drum (3), wherein the rotor (2) provided with the drum (3) is held in a suspended state and rotatably mounted, and includes the rotor units (4, 5) rotatably set within the housing during the separation operation. Furthermore, receiving portions (I-4, I-5) spaced apart from each other are formed on a frame (I) for stator units (4a, 5a) of the magnetic bearing devices (4, 5). A housing (1) of a separator insert is rotatably fixed and held between these receiving portions. The rotor (2) rotates together with the drum during the separation operation in step c. The housing (1) has a drain line, and in step d, residual liquid is drained from the drum through the drain line. The method according to claim 1 or 2.

12. In step d, the residual liquid is drained from the drum (3) and from the housing (1). The method according to claim 11.

13. By changing the relative positions of the receiving portions (I-4, I-5) and the stator units (4a, 5a) of the magnetic bearing devices (4, 5), a contaminated first separator insert (II) is removed in step e and replaced with a new second separator insert. The method according to claim 11.

14. The discharge of the first and second product streams (LP, HP) separated from the suspension (S) through two separate product discharge lines from the separator is performed during the separation operation of the separator in such a way that there is no connection between the product supply system (PZS) and the product discharge system (PAS) outside the separator inserts (II, III). The method according to claim 11.

15. The discharge of the first and second product streams (LP, HP) separated from the suspension (S) through two separate product discharge lines from the separator is performed during the separation operation of the separator in such a way that there is no connection between the product discharge system (PAS) and the drain discharge system (DS) outside the separator inserts (II, III). The method according to claim 11.

16. The method according to claim 11, wherein drainage of the residual liquid from the separator is performed in such a way that there is no connection between the product supply system (PZS) and the drainage system (DS) outside the separator inserts (II, III) when the separation operation of the separator is stopped.

17. The drainage line (120) is formed on the housing (1, 68) so that no medium leaks, has a surface that comes into contact with the product, and includes a nozzle that protrudes with respect to the adjacent outer wall of the housing (1, 68), and a line element, particularly a pipe or a hose line, that is connected to the nozzle, preferably airtightly, and discharges the residual liquid into the recovery container (74, 109). The method according to claim 11.

18. The housing (68) has a product supply section provided with a supply line (61) and first and second product discharge sections (62, 63), and the drainage line (120) is arranged as another line on the side opposite to the product supply section and the product discharge sections (62, 63). The method according to claim 11.

19. The method according to claim 18, wherein the supply line (61) has a supply nozzle (73) that protrudes inside the housing (68).

20. The product supply system (PZS), the product discharge system (PAS), and the drainage system (DS) as an exchangeable system are provided with hoses or pipeline connections, particularly to the product supply line, the product discharge line, and / or the drainage line. The method according to claim 11.

21. The method according to claim 18, wherein the hose or pipeline has a sterile connection (112) at the end.

22. The product supply system (PZS) is provided with a pump (101), preferably a centrifugal pump, and is preferably replaced after being stopped in step d. The method according to claim 20.

23. The flow rate of the supplied product or a physical measurement equivalent to the flow rate is determined, particularly by a measurement without contact with the medium, in order to regulate the pump output. The method according to claim 20.

24. The method according to claim 20, wherein the pump (101) and the flow meter (102) are arranged in the riser of the product supply system (PZS).

25. The heavy-phase (HP) discharge line of the product discharge system (PAS) is provided with a pump (110), preferably a peristaltic pump, which remains as part of the separator after the stop of step d, while the line element connected to the pump (110) is replaced. The method according to claim 20.

26. The heavy-phase (HP) discharge line has a flow meter (111) and / or a pressure sensor for adjusting the pressure in the discharge of the heavy phase (HP) based on the rotational speed of the pump (110), and at least the flow meter (111) is arranged along the riser. The method according to claim 24.

27. A container (105) for temporarily storing the light phase (LP) is arranged in the light-phase discharge line. The method according to claim 11.

28. An optical sensor (106) for quality control is arranged, and the optical sensor is preferably arranged hydrodynamically downstream of the container (105) in the light-phase (LP) discharge line. The method according to claim 11.

29. A pump (107) is arranged in the light-phase discharge line, and the pump is preferably arranged hydrodynamically downstream of the container (105). The method according to claim 11.

30. The pump output is controlled by measuring the weight of the container (105), preferably by a filling level measuring device (104). The method according to claim 28.

31. Measuring the amount of residual liquid drained in step d. The method according to claim 11.

32. Before or during steps b and c, preferably nitrogen or an inert gas is introduced into the separator insert, in particular through one or more connection pieces (76) arranged in the housing (68) of the separator insert (III) separate from the product supply and drainage parts (8, 35, 40) and the drainage part (120). The method according to claim 11.

33. Before step b, air is sucked from the separator insert (III) through the connection piece (76). The method according to claim 32.

34. While emptying the separator insert (III) according to step c, gas is introduced into the separator insert (III) through the connection piece (76). The method according to claim 33.

35. In the product supply system (PZS) and / or the product discharge system (PAS), or by a regulating element on the product supply system (PZS) and / or the product discharge system, the separation process is controlled and / or regulated by a separator, preferably by a pinch valve acting from the outside of the hose line of the product supply system (PZS) and / or the product discharge system (PZS), the method according to claim 20, wherein the separation process is controlled and / or regulated.

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