M EMBRANE TECHNOLOGY for Process Industries

Transcription

1 M EMBRANE TECHNOLOGY for Process Industries Microfiltration Ultrafiltration Nanofiltration Reverse Osmosis Sanitaire

2 PCI-MEMTECH PCI-Memtech is a division of the specialist filtration and separation company PCI Membranes, which in turn is a business unit of ITT Sanitaire. It specialises in custom-built crossflow membrane filtration systems for liquid separation in the process industries. With experience developed over thirty years, PCI-Memtech is able to offer process solutions for a wide variety of filtration applications using microfiltration, ultrafiltration, nanofiltration and reverse osmosis technologies. PCI-Memtech has developed expertise using all of the leading polymeric and ceramic crossflow membranes and membrane configurations available on the world market and is therefore ideally placed to match a membrane to a specific application. In addition, PCI-Memtech manufactures and supplies hygienic stainless steel components and is a specialist in the use of stainless steel. Benefits of Membrane Technology Pressure driven separation giving high value product Established technology Robust, reliable and easily maintained Selective and consistent separation Small footprint and lightweight Fits into existing process lines Modular, allowing for expansion in capacity Can be used in a wide variety of applications Ceramic ultrafiltration clarification plant Dyehouse effluent treatment RO plant

3 Applications Pharmaceutical and Biotechnology Microbial cell separation and clarification Antibiotic broth clarification Enzyme separation, purification and concentration Endotoxin removal Organic acid concentration Nutraceutical product purification Chemical Industries Dyestuff and pigment concentration, purification and desalting Surfactant and cosmetic concentration and clarification Lignosulphonate recovery and fractionation Silica sols concentration Food & Beverage Industry Apple juice clarification Fruit juice, wine and beer clarification and concencentration Sweetener and sugar clarification and concentration Flavour and fragrance concentration Whey protein concentrate production Evaporator condensate recovery Preconcentration of milk for soft cheese and yoghurt manufacture Yeast purification Recovery of product from beer and cider tank bottoms Process Effluents Biomass separation Textile and dye effluent treatment Pulp and paper effluent treatment Landfill leachate concentration CIP solution recycle Pesticide and herbicide removal Food industry effluents Oily wastewater treatment PCI-Memtech s total capability Independent initial process and membrane evaluation Dedicated laboratory and test plant facilities Over 20 pilot plants available for site trials Economic feasibility studies Integrated design, build and commissioning to FDA, GAMP and other standards Full process design validation Operator training and process optimisation Comprehensive after-sales support

4 Membrane Filtration The Principles In crossflow membrane filtration, liquid flowing tangential to the membrane surface inhibits the formation of deposits. The membrane retains dissolved and suspended solids. The retained fraction is known as the concentrate or retentate. The fraction passing through the membrane, driven by pressure, is the permeate or filtrate. The product may be the permeate (e.g. clarification of fruit juices, effluent purification) or the concentrate (e.g. concentration of antibiotics) or both. Depending on the size and type of the particles or solutes contained in a liquid there is a wide range of separation processes available. Crossflow membrane filtration covers a range from approximately 2 micron down to the molecular level below micron. There are four main classifications of membranes, microfiltration (MF), ultrafiltration (UF), nanofiltration (NF), and the finest of these, reverse osmosis (RO). Microfiltration Microfiltration membranes are capable of retaining particles of about 0.01 microns or larger. Smaller particles (e.g. salts, sugars and proteins) pass through the membrane. The operating pressure for microfiltration is usually bar. Ultrafiltration Particles of about microns (MW > 1000 Dalton) or larger are retained by ultrafiltration membranes. Low-molecular substances (e.g. sugars and salts) pass through the membrane. The operating pressure for ultrafiltration is bar. Nanofiltration Water and monovalent ions, as well as low molecular weight organic compounds (MW < 250 Dalton), pass through nanofiltration membranes. Divalent or multivalent ions (e.g. S ) are retained. The operating pressure is usually 8-40 bar. Reverse osmosis Reverse osmosis membranes basically allow only water to pass through them (plus some organic molecules). Salts and dissolved organic substances with a higher molecular weight than 50 Dalton are retained almost without exception. The operating pressures used for reverse osmosis usually vary between 20 and 60 bar and in some cases can be over 80 bar.

5 Membrane Configurations Plants are designed using a variety of membrane configurations, each with unique characteristics, offering a wide range of process solutions. Membrane modules and housings have been carefully designed to achieve the maximum membrane surface area. They allow optimum operating parameters, such as crossflow velocity, pressure and temperature to be established ensuring optimum membrane performance. Spiral Wound A compact format which can be operated at high pressures and with suitable spacer materials, accept high viscosity feeds. Flat Sheet (not shown in picture) Often used in research laboratories for testing very small samples or in the development of new membranes. Tubular Intended for high solids or large suspended solids, the tubular membranes, either ceramic or polymeric, range from 4-25 mm internal diameter. Hollow Fibre Hollow fibres range from mm internal diameter and enable a large surface area to be housed in a small volume. Modules and Housings The outer shroud, commonly stainless steel or GRP, protects the membranes, retains the permeate and directs it to the intended transfer point.

6 Developing a System PCI-Memtech has over 30 years experience in developing costeffective solutions to liquid separation problems. Its comprehensive range of laboratory services and pilot plants enables PCI-Memtech to tackle a wide range of applications from antibiotic broths to dyehouse wastewater. Experience with a wide range of crossflow membranes and an unbiased membrane selection procedure means a truly independent solution for each application can be developed. Choosing the right membrane A full range of membrane geometries is offered including spiral wound, hollow fibre and both ceramic and polymeric tubular membranes. This range of configurations allows PCI- Memtech to test right across the filtration spectrum from reverse osmosis, through nanofiltration and ultrafiltration to microfiltration. Trials can either be carried out in PCI- Memtech s laboratories or on-site by clients, with or without assistance. Versatile pilot plants The versatile pilot plant range of over 20 units extends from bench-top models, designed to process feed samples up to 10 litres, to small industrial systems, capable of processing up to 50 m 3 per day. PCI- Memtech s pilot plants are designed to operate over a wide ph and temperature range.

7 Optimising plant design Using a dedicated applications database, engineers objectively select the best membrane and geometry for a given application. During pilot trials these membranes can be evaluated and the process tested. The optimum full-scale plant design can be developed using proprietory design programs for batch or continuous plant operation. Project management PCI-Memtech manufactures and assembles engineered systems inhouse working to the appropiate industry requirements such as GAMP and FDA. Plant control and automation can be developed and fully validated in-house prior to delivery. Systems can be installed and commissioned under the direction of PCI-Memtech s engineers who would be responsible for ensuring that the upstream and downstream conditions satisfy the operating requirements of the system. Operator training is considered to be one of the most important services provided. This is an integral part of the whole design, build and supply package which PCI-Memtech specialises in providing. Technical support PCI-Memtech can provide technical support, training, commissioning, process optimisation and a remembraning service to clients both in the UK and overseas. Regular service visits can be offered on a contract basis to maintain plant installations and to ensure optimum plant performance.

8 The world s largest tubular membrane effluent treatment plant comprising of 13 stages of PCI 3.6m long B1 modules. A total of 1784 modules providing 4650m 2 membrane area PCI-Memtech helps industry world-wide to produce quality products, to recycle water and to meet stringent regulations for the protection of the environment, efficiently and economically. PCI-MEMTECH Laverstoke Mill, Whitchurch, UK RG28 7NR Tel: Fax: pcimemtech@uk.itt.com Sanitaire TP105.4