Alfa Laval Membrane Presentation

7/21/2019 Alfa Laval Membrane Presentation

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Membrane filtration



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Alfa Laval Nakskov A/S

What is membrane filtration?

Product range

Applications

References/case stories




One of the pioneers

1965

DDS Filtration

1989

Dow Liquid Separation Systems

1997Danish Separation Systems AS

2002

Alfa Laval

Late 1950‟s

Membrane filtration introduced




Alfa Laval Nakskov A/S

• In-house membrane production

• Spiral membrane rolling

• Plate-and-frame and spiral module

production

• Customer test centre for application

development

• Pilot equipment from few m² to 200m²

• Engineered membrane systems

• R&D department

• Complete separation solutions (synergy)Nakskov

•Copenhagen




What is membrane filtration?

Membrane filtration is a physical

separation process and the driving

force is the pressure difference across

the membrane. It is characterised by

the ability to separate molecules of

varying sizes and characteristics by

using different membrane types.




Separation processes and mechanisms




Membrane filtration

• Physical separation process

• Semi-permeable barrier

• One feed stream split into two individual

streams

• Driving force is pressure

• Either stream may contain the desired product

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Permeate

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Permeate

Retentate. . ....

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Cross-flow filtration

• No filter cake

• No use of filter aids

• Uniform, controllable product quality

• Continuous, automated process

• Long membrane lifetime

• CIP cleaning

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Feed

Permeate

Retentate. . ....

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Cross-flow filtration

Filter cake




Membrane structure

UF & MF membrane

NF & RO - thin-film membrane

• Thin top layer (0.1 –0.5 µm)

• Porous sub-layer (50 –150 µm)

• Support paper for mechanical

stability (100 –200 µm)

• Different polymers

– Cellulose acetate/triacetate

– Polysulphone/polyethersulphone

– Fluoropolymers• Composite membranes –

polymerization of barrier layer




The membrane

• High mechanical strength

• High porosity

• Sharp cut-off value

• Excellent temperature, pH, andchemical resistance

• Easy to clean

GR60PE surface, mag

100,000 x

GRM 0.2µm surface,

20,000 x




Reverse osmosis

• Only water will pass

• NaCl rejection > 95 –96%

• Typical operating pressure 15 –60 bar

• Concentration of liquids with low molecular

compounds at low solid levels




Nanofiltration

• Slightly more open than RO

• MgSO4 rejection > 97%


• Allows monovalent ions to pass

• Rejects divalent and larger ions and most organic components




Ultrafiltration

• MWCO: 1,000 –100,000


• Allows salts, sugars, organic acids and smaller peptides

to pass

• Rejects proteins, fats and polysaccharides




Microfiltration

• Pore size 0.1 –1 µm

• Typical operating pressure < 2 bar

• Only suspended solids, bacteria and fat globules are

rejected




Operation

• Batch

• Continuous

• Diafiltration

• Pre-treatment

• Automation and control

• Cleaning

Batch




Batch operation

• Retentate recycled until final concentration is reached

• Minimum membrane area

• Minimum automation

• Used when holding time is not critical




Continuous operation

• Multiple loops with own recirculation pumps

• Module selected to fit actual viscosity

• Low residence time

• Can be fully automated

Feed

Permeate

Retentate

Feed

Permeate

Retentate




Diafiltration

• To increase the purity of a given

product

– Addition of water (or permeate) to retentate

to wash away impurities

– Batch or continuous

– Additional membrane area required to remove added water

Diafiltration water

Feed

Permeate

Retentate

Diafiltration water

Feed

Permeate

Retentate




Pre-treatment

• To reduce fouling and ensure optimum plant

performance

– Most common pre-treatment methods:

• Centrifugation

• Filtration

• Heating/cooling

• pH adjustment

• Enzyme treatment




Automation and control

• To secure overall plant

performance

• To protect sensitive membranes

(temperature, pressure, pH)

– Different levels of automation

• Manual

• Semi-automatic

• Automatic




Cleaning

• To promote the optimum membrane

performance

– Cleaning In Place (CIP)

– Typically once per day or batch

– Chemical cleaning agents

– Recycling through system

– Given pH, temperature and pressure

– Specific water quality requirements






Major processes

• Membrane filtration can sucessfully be used for the followingprocesses:

– Concentration

– Purification

– Clarification

– Recycling

– Product upgrading

– Extraction

– Recovery

– Effluent upgrading

– Fractionation




Wide range of products

• Membranes

• Modules

• Pilot equipment and test facilities

• Systems and process lines

• Spare parts and service




Membranes

• For all filtration processes – RO, NF, UF, MF• Different combinations of polymers and support paper

• Resistant to high temperature and wide pH range

• Compliance with EU and FDA

Flat sheet membranes

• Available

– by the metre

– 20 x 20 cm sheets

– Rolls 500 – 750 metres

– for all plate-and-frame configurations




Membrane overviewSeries Name pH Pressure, bar Temperature, °C

CA995PE Cellulose triacetate/diacetate

blend

NaCl rejection ≥

95% 5-6.5 1-50 0-30

RO98pHt Thinfilm composite on

polypropylene

NaCl rejection ≥

96% 2-11 1-60 0-60

NF NF NF99 Thinfilm composite on polyester MgSO4 rejection ≥

99% 2-10 1-55 0-50

UFX5 MWCO = 5,000 1-13 1-15 0-75

UFX10 MWCO = 10,000 1-13 1-15 0-75

GR40PP MWCO = 100,000

GR51PP MWCO = 50,000




GR95PP MWCO = 2,000

UF-PP CA600PP Cellulose acetate MWCO = 20,000 2-8 1-10 0-50

FS40PP MWCO = 100,000

FS61PP MWCO = 20,000

UF-RC RC70PP Regenerated cellulose acetate MWCO = 10,000 1-10 1-10 0-60

ETNA01PP MWCO = 1,000


FSM0.15PP Pore size 0.15 µm


GRM0.1PP Pore size 0.1 µm


MF

Membrane

process

RO

UF

0-75

Fluoro polymer

1-11 1-10 0-60

1-11 1-10 0-60

Composite fluoro polymer

Polysulphone

Fluoro polymer

0-75

1-11 1-10 0-60

1-13 1-10

Membrane material

Polysulphone

Polyethersulphone

UF-pHt

Membrane

RO

UFXpHt Polysulphone permanently

hydrophilic

UF-FS

UF-ETNA

MF-GRM

MF-FSM

Recommended operation limits - productionCharacteristics

1-13 1-10




Membranes

Spiral membranes

• Cost-effective

• Full-fit, sanitary design

•Comprehensive range of elements

(membrane, diameter, length, spacer)

Permeate tube

Membrane

Feed spacer

Permeate spacer

Membrane

Permeate tube

Membrane

Feed spacer

Permeate spacer

Membrane

Membrane

Feed spacer

Permeate spacer

Membrane




Membranes




Spiral membrane overviewSeries Name pH Pressure, bar Temperature, °C

CE4040C-30D

(based on CA995PE)

Cellulose triaceate/diacetate

blendNaCl rejection ≥ 95% 5-6.5 10-28 5-20

RO98pHtThinfilm composite on

polypropylene support paper NaCl rejection ≥ 97% 2-10 1-55 0-60

RO99 Thinfilm composite NaCl rejection ≥ 98% 3-10 1-55 0-50

NF97MgSO4 rejection ≥

97%

NF99MgSO4 rejection ≥

98%

NF99HFMgSO4 rejection ≥

98%

UF SSE20 Polyethersulphone

MWCO = 20,000. In-

line sterilisable spiral

element

2-10 1-10 0-75

GR40PP MWCO = 100,000

GR51PP MWCO = 50,000GR60PP MWCO = 25,000



GR95PP MWCO = 2,000

UFX5 pHt MWCO = 5,000

UFX10 pHt MWCO = 10,000

GR60PE MWCO = 25,000



GR81PE Polyethersulphone MWCO = 10,000

UF-FS FS40PP Fluoro polymer MWCO = 100,000 2-10 1-10 0-60

UF-RC RC70PP Regenerated cellulose acetate MWCO = 10,000 2-10 1-10 0-60






GRM0.2PP Pore size 0.2 µmMF-GRM Polysulphone 1-11 Max. 1.5 0-60

0-60

0-60

MF-FSM

Recommended operation limits - productionCharacteristics

MembraneMembrane material

UF-pHt

UF-PE

UF-ETNA

Polysulphone

Polysulphone

Polyethersulphone

Composite fluoro polymer

UFX-pHtPolysulphone permanently

hydrophilic

0-75

3-9 1-10 0-50

1-102-10

1-13 1-15 0-75

Fluoro polymer 1-11 Max. 1.5

2-10 1-10

Max 50NF

RO

Polyamide type thinfilm

composite on polyester 3-10 Max. 55




Modules

Spiral modules

• Compact

• Inexpensive

• Easy to use

Spiral element ATD

Feed

Permeate

RetentateHousing




Modules

Plate-and-frame modules

• Wide viscosity range

• Channel height to match

varying product characteristics

• High tolerance to suspended

material, therefore less pre-

treatment required

• Easy re-establishment ofmembrane performance




Module range

Plate-

and-frame

Spiral

Reverse Osmosis Nanofiltration Ultrafiltration Microfiltration

- high viscosity and solids capability for max. concentration

- open channel sanitary design

- low running cost

- compliant with FDA and EEC regulations

- large membrane area per module for compact design

- resistant to high temperature and full pH scale

- low investment cost- compliant with FDA and EEC regulations




Pilot laboratory equipment

• To establish process feasibility• To determine design data for scale-up

– final product composition

– required operation parameters

– necessary cleaning procedure

• To demonstrate process solutions

• To optimize existing production lines

• For small-scale processing




From lab to pilot

Scale0

Capacity

R&D

&

lab

tests

Lab

tests

&

pilot

Rental

equipment

Pilot plant

Nakskov





Rental equipment

• For on-site testing

• Close technical support

• Wide range of equipment





Pilot plant Nakskov

• State-of-the-art customer test

facilities

• Production size modules

• Large volumes

• Expert technical staff

• Joint tests with customers




Membrane filtration systems

Tailor-made solutions

• Developed in close cooperation with

customers

– application

– process requirements – choice of membranes

• Spiral, plate-and-frame or combined

systems

• Batch and continuous operation• Sanitary and industrial design

• Installation support and commissioning

More than 2,000 membrane f i l t rat ion systems ins ta lled wo r ld-wide




Plate-and-frame systems




Plate-and-frame systems




Spiral membrane systems




Spiral membrane systems




Process linesOne system – one supplier

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F l u i d

H a n d l i n g

M e m b r a n e

F i l t r a t i o n




Process linesSynergies - Evaporator




Process linesSynergies – High speed separator




Process linesSynergies – Decanter




Spare parts and service

Genuine spare

parts

• Membranes

• Plates• System spares

Guarantee of

performance quality

Day-to-daysupport

• Re-membraning

• Emergency service• Troubleshooting

• Training

Reduction of

downtime

Tailor-made

service

agreements

• Performance analysis

• Upgrading• Preventive maintenance

• Re-membraning

• Training

Long-term costsavings




Major applications

We help customers to

separate products such aswater, chemicals, beverages,

foodstuff, starch and

pharmaceuticals.




Major applications




Pharma and biotech

• Antibiotics

– UF and MF recovery and purification

– NF and RO concentration anddesalting

– For increased efficiency and higherproduct quality

• Enzymes

– UF for concentration, purification, anddesalting

– NF for recycling of water

– For higher concentration and puritywith minimum loss of activity




Pharma and biotech

• Polysaccharides

– UF and NF concentration and purificationin one process at low cost

• Amino acids

– UF recovery and purification and ROconcentration

– For high product quality and low costs

• Yeast extract

– UF for recovery and purification

– RO for concentration

– For high purity and reduced water

consumption




Major applications




Food and beverages

• Beer

– RO for beer dealcoholization

– Quality in line with standard beerat low cost

• Food gums

– UF for concentration and purification

– RO for recycling of permeate

– High purity at minimum operating costs

• Gelatine

– UF for fractionation, concentrationand purification

– For gentle processing to avoiddenaturation




Food and beverages

• Juice

– UF for clarification

– RO for concentration

– For greater profitabilityand better quality

• Eggs

– UF for concentration of egg white and whole egg

– RO for dewatering of egg white prior to drying

– For gentle treatment and high-quality product




Food and beverages

• Wine

– RO for the concentration of grape juice

– RO for colour concentration from red wine

– NF for aciditiy reducation in wine – NF/RO for dealcoholisation of wine

• Animal blood plasma

– UF for concentration and purification

• Vinegar

– UF for clarification




Sugar and starch

• Sugar industry

– UF for removal of haze and colour from

sugar syrup

– RO for concentration of sugarwater

• Starch industry – MF/UF for mud removal after

saccarification

– UF for polishing/pyrogen removal from

dextrose and HFCS

• Sugar and starch industry

– RO for evaporator concentrate polishing

– RO for sweet water purification and

polishing




Pulp and paper industry

• Paper industry

– UF for colour recovery

– UF & NF/RO for white water purification

• Pulp industry – UF for the purification and concentration of

lignin from KBL and SSL

• Pulp and paper industry

– UF/NF/RO for evaporator condensate

polishing




References

• Novo Nordisk

• Glaxo SmithKline

• Antibioticos

• Milei GmbH

• Arla Foods

• Unilever

• Citrosuco

• Danisco Cultor

• Lonza Biotec s.r.o

• Biotech Paskov




Lonza Biotec s.r.o., Czech Republic

Reliable performance

Through 16 years of collaboration, Alfa Laval has installed, restored

and replaced a number of membrane filtration systems.

“For us, the important things are an informal yet close collaboration,

mutual trust, willingness to cope with problems, and a

high degree of professionalism. It is a pleasure to work with a

company that acts like a real partner, rather than a mere supplier.

It‟s exactly what we‟re trying to provide for our own customers.”

Tomasz Cieslewski, site manager, Lonza Biotec, s.r.o., Czech Republic

S G




Serum-Werk Bernburg, Germany

Easy expansion

Serum-Werk Bernburg installed its first membranes from Alfa Laval

in 1996. Advanced membranes ensure that only molecules of a

specific size are retained. It is also important that the processed

products are sterile, and “ultrafiltration at high temperatures is how

we stop the growth of germs.”

Due to the modular design of the membrane filtration system it was

easy to double the company‟s production capacity in 2002 and “wewant to achieve another doubling of capacity next year …”

Werner Zimmermann, head of technology, Serum-Werk Bernburg,

Germany

Ci B il




Citrosuco, Brazil

Fruitful cooperation

Citrosuco installed an ultrafiltration plate-and-frame plant for orange

juice processing in 1996. However, peel oil is very aggressive, and

“the oil was basically destroying part of our equipment. Alfa Laval‟sengineers worked with us on a series of tests and experiments” and

support plates were developed that could withstand the oil-rich juice.

The success of this innovation led to upgrading of all 16 modules in

2002, and the signing of a five-year service agreement.

Sérgio Moretti, production manager, Citrosuco, Brazil

Edid /D i h C D k




Edidan/Danish Crown, Denmark

Boosting capacity

“When we reached our capacity limits, Alfa Laval gave us an

alternative to extending the dryer unit – by installing a spiral

„booster unit‟ prior to the existing Plate & Frame unit.

This spiral unit undertakes preliminary concentration of blood

plasma. We can now boost production capacity by 50% – with no

changes to the drying unit. Obviously, it‟s much cheaper to remove

water by simply filtering it out.”

Aage Christensen, plant manager, Edidan/Danish Crown, Denmark

BIOTECH P k C h R bli




BIOTECH Paskov,Czech Republic

”As it is fully automated, the ultrafiltration plant requires very little

attention from operators. They occasionally check the relevant

parameters, but do not generally have to take specific action.”

Jan Jonáš , production manager, BIOTECH Paskov, Czech Republic

Experience makes the difference

Documents

Alfa Laval Membrane Presentation