Applications of Membrane Technology - icheme.org · 3 Some Typical Membrane Applications MEMBRANE...
Transcript of Applications of Membrane Technology - icheme.org · 3 Some Typical Membrane Applications MEMBRANE...
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Axium Process Ltd
Applications of Membrane Technology
Peter Esteban
Managing Director
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Axium Process – who are we?
• An independent bespoke membrane systems provider
• Combined 150 man years of membrane filtration and product separation experience
• Project design & management expertise involving microfiltration, ultrafiltration, nanofiltration and reverse osmosis technology
• Process and product development
• Technical training and support
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Some Typical Membrane Applications
MEMBRANE FILTRATION – TYPICAL APPLICATIONS
Water and Effluent
Treatment
Recovery & reuse of water
Condensate upgrade for reuse
Final filtration of bottled water
Animal and vegetable processing waste recycling
Dairy/Food
Processing
Whey protein concentration
Quarg cheese production
Dilute sugar stream concentration
Chemical
Industries
Dyehouse water recycling
Recovery of cleaning chemicals
Laundry waste recovery
Beverage
Production
Clarification and purification of fruit juice and beer
Recovery of cider and beer from tank bottoms
Process water recovery and waste volume minimisation
Pharmaceutical
Manufacturing
Fermentation broth clarification
Precursor purification
Enzyme concentration and purification
Organism concentration by physical means
How do we go about selecting the correct membranes for the process
• Meeting and discussion of requirements with clients, possibly a site visit. Understand the process
• Get feed analysis
• Initial pilot trials at Axium
• If successful possible site trials on fresh feed (data accumulation and membrane clean ability)
• From trial data we can scale up into a commercial plant.
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Membrane Pilot Trial Capability
• Mobile membrane test plants
• Pilot plants are flexible and are able to take a variety of different membranes and configurations
• Trials can be carried out at Axium or on customer’s site
• Variety of full size commercial membranes tested for optimum membrane choice
• Independent of membrane suppliers
Pilot Equipment
Site trials are not for the faint hearted
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Wool Scour Trial
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What comes off sheep when you wash them is not nice!
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What sort of things are we asked to look at
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Example: Raw Ice Cream Plant Effluent Recycling Plant
• Successful pilot trial conducted and system commissioned
• 400m3 m/day wastewater recycling plant – increased to 700 m3/day, with recent expansion to 1,500 m3/day
• System replaced old DAF technology
• Small footprint
• Major saving in chemical use
• Concentrated slurry recycled as compost
• Permeate water is hot and sanitised
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Axminster Carpets Key Considerations
Environmental • water supply was variable (River Dart) • effluent discharge was limited Legislation • stringent effluent discharge consent levels Process Control • consistent water quality supply essential • at least as good as existing source • no chemicals to be added to effluent • thermal energy capture Economics • Energy consumption • Water usage • Disposal costs (aim for Zero discharge) • Minimum footprint
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Axminster Carpets (Tubular UF and
Spiral RO)
Scour & Dyehouse Installation
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Textile Membrane Applications
MEMBRANE FILTRATION – TYPICAL APPLICATIONS IN THE TEXTILE INDUSTRY
DYESTUFF WATER
Recover hot clean water from the dyehouse operations, including dying and rinsing for recycling.
Energy savings (heat) Substantial reduction of water useage, reduced disposal of concentrate Consistent supply compared to natural water
PRINTING Printing wash water recycled by Ultrafiltration Energy (heat) and water savings Reduced cost for disposal of dilute chemicals 90% reduction in BOD Colour removal
WOOL SCOURING Removes oils, waxes and dirt from wool Permeate can be reused in the cleaning process as it is already warm and carries the cleaning agents
LATEX RECOVERY Used as a binder – often produced as a dilute stream.
Reduced dispoal of COD Lower purchase costs for new latex
SIZE RECOVERY PVA and other sizing materials from de-sizing baths can be concentrated and reused
Heat savings and reduced water purchase Reduced purchase of size and lower BOD disposal costs
INDIGO DYE Recovery of washed out Indigo Dye by Ultrafiltration
Reduced costs for purchase of fresh water Dye stream can be re-used Reduced effluent volumes
WATER SOFTENING
Removes bacteria, viruses and other organisms from the process water. Reduces calcium levels without adding sodium.
Less expensive than ion exchange Provides clear, colourless, consistent water No salt discharge
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Benefits of using membranes in the textile industry
• Recovery of energy in the form of heat
• Reduced water purchase charges
• Reduced effluent charges
• Potential recovery of chemicals such as size, detergents, latex, dyes
• Consistent stable quality water supply without interference from colour contamination, or suspended solids from variable natural waters
• Stable performance, easy maintenance and small footprint
• Straightforward installation requirements
• Reduces waste
• Saves energy
• Saves water
• Saves money
Landfill Leachate (Tubular UF)
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Purification of Printing Dye
• Removal of salts from raw dye to produce a better ink (Tubular NF System)
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And many many more
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Salt removal from Betaine Laundry Wash Water Recovery
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Benefits of Membrane Technology Over Conventional Methods
• No addition of chemicals to effect the separation
• Better and more absolute separation
• No special civil engineering required, smaller footprint
• Physical separation process – avoids sensitivities of biological processing
• Wide range of separation cut-off
• Both permeate and concentrate uncontaminated by chemicals – can be reused – RO water is soft
RO Permeate
Feed
Concentrate
UF Permeate