spintek filtration: improving aqueous coalescers · brane filter. she was fine, but asked john to...

I N T E R N A T I O N A L

Your Global Source

FILTRATION NEWS

January/February 2013Volume 32 No. 1

www.filtnews.com

SpinTek Filtration:

Improving Aqueous Coalescers

Special Reports on Water Filtration:

• Integrated Dual Membrane Systems for Drinking Water Production

• Perforated Metals: Clarifying Options

• Cloth Media Filtration For Wastewater Treatment

Special Reports on Water Filtration:

• Integrated Dual Membrane Systems for Drinking Water Production

• Perforated Metals: Clarifying Options

• Cloth Media Filtration For Wastewater Treatment

SpinTek Filtration:

Improving Aqueous Coalescers

Filtration...Perhaps the Greenest of All Industries

Filtration...Perhaps the Greenest of All Industries

Xinxiang Tiancheng Aviation Purification Equipments Co. Ltd.

Our company specializes in designing & manufacturing and supplying many kinds of filters,

complete filtrating equipments and their elements with different materials according to your

drawings or new & old samples.

Xinxiang Tiancheng Aviation Purification Equipments Co. Ltd.No. 1, Chuanye Road, Dvelopment Area, Xinxiang City 453003, Henan

P.R. China

Contact Person in China: Mr. Li Minghao

Tel: +86-13673735086 Fax: +86-373-3520026 Website: www.tchkjh.comEmail: [email protected] • [email protected] • [email protected]

Contact Person in USA: Mr Liu Shengyuan

Tel: 4015881868 • [email protected]

For airplane For special vehicle

For coal machinery

For fluid cleaning systemFor dust collector of cement industry

For ultrafilter

2 • February 2013 • www.filtnews.com

Published byINTERNATIONAL

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Carol and Arthur Brown, FoundersKlaas DeWaal, Publisher and CEO

Antoinette DeWaal, Associate Publisherand Vice President

Editorial DepartmentKen Norberg, Editor in Chief, [email protected]

Adrian Wilson, Intl. CorrespondentChen Nan Yang, China CorrespondentEditorial Advisory Board, See page 4

Administration DepartmentBarbara Ragsdale, [email protected]

Circulation DepartmentCherri Jonte, [email protected]

Advertising Sales RepresentativesUSA:

Joan Oakley, [email protected] Klupacs, [email protected]

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Publication DataFiltration News (ISSN:1078-4136) is publishedbi-monthly by International Media Group, Inc.Printed in U.S.A., Copyright 2013.This publication has a requested and controlledsubscription circulation - controlled by the staff ofFiltration News; mailed bi-monthly as PeriodicalsPostage Paid (USPS 025-412) in Novi MI andadditional mailing offices.Filtration News is not responsible for statementspublished in this magazine. Advertisers, agenciesand contributing writers assume liability for allcontent of all submitted material printed andassume responsibility for any claims arisingthere-from made against publisher.

Mailing Address for advertising,news releases and address changes:International Filtration NewsInternational Media Group, Inc.6000 Fairview Road, Suite 1200Charlotte, NC 28210 USAPhone: +1-704-552-3708Email: [email protected]: www.filtnews.com

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IN THIS ISSUEJanuary/February 2013, Vol. 32, No. 1

Industry | News

Filtration...Perhaps the Greenest of All Industries 6

Environment Effort Boosts Filtration and Separation Industry 12

Cover Story | SpinTek Filtration

CoMatrix and Aqueous Coalescer for Entrained Organic Removal 16

Water | Filtration

Integrated Dual Membrane Systems for Drinking Water Production 20

Perforated Metals: Clarifying Options 24

Cloth Media Filtration For Wastewater Treatment 28

Filtration | Recycling

Advanced Filtration Technology Enables the Production of High-Quality Recycled PET Fibers for the Textile Industry 32

Coolant | Filtration

The Best Practice for Supplying Filtered Coolant to High Pressure Pumps 38

News | Briefs

Call for Papers for FILTECH 2013 41

Eliminating High Maintenance Costs With Orival Filters 41

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Cover courtesy of SpinTek Filtration


Editorial Advisory Board

Editorial Board ChairmanEdward C. Gregor, ChairmanE.C. Gregor & Assoc. LLCTel: 1 704 442 1940Fax: 1 704 442 [email protected]&A, Filtration Media

Haluk Alper, PresidentMyCelx Technologies Corp.Tel: 1 770 534 3118Fax: 1 770 534 [email protected] Removal – Water and Air

Jim JosephJoseph MarketingTel/Fax: 1 757 565 [email protected] Filtration

Robert W. McilvaineTel: 1 847 272 0010Fax: 1 847 272 [email protected]. Research & Tech. Analysis

Dr. Graham RidealWhitehouse Scientific Ltd.Tel: +44 1244 33 26 26Fax: +44 1244 33 50 [email protected] and Media Validation

Tony ShucoskyPall MicroelectronicsTel: 1 410 252 0800Fax: 1 410 252 [email protected], Filter Media,Membranes

Scott P. YaegerFiltration and SeparationTechnology LLCTel/Fax: 1 219 324 3786Mobile: 1 805 377 [email protected], New Techn.

Mark VanoverBayer MaterialScience LLCKey Account ManagerTel: 1 314 591 1792Email:[email protected] Systems

Dr. Bob BaumannAdvisory Board Member Emeritus

Andy RosolGlobal Filtration Products Mgr.FLSmidth [email protected]: 1 800 826 6461/1 801 526 2005Precoat/Bodyfeed Filter Aids

Clint ScobleFilter Media Services, LLCOffice: 1 513 528 0172Fax: 1 513 624 [email protected] Filters , Filter Media, Baghouse Maintenance

Gregg PoppeThe Dow Chemical CompanyTel: 1 952 897 4317Fax: 1 942 835 [email protected] Water, Power,and Membrane Technology

Henry Nowicki, Ph.D. MBATel: 1 724 457 6576Fax: 1 724 457 [email protected] Carbons Testing,R&D, Consulting, Training

Brandon Ost, CEOFiltration GroupHigh Purity Prod. Div.Tel: 1 630 723 [email protected] Filters, Pharmaceuticaland Micro-Electronic

Dr. Ernest Mayer E. Mayer Filtration Consulting, LLC Tel: 1 302 981 8060Fax: 1 302 368 [email protected]

Wu ChenThe Dow Chemical CompanyTel: 1 979 238 [email protected] Filtration (liquid/gas)Equipment and Media

Peter R. Johnston, PETel/Fax: 1 919 942 [email protected] procedures

Peter S. Cartwright, PECartwright Consulting Co.Tel: 1 952 854 4911Fax: 1 952 854 [email protected], RO,Ultrafiltration


Industry | News

here isn’t a pollution orenvironmental problemthat cannot either be

prevented or remediated through the useof filtration, separation or coalescing.”

I’ve been making the above state-ment for 20 plus years and have neverhad its veracity questioned or chal-lenged. A few processes may not be 100percent perfect yet, but the principal re-mains and is hard to dispute.

Filtration, separations and coalesc-ing companies are always on thesearch for new opportunities and chal-lenges, which brought to mind theidea of exploring the broad world offiltration, separations and coalescing,

through examples. What follows is a “day in the life” of

a married couple – John and Mary –and noting some of the many technolo-gies that engineers, scientists, academiaand companies have created to preventor resolve many pollution problemsthat result in a higher standard of livingfor us while also maintaining a cleanerand safer world environment.

THE DAY BEGINSJohn and Mary wake in the morn-

ing with the help of their digital alarmclock – who’s acids, solvents and de-ionized water were safely used tomake its microchip, and which was

filtered by prefilters, reverse osmosisand microfiltration. John turns up thethermostat, not giving a thought tohow their home air filters protect theheating unit. The electricity beingprovided by the local utility companyfrom a coal-fired power plant usesscrubber technology and baghouse fil-tration to remove particulate from theexhaust stream. Mary heads to thekitchen to make a pot of coffee,pulling out a coffee filter, withoutknowing the coffee had the caffeineremoved safely via super-critical fluidextraction. Her water is pre-filteredthrough a series of meltblown andcarbon prefilters as well as an RO unit

Filtration...Perhaps the Greenest of All IndustriesBy Edward C. Gregor

Filters, separation or coalescing can solve any pollution or environmental challenge the world is facing.

“T

Filtration...Perhaps the Greenest of All IndustriesBy Edward C. Gregor

hidden under her sink. Now, Maryheads back to the bathroom whereJohn is in the shower, using clean andodorless filtered municipal water.Mary applies her cosmetics, many ofwhich were filtered for purity. Gettingdressed, neither considers the poly-ester fiber in their clothing that wasfiltered during the fiber manufactur-ing process. Included, were the man-ufacture of John’s cotton/polyesterblend shirt and Mary’s dress, whichwere both finished with a filtered anti-microbial treatment. Running a bitlate for work, they quickly openbreakfast protein bars wrapped inmulti-layered plastic packaging used

to keep convenience-foods fresh, andwhich have benefited from polymerfiltration once again. They drink theircoffee and orange juice, where pulphas been removed using ultrafiltra-tion. Being diabetic, John uses hismembrane diagnostic test kit andgives himself an insulin shot, whichhad been filtered by the pharmaceuti-cal supplier.

OFF TO WORKTime to leave and both jump in

their cars. Mary drives a hybrid, butdislikes the odor of exhaust fumes andpollutants and made sure a cabin airfilter came with her car. It’s a foggy

winter morning as she leaves, notthinking about a potential moisturebuild-up in the head and tail lamps,which evaporated overnight via theoleophobic membrane media ventsembedded in the glass. These are sim-ilar to the vents where water by-passedthe gaskets in the small motors con-trolling the windshield wipers andpower windows in her car, which col-lected when she was driving in the rainthe afternoon before. John’s a lead-footand an amateur racer, driving his prideand joy “muscle” car with its high-per-formance engine. In the back of hismind, he knows he can rely on the gastank filter from monofilament and

www.filtnews.com • February 2013 • 7


Industry | News

meltblown fabric and the fuel injectorfilters of monofilament woven fabricsto provide clean fuel, and that the en-gine air-intake and lube oil wetlaidmedia filters will provide peak per-formance as well. He’s also confidentthe space between the engine blockand the pistons, only a few micronswide, are clean, thanks to two honingcoolant filtration systems at the en-gine production plant that eliminatedshavings and other debris, using 25micron bag filters, and the other linewith gradient density nonwoven fab-ric roll stock to clear debris duringprecision machining of both his en-gine and transmission. Mary’s car hasan automatic transmission, which in-corporates a transmission filter con-taining needlefelt and/ormonofilament woven fabric. BothMary and John’s batteries also utilizeporous plastic media vents to preventa build-up of gasses, eliminating thepotential of a battery failure and evenan explosion. Before reaching the of-

fice John calls his mother on his cellphone, which contains a microchip,not all that dissimilar to the digitalclock. Mom is receiving hemodialysisusing a cleanable hollow fiber mem-brane filter. She was fine, but askedJohn to please come by over theweekend to get her lawn mower readyfor the spring with a new paper fueland reticulated urethane foam air fil-ter as well as to look at her gas dryer’slint filter screen, which might needreplacement.

As Mary reaches her office as VP ofOA/QC Manager at Living Well Phar-maceutical & Medical Device Com-pany, LLC, she turns on her computercontaining an e-PTFE disk-drive airvent, but before she can remove hercoat, an anxious employee tells herabout problems on the productionline over night. The injectables pro-duction line used to produce diabetesmedication was having problems. Themeltblown prefilter and membranesterilizing filter line might not be

working properly as the microbiologytest lab detected bacteria in the serumon their membrane disk filter. Fur-thermore, the insert molding linesused to produce I.V. vent and in-linebacteria medical filters were actingup. Yesterday, they had a similar prob-lem with the ophthalmic and pre-by-pass filter line used in extracorporealopen heart surgery.

In the meantime, John arrives athis chemical plant where he is Direc-tor of Operations. Unlike Mary’s situ-ation, everything is runningsmoothly. The filter presses usingwoven fabric, flat bed filters with rollsof nonwoven media and filters, andleaf filters using filter aids are all op-erating efficiently. However, onechamber of the bag house needs tohave its filters replaced today as partof routine maintenance along with allthe meltblown box air filters in theoffices. The new fleet of large dieseltrucks used to transport liquids andpowders produced at his facility had

Virtually every aspect of human life is touched by the principles of filtration.


Industry | Newsfinally arrived overnight. John feelsrelieved, as he has had many com-plaints about the diesel soot exhaustfrom the neighbors. He is also pleasedto learn in the company newsletter,printed using filtered ink, that the oiland gas drilling operations the com-pany owns elsewhere, has success-fully installed improved coalescingand absorption separation systems.This was done to remove the higherpercentage of oil and fine dropletchemicals from produced water in theoil and gas recovery process.

TRAVEL TO HEADQUARTERSThe day goes smoothly for John,

before leaving for lunch and the air-port and a flight to headquarters. Atlunch, John enjoyed a burger, friesand sweet tea - the fry oil efficientlyfiltered using a polyester media, andthe sugar sifted to size for his tea. On

his way, John drove by a plating facil-ity, where he previously was em-ployed, and said hello to hisreplacement that had just installedboth tubular and RO crossflow mem-brane systems to remove heavy met-als before water disposal andrecycling. Once at the airport, Johnboarded the aircraft confident theFAA-approved fuel, cabin air and hy-draulic filters would perform per-fectly. Looking out the cabin window,John noticed the hydrant cart, coa-lescing water out of the aviation fuelbeing loaded onto the aircraft.

Upon arrival at the hotel, John hadsupper, called Mary asking how thingswent today. Mary said she had concerns,but everything turned out well, relatingthe microbiology lab diabetes reportproved to be a false-positive. John saidthe same from his end and mentionedhis company has just uncovered a new

highly-efficient technology that soundscapable of complete mercury removaland direct recovery at the company’shuge natural gas drilling facility. Best ofall, there were no disposable absorbentsrequiring post-cleaning. John said good-night and he’d call in morning. Beforeturning out the lights, John watched thenews, where the TV had an LCD screenmade in a factory cleanroom usingHEPA filters to prevent surface contam-ination during the manufacturingprocess. And so it goes...another healthyand trouble free day for John and Maryas well as the rest of us, thanks to safeand reliable filtration, separations andcoalescing technologies.

Ed Gregor is a specialist in filtration technologies and media, and has both Consulting and M&A businesses in filtration.He can be reached by phone: 704-442-1940or email: [email protected]

FN

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t the 4th Filtration & Separa-tion Asia and the 7th ChinaInternational Filtration &

Separation Exhibition & Conference(FSA + CIFS 2012) held November 14 -16, 2012, experts and executives from

all around the world discussed the mar-ket and technology trends of the Chi-nese, Asian and global filtration andseparation industry. The participantsconcluded that a strong market growthwould continue in the next few years,

which will continue to provide ongoingmomentum to innovation.

EXHIBITORS AND EXPERTSThe event was sponsored by the

China Technology Market Associa-

A

Industry | News

Environment Effort Boosts Filtration and Separation IndustryBy Jason Chen, China Correspondent

More than 300 exhibitors participated at Filtration & Separation Asia 2012, where experts predicted a strong growth for filtration in the coming years.

tion (CTMA) and the China Filtra-tion Society (CFS), and was sup-ported by International FiltrationNews, the American Filtration & Sep-arations Society (AFS), the Asia Non-woven Fabrics Association (ANFA),

and the European Disposables andNonwovens Association (EDANA).The organizers included CNTA Sci-ence & Technology Co Ltd (CNTA),UBM Asia Trade Fairs Pte Ltd (UBM),and Shanghai Technology Conven-

tion & Exhibition Co Ltd.Around 300 exhibitors from Main-

land China, France, Austria, HongKong, Japan, Germany, Taiwan, Bel-gium, Finland and the United Statesattended the FSA + CIFS 2013 atINTEX Shanghai, covering exhibi-tion halls of 6,000 square meters.They included filtration materialsmanufacturers, filtration and separa-tion equipment producers, researchand development institutes, associa-tions, and industrial publications.

Some of the exhibitors said thatthe growing market demand was thedeciding factor in participating atthis biannual event. “We expect agrowth of sales this and next year. Sowe are here to look for more businessopportunities,” said Mr. Zhou Shen,manager of a Shanghai-based filtra-tion equipment company.

One the other hand, experts dis-cussed recent advances in technolo-gies and market trends of thefiltration and separation industry inthe forums of the FSA + CIFS 2012.

ENVIRONMENTAL PROTECTION EFFORTSSome of these forums focused on

the market opportunities that will bebrought by the Chinese government’senvironmental protection efforts.

One of these opportunities is cre-ated by the Chinese government’splan to improve the nation’s sewagetreatment and recycling system.“This effort will provide a strong mo-mentum to the Chinese filtration andseparation industry in the next threeyears or more,” said Mr. DengZhiguang, deputy president of theChina Central and Southern ChinaMunicipal Engineering Design & Re-search Institutes. He described theChinese government’s policies andtargets for sewage treatment and re-cycling by 2015, and the consequentmarket demands and related oppor-tunities. According to the targets,China’s sewage water treatment willincrease from 124.8 million cubicmeters to 208.1 million cubic metersper day from 2010 to 2015, andsewage sludge treatment will increase5.18 million cubic meters per day inthe same period. In addition, recy-

Environment Effort Boosts Filtration and Separation IndustryBy Jason Chen, China Correspondent

More than 300 exhibitors participated at Filtration & Separation Asia 2012, where experts predicted a strong growth for filtration in the coming years.



Industry | News

cling water will triple to reach 38.85million cubic meters per day from2010 to 2015.

Another opportunity is China’s ef-forts to reduce air pollution. TheChinese central government has seta plan to reduce the Chinese indus-tries’ air emissions per metric ton ofproduction by 10% to 29% between2010 and 2015. This plan willstrongly boost the consumption offiltration fabric. According to Mr.Sun Jinliang, member of the ChineseAcademy of Engineering (CAE), theChinese industries emit a total ofabout eight million metric tons offine particles (PM2.5) a year, whichaccounts for 80% of China’s total airpollution. The fine particles emissionis hard to be eliminated through tra-

ditional ways. The main solution isfilter bags made by filtration fabric.

“Last year (2011), China pro-duced about 120 million square me-ters of filtration fabric, with a totalvalue of 20 billion yuan ($3.2 bil-lion). In 2012, the market in valueterms will grow by 25% and reach 25billion yuan ($4.0 billion),” said Mr.Jiang Shicheng, vice president of theChina Chemical Fiber Association(CCFA).

But Mr. Jiang said that the Chi-nese filtration fabric manufacturersstill had many problems. “Among thefiltration fabric made in 2012, about70 million square meters were com-mon filtration fabric with poor heat-and corrosion-resistance, and only50 million were high-quality prod-

ucts. On the other hand, amongChina’s more than 200 filtration fab-ric production lines, only 15 lines areadvanced lines introduced fromother countries, and more than 100lines are low-quality ones. Overca-pacity of low-quality products hasappeared in the industry and restruc-turing will be required,” explainedMr. Jiang.

Other experts said that the rela-tively high cost would be anotherfactor that retards the growth of filterbags and filtration fabric. For exam-ple, the investment on the filter bagsfor a chimney in a steel plant couldcost up to a half million yuan($81,000) and the lifespan of the fil-ter bags is only about two years, ac-cording to Mr. Huang Ning, engineer

A rosy outlook for the filtration industry in the coming years was a deciding factor for many of the exhibitors at the event.

FN

of the environmental department ofChina’s Ji Nan Steel and Iron Plant.“The cost is too high and we are al-most unable to afford it. Therefore,cost reduction and lifespan increaseof the filtration products will be cru-cial to our environmental protectionefforts,” said Mr. Huang.

To reduce the environmental pro-tection costs of the Chinese compa-nies, the government has started tosubsidize the filtration fabric produc-ers. For example, the government ofChina’s Funing County subsidizes10% to 17% of the prices of newequipment bought by local filtrationfabric manufacturers, which will re-duce their cost of manufacturing ad-vanced filtration fabric. Since 2011,the Funing government has givenabout $700,000 to 146 local filtration

fabric manufacturers. “Supported bythe government, the Chinese filtrationfabric industry will have an averageannual growth rate (AAGR) of no lessthan 15% in the next five years,” saidMr. Li Lingshen, president of theChina Nonwoven & Industrial Tex-tiles Association (CNITA).

MATERIALS, APPLICATION, METHODSIn some other forums, experts dis-

cussed the applications of filtrationand separation technologies for vari-ous industries. For example, Mr.Liang Jinlong, researcher of China’sNanchang Filter Machinery ResearchInstitute, described in a forum the re-cent development of uranium separa-tion and concentration technology;Mr. Chen Gangjin, researcher of theLaboratory of Electrets and Applica-

tion at China’s Hangzhou Dianzi Uni-versity, provided his recent findingsof melt-blown polypropylene elec-trets web in medical applications.

New materials for filtration andseparation were discussed at the FSA+ CIFS 2013 too. For example, Ms.Bian Sisi, researcher of the Northeast-ern University of China, describedher recent experimental research ondegradation of aramid filter media.

Some experts presented their re-cent research on new manufacturingmethods for filtration materials. Forexample, Mr. Lu Jiankang, researcherof the Qidong Kanghui Coating &Lamination Co Ltd, described theirrecent research and development(R&D) of the manufacturing tech-nologies and equipment for multi-layer filtration materials.




development and field-test-ing program was undertakenfor an improved aqueous co-

alescer for produced water, oily water,and electrolyte and raffinate streams.The achievement of such a programwould provide low cost and effectivecoalescence of entrained organics thatwould improve the performance of sub-sequent dual-media filters and on raffi-nate provide for a stand-alone solution.

The desired goals as a pre-treatment todual-media filters are to 1) improvefinal effluent quality, 2) reduce back-wash frequency of the filters, and 3)provide a more easily recovered organicthen the reprocessing of backwash elec-trolyte or water.

The system was shown capable ofoperating at pressures under 140 kPaand obtained entrained organic re-moval of up to 95%. The low operat-

ing pressures allow for lower capitalcosts and the ability to treat entire raf-finate streams previously not feasibledue to extremely high capital and op-erating costs.

This paper discusses the design andbasic operational considerations of thisimproved coalescer and how it can beapplied to new construction as well asoperating plants. A unique feature willbe discussed as how the coalescer can

CoMatrix and Aqueous Coalescer for Entrained Organic Removal By William A. Greene, President, SpinTek

ASpence Copper Mine, Chile

be incorporated into existing dual-media filters to significantly improveorganic removal, extend service runsand reduce backwashing frequency.

INTRODUCTIONThe removal of entrained organic

from aqueous streams is an essentialprocess to minimize plant operatingcosts and maximize the quality of theelectrolyte. Current technology in-cludes the CoMatrix™ filter and con-ventional Dual-Media filters. The desireis to produce a low operating and cap-ital cost coalescer that can be used tofeed these media based systems. It isdesirable to remove high levels of en-trained organic to provide a more con-stant aqueous feed stream to this typeof equipment.

In addition, entrained organic re-covery equipment has found very lim-ited commercial implementation dueto the very high flow rates comparedto electrolyte and subsequent higherthan acceptable capital costs. Anothergoal then is to produce a low cost butvery high flow rate system that canconsistently remove 75% or greater or-ganic removal.

The following reports on the recentstudy of an improved Matrix Tower™and the initial application is for the re-moval of organic (liquid ion exchange+ diluent) from a strong copper elec-trolyte solution.

A Matrix Tower coalescer designproduces an enlarged droplet size of theorganic for more efficient removal bythe subsequent filter. It is commonlyknown that as modern SX-EW plantsbecome increasingly more advanced indesign, the organic droplet sizes de-crease accordingly as a result of this en-hanced mixer/settler operation. Thisconsequently causes lower efficiency inthe filters. Crud and organic loads as-sociated with crud can also be reducedfrom the electrolyte by placing less of aload on the filters.

An added benefit is that a reliablecoalescer can smooth out levels of en-trained organic to a media filter andthus compensates for normal plant up-sets that can cause excessive organiclevels from entering a filter. Stabilizingthe organic level to electrolyte filters re-




duces the chance of overrunning thesefilters, which send organic to the tankhouse. The service cycle of the filtersprior to backwash can be more accu-rately predicted. The added benefit offewer backwashes is that filters are online for longer periods of time and theamount of water or lean electrolyteused for backwashing is minimized.

METHODOLOGYThe coalescer can be viewed as a

“tank within a tank” where the outertank can be pressurized up to 100 kPaand has an access man-way and nozzlesfor service inlet, service outlet and or-

ganic recovery. The inner tank is acylinder that is connected at the bottombut open at the top. The flow path is upthrough the center of this cylinder andthen the electrolyte changes directionand flows down through the annulusformed by the inner cylinder and theinner walls of the outer tank. The or-ganic floats to the top of the tank andexits the system.

The operation of the system is en-hanced by placing anthracite or poly-ethylene beads in the cylinder andputting a grid on the top of the cylinderto prevent the escape of the coalescingmedia. In the annulus area, SpinTek in-stalls a Matrix packing™ that consistsof hydrophobic corrugated packing.The distance between the corrugationsare typically 12 mm up to 17 mm. Theflow rate through the cylinder is in the60 m3/hr-m2 range hence if anthracite

is used the flow velocity forces it to thetop of the cylinder and the containmentplate.

Free organic can be formed and flowto the top of the cylinder. To further im-prove organic removal efficiencies – ifthe organic touches the Matrix packing– the hydrophobic nature of the pack-ing will cause the organic to stick to itssurface. This organic on the plateseventually form larger droplets thatbreak free from the Matrix packing andare buoyant enough to flow upwards(counter flow to the electrolyte) andmigrate to the dome of the tank andexit the coalescer.

A further enhancement is to intro-duce air into the feed inlet. The airprovides lower surface tensions andhence helps coalesce organic. Theair/organic then reaches the medialayer where larger organic droplets areformed that will float up to the top ofthe domed top.

The test system was set up and op-erated at 38 l/m and used the feed pres-sure from the electrolyte filter feedpumps and after usage the electrolytewas returned to the same feed tank.There was no loss of electrolyte fromthe plant during operation of the pilot.

The coalescer was operated for 48hours without sampling to stabilize op-eration and to coat the system with or-ganic from the feed electrolyte. It isnecessary to coat the coalescer with or-ganic as this will be its normal operat-ing condition.

RESULTS AND DISCUSSIONThe chart shows the result of the

Matrix Tower coalescer over a contin-uous five (5) day service run. As canbe seen, the results show low levels oforganic in the total effluent with thevast majority of organic removed bythe coalescer.

Efficiency removals approached 95%during parts of the service run.

The raw data in Table 1 gives an in-dication of system performance. As canbe seen with organic inlet concentra-tions as low as 9 ppm the average en-trained organic removal was 75%.

When the entrained organic level isabove 20 ppm, indicating less organicassociated with crud, the efficiencyrises to 88%.

CONCLUSIONSThe coalescer performed well even

with the presence of significantamounts of crud (organic + sus-pended solids), and the system wasnever out of service during the five(5) day test run.

The system consistently averaged75% organic removal from the feedelectrolyte. When the organic presentin the feed was greater then 20 ppm the

efficiency rose to 88%. As the level oforganic is even higher in the 30 ppmrange removal efficiency rises to the95% range.

The Matrix Tower has the ability tosignificantly reduce the amount of or-ganic in the electrolyte, which will ex-tend the service run of CoMatrix orDual-Media filters used to polish andfilter the electrolyte.

The system is a low cost method ofentrained organic removal either as astand-alone system on raffinate or apre-treatment to polishing filters onelectrolyte. As an example, a 4872 mmdiameter Matrix Tower coalescer oper-

ates at 600 m3/hr and can be con-structed of FRP or thin wall stainlesssteel, which is enough for many elec-trolyte or strip applications.

Large raffinate streams, for example,at 2400 m3/hr could be configured asfollows:

Four (4) Coalescers:4872 mm diameter

Three (3) Coalescers:5785 mm diameter

Two (2) Coalescers:7308 mm diameter

SpinTek Filtration, Inc.William A. Greene10863 Portal DriveLos Alamitos, CA 90720 USATel: +714-236-9190Email: [email protected]: www.spintek.com

DELKOR AMERICAS Diego Rubio, Senior Sales & Process EngineerTel: Central: +56 (2) 650 4700, Direct: +56 (2) 650 4775Fax: +56 (2) 650 4701Email: [email protected]: Diego Rubio DelkorWebsite: www.delkorglobal.com

For more information contact:

FN


Water | Filtration

he use of Ultrafiltration (UF) aspretreatment to Reverse Osmo-sis (RO) has been increasing in

recent years. Its operation utilizing sur-face water as source to produce drink-ing water has been of particular interest,since it varies based on location (Pearce,G.K., 2008 [1]), raw water origin andlocal particularities. When consideringsurface water, the difficulty usuallycomes from its fluctuating characteriza-tion, being especially challenging dur-ing periods with high natural organicmatter (NOM), high turbidity or highsuspended solids and seasonal biologi-cal activity, which inevitably affects per-formance and other factors such as,cleaning (duration and frequency),down time and chemical dosing.

The effects of fouling increase inseverity over filtration cycles – buildingup and resulting in higher energy con-sumption. Establishing a protocol tooptimize the type of cleaning and its re-quired frequency is therefore of greatimportance. Optimization allows formore effective operational protocols tobe considered, providing an economi-cally attractive alternative to conserva-tive operating modes (Porcelli andJudd, 2010 [2]). Non-optimized sys-tems can lead to filtration cycles thatare too short, coupled with high back-wash duration and higher chemicalconcentrations during chemically en-hanced backwashes (CEB) and clean inplace (CIP) operations. This will ulti-mately result in a higher cost of pro-

duced water.In the present project, a DOW™

Ultrafiltration system has been chal-lenged with raw surface brackishunder highly variable conditions ofturbidity (5 - > 1000 NTU) and tem-perature (10 – 29ºC). In order to es-tablish the feasibility of the processconsisting of a basic filtration (hydro-cyclon and ring filter), Ultrafiltrationand Reverse Osmosis, the followingobjectives were considered:

• Assessing the viability of using direct UF as an alternative to conventional pre-treatment (coagulation/ flocculation – settling – sand filtration) in drinking water treatment

Integrated Dual Membrane Systems for Drinking Water Production Spain’s Llobregat River directs Ultrafiltration pilot plant: Operation and Optimization Experiences

By Wu Chen, Dow Water & Process Solutions

Figure 1: Process flow diagram, Barcelona unit for drinking water applications.

T


plants (DWTPs)• Evaluation of the suitability of directUF as pretreatment step for RO froma hydraulic and quality perspective

• Determination of the sustainabilityof the process (UF + RO) and characterize its performance takinginto consideration various parameters, such as water yield, reagents’ consumption, energy consumption, etc.)

• Optimizing the performance of theUF to increase the efficiency of theprocess, through controlling filtration cycles operational parameters, such as filtration duration, backwash duration, chemically enhanced backwash frequency, etc.

MATERIALS AND METHOD The work described in this paper

was developed in a pilot plant consist-ing of a UF and a RO system with directsurface water feed. Water was pumpedto the pilot plant from the Llobregat

River (Barcelona, Spain), and solelypretreated by a combination of hydro-cyclone and a ring filter. After primarystorage, the feed was sequentiallypumped to two parallel independentDOW SFP - 2880 UF modules (pres-surized outside-in PVDF hydrofilicmembranes with 30 nm pore size; 3.0– 4.6 m3/h capacity each module). Oneof the modules was employed as thecontrol line (Line – 201) and the otheras the experimental line (Line – 200).To optimize the process, modificationsin the operating sequence were firstlyimplemented in the experimental line.The benefit of the change was then val-idated from a process point of view andthe sustainability of the operation wasdemonstrated by comparing with thecontrol line. The response of changingoperational parameters with respect tovariations in feed water quality was alsoevaluated. The filtrate produced by theUF modules was purged into an inter-mediate tank, which was used to sup-ply water to the subsequent RO system

downstream (2 stage process; 4.5 m3/hnominal capacity). Permeate from stageone and two was stored in a permeatetank, while the concentrate from bothstages was discharged (See Figure 1).

RESULTS AND DISCUSSIONInitially the filtration flux was set at

50 L/m2h, and fairly conservative op-erational cleaning regimes were ap-plied: Air Scouring (AS), Air Scouring+ backwash top (AS +BWT), backwashbottom (BWB), forward flush (FF)and draining (D) were set at 75, 60,15, 20 and 30 seconds, respectively. Asthese operating conditions demon-strated stable membrane performance,backwash frequency was decreasedfrom 30 to 60 minutes. Results of thisperiod also highlighted manageableperformance, allowing for further im-plementation of constraints. However,this time, a significant reduction in theBW sequence was carried out to testthe performance outcome, so the onlyfunctioning parameters were AS +

Water | Filtration


BWT (30 s) and FF (30 s), results in-dicated a significant and irreversiblerise in fouling or TMP (Trans Mem-brane pressure). Conditions werethen altered so that the default fivesteps were implemented again but

each one with duration of 30 seconds.Once these changes were imple-mented, operation was stable at 30minutes filtration cycles, which wasthen increased to 60 minutes soonafter, showing a similar trend (Figure

2). Consequently, it was decided to re-duce the CEB frequency in order tominimize chemical usage, so an ad-justment was made from 12 hour cy-cles to once every 24 hours, yet againimplication of such a constraint

Figure 2: Normalized TMP variation along time both at theexperimental line (UF200) and the control line (UF201) at60 and 30 minutes of filtration, respectively.

Figure 3: Normalized TMP variation along time both at theexperimental line (UF200) and the control line (UF201) at24 and 12 hours of CEB frequency, respectively.

Figure 4: Varying feed and UF permeate turbidity


showed no hindrance on performance(Figure 3). More recently the operat-ing flux was increased to 60 L/m2hwith a 60 minute filtration cycle; bothUF modules continue to display satis-factory operation, however, more test-ing is required before a finalconclusion can be drawn.

Thanks to the optimization under-taken, the recovery or water yield,which is described as the ratio of waterproduced and feed water has been in-creased from 87% to 96.5%

PERMEATE QUALITYThe Llobregat River is known for

presenting a highly variable waterquality as highlighted in Figure 4,which shows that turbidity during theexperimental period ranged from 5 toover 1000 NTU. Despite the high vari-ability of the influent water, thevolatile nature of the river has a veryminimal affect on UF filtrate quality:from the middle of March 2012 untilthe beginning of September 2012, thefeed turbidity has varied significantly,whereas the filtrate turbidity averaged0.06 NTU and deviated as little as0.036 NTU.

CONCLUSIONSUltrafiltration demonstrated an

adept ability to deal with challengingsurface water conditions, becoming afeasible solution to conventional pre-treatment for drinking water treatmentplants (DWTPs). Direct UF sustain-able performance was accomplishedeven with reduced BW step duration,increased flux, increased filtrationcycle and reduced CEB frequency,achieving a water yield of 96.5% ofraw water intake for the tested condi-tions. Furthermore, UF confirmed thatonce an acceptable protocol has beenreached, a CEB and CIP could be ini-tiated every 24 hours and 3 months,respectively, ultimately reducingchemical consumption, within thetested conditions. Although the ultra-filtration application was successful,further optimization is believed still tobe possible.

The innovative scheme proposed,direct UF followed by RO, would en-compass compact systems with low

chemicals’ consumption and a rela-tively high water yield. Additionally,due to the constant and high waterquality produced by the DOW Ultra-filtration system, RO membrane life-time may also be extended, benefitingthe overall treatment scheme.

For more information email:[email protected]

AcknowledgementsThis work has been conducted under the fi-nancial support of the LIFE+ Program of theEuropean Commission within the frameworkof the UFTEC Project (LIFE09ENV/ES/000467 UFTEC).ReferencesPearce, G.K. (2008), UF/MF pre-treatment toRO in seawater and wastewater reuse appli-cations: a comparison of energy costs, De-salination 222, 66-73.Porcelli, N.; Judd, S. (2010), Chemical clean-ing of potable water membranes: The costbenefit of optimization, Water Research 44,Issue 5, 1389-1398.

FN


n many of the tough conditionsassociated with water filtration –whether dealing with coarse sep-

aration, desalination, deionization orother applications – perforated metalsprovide strength, structural integrityand flexibility for a long-lasting, cost

efficient solution.The water purification uses of perfo-

rated materials are growing more di-verse, including a wide array ofapplications that sort and manage de-bris in liquid. To match unique needs,perforated metal can be as thin as foil

or as thick as a 1½-inch steel plate,with holes punched in a wide array ofshapes, patterns and sizes from micro-scopic up to 3 inches in diameter.

Cost-efficiency heavily influencespurchase decisions. Since engineershave access to many alternative mate-

Drop in perforated stainless steel basket allows for easy removal and cleaning.

I

Water | Filtration

Perforated Metals: Clarifying OptionsFunction, selection and benefits of perforated metal in water filtration applications

By Keith Mailloux, IPA Technical Committee Chair


rials, including wire mesh, expandedmetal, PVC or plastic screens, it’s im-portant to know when and where per-forated metals are the best choice. Thisarticle will discuss the key functionsand advantages of perforated metals,as well as considerations for specifyingthe right hole configurations, metaland options.

PRIMARY FUNCTIONSPerforated Metals can be used in a

variety of ways in water filtration appli-cations, but they generally serve twofunctions better than competitive prod-ucts: Primary Treatment (Coarse Sepa-ration) and Support Cores.

Coarse Separation: Perforated met-als are commonly used as primarytreatment filters. Wastewater is passedthrough a perforated metal screen to re-move large objects and/or a series of in-crementally smaller screens to removegrit that can cause excessive wear onequipment. Typically, these filters aren’tintended to be disposable; they’re usedin a system where they’re easy to cleanoff with a scraper bar.

Support Mechanisms for other Fil-ter Media: Since pass-through open-ings in perforated metal can’t be mademuch smaller than about 1/100th of aninch, removing tinier particles requiresother filtration media. The secondcommon function of perforated metalis as a support mechanism for thesemore delicate, non-rigid filters, com-monly made from paper, Styrofoam,fabric or sintered metal. While it is pos-sible to use plastic or other materials asthe support core, perforated metal isnecessary when dealing with high pres-sures or temperatures.

Another common application is tocombine the two functions. Many fil-ters will have a perforated metal cylin-der and an inner support core with aninner filter media sandwiched in be-tween, similar to an oil filter. Theouter core serves to filter out thecoarse materials, and the inner core,usually permanently attached to thefilter material, keeps it from collapsingon itself. This type of filter is com-

monly found in large commercialbuildings, factories, power generationplants, hospitals or other buildings todemineralize and deionize water up-stream of ion exchange units or otherfiltration systems.

STRENGTH AND DURABILITYIn general, perforated metal is

stronger and more durable than otheralternatives, such as wire cloth or ex-panded metal. The perforationprocess, usually accomplished

through punching holes out of a sheetof metal, maintains much of the struc-tural integrity of the original metalsheet – enabling the design to with-stand high amounts of stress.

Because of its strength, perforatedmetal handles high-temperature andhigh-pressure applications much betterthan its alternatives. For example, dem-ineralization takes place in a high-pres-sure tank. If that pressure builds up toohigh or suddenly drops, wire cloth issusceptible to bending or breaking.


Water | FiltrationPerforated metals provide the struc-tural integrity to withstand the stresswithout adding much weight.

Perforated metals are most oftenused in commercial settings, wherepressure and temperature are a factor,rather than in residential applications,where lower-cost material functionsjust as well.

DESIGN CRITERIAMost filters are design-engineered

products, meaning their design mustmeet certain known specifications. Thetype of metal used, the hole design andsize, all impact the strength, flexibilityand capabilities. However, the sciencebehind filtration and water flow is ad-vanced enough that engineers can calcu-late pressure drop across a perforatedsurface, pressure drop against fluid flow,flow dynamics, cavitation and other fac-tors that influence design. From there,they can specify what they need in a de-sign and know with a high degree ofconfidence how the part will function.

While hole patterns are fairly con-sistent for water filtration applications,most perforators have the flexibility tocustomize tooling to meet customizeddesign requirements. They can alsoprovide recommendations for morestandard options that have similarproperties to help manage cost.

SPECIFYING MATERIALSIn the same way that the desired

flow rate and pressure gradient willdictate the hole size, the environmentwill dictate the type of metal needed.For low-cost applications, it makessense to use as thin and inexpensive ofa material as possible. However, corro-sive or high-pressures environments re-quire more robust metals. Four of themost common metals are StainlessSteel, ETP, Brass and Titanium.

Stainless Steel: Perforated stainlesssteel sheet is essentially a low carbonsteel that contains chromium at 10% ormore by weight. The chromium con-tent of the steel allows the formation ofa rough, adherent, invisible, corrosion-

Perforated filter core provides stable support and initial filter stages for outermicro-filtration media.


resisting chromium oxide film on thesteel surface. If damaged mechanicallyor chemically, this film is self-healing inmost environments.

Austenitic: Austenitic stainlesssteels are non-magnetic, non-heat-treatable steels that have excellent cor-rosion and heat resistance with goodformability over a wide range of tem-peratures. Additions of molybdenumcan increase the corrosion resistance.

Ferritic: Ferritic stainless steels aremagnetic non heat-treatable steels thatcontain chromium but not nickel. Theyhave good heat and corrosion resist-ance, in particular to seawater, andgood resistance to stress-corrosioncracking.

Martensitic: Martensitic grades aremagnetic and can be hardened by heattreatment. They are not as corrosion re-sistant as austenitic or ferritic grades,but their hardness levels are among thehighest of all the stainless steels.

ETP: Commonly called tinplate,ETP is a coated steel product composedof a thin sheet of steel, providingstrength and structural integrity, elec-trolytically coated with a layer of tin forcorrosion resistance and other protec-tive characteristics.

Titanium: While it’s one of the mostexpensive options available, Titaniumprovides the best strength-to-weight ratioamong metals – 40 percent lighter thansteel and 60% heavier than aluminum.

Inconel Alloys: Inconel refers to afamily of high strength nickel-chromium-iron alloys known for their resistance tooxidation and their ability to maintaintheir structural integrity in high-temper-ature environments. While each variationof Inconel has unique traits that make iteffective in a different circumstance, theyall stand up very well to caustic corro-sion, corrosion caused by high puritywater, and stress-corrosion cracking.

Brass: When zinc is added to copper,it forms brass, which is stronger andharder than either of the pure metalsand extremely useful for many perfo-rated metal applications. As a generalrule, corrosion resistance decreases as

zinc content increases, so brass used forwater filtration applications usually re-quires a copper content as high as 80percent and 90 percent.

CHOOSING THE RIGHT OPTIONAs mentioned earlier, there are many

different filtration options available to en-gineers. Perforated metal, expandedmetal, wire cloth or plastic polymers allpresent different advantages. It’s impor-tant to consider more than just pricewhen evaluating these options. It’s alsocrucial to understand the functional de-mands of the application and find the ma-terial that strikes the best balance betweenlong-term cost efficiency and utility.

For perforated metals, the main factorsinfluencing the cost are material cost, theperforated pattern’s level of difficulty (holesize versus material thickness, margins), tol-erances and the quantity ordered. Workingwith a member company of the IndustrialPerforators Association assures a reputableperforator and a known standard of quality.This can open up new avenues of cost sav-ings throughalternative op-tions, stan-dardized holearrangementsor new tech-nologies.

Today, thewater purifi-cation uses ofpe r f o r a t edmaterials aregrowing morediverse, andperforators arehelping pushthe bound-aries throughr e s e a r c h ,knowledgesharing andinnovation.They can bean excellentresource tohelp over-come many ofthe toughchallenges. Sowhen consid-ering water fil-

tration choices, reach out to experts in theperforation industry. They’ll help identifyspecific needs, consider options and em-brace the proven benefits and boundlesspotential of perforated materials.

This article was written by a joint collabora-tion of the members of the Industrial Perfo-rators Association (IPA). About the Industrial Perforators Association:As the only North American organization de-voted to the advancement of perforated ma-terials, the Industrial Perforators Associationcontinues to push the boundaries of whatthese materials can do. Through extensiveresearch, knowledge sharing, standards set-ting and more, the IPA provides memberswith the tools to drive innovation and in-crease utilization in perforation. In theprocess, they act as an essential resource toanyone who may benefit from incorporatingperforated materials into their design.

For more information on perforated metals,their applications and their benefits, visitwww.iperf.org

FN


Water | Filtration

evolutionary” and“New” are adjectivesgenerally reserved for

the consumer products industry, notfor the traditionally conservative waterand wastewater treatment markets.Conservative, by rights, since the pub-lic welfare is the most important con-sideration. However, there are fewwords to describe the impact of ClothMedia Filtration, the most revolution-ary innovation to influence tertiarytreatment in decades.

Tertiary filtration of secondarytreated wastewater has become more ofa focus in recent years due to evertightening discharge limits on manycontaminants. For instance, the adventof reclaimed wastewater for beneficialreuse and the establishment of totalphosphorous limits below 0.1 mg/l re-quire plant operators to provide spe-cialized levels of treatment.

Historically, deep bed rapid gravity

filters have been called upon to providethese low filtered effluent dischargelevels. That is, until a technology wasintroduced that provided the filtrationcharacteristics of deep bed filters butoffered many desirable advantages. Thetechnology is commonly referred to asCloth Media Filtration.

Textiles have been used for sometime as filtration media in a variety ofapplications. Swiss manufacturerMecana Umwelttechnik developedcloth media filter technology forwastewater filtration in the 1980s. Inthe early 1990s, Aqua-Aerobic Systemsof Rockford, Ill., utilizing the Mecanadesign, introduced it to the UnitedStates. Over the past 30 years, bothcompanies have improved the technol-ogy and have combined for the instal-lation of thousands of cloth mediafilters in a variety of applicationsaround the world.

The key to the high performance of

the technology is the cloth. OptiFiber®cloth filtration media is a woven textilehaving 13mm long bundles of fibersthat are woven into a structured, grid-like carrier fabric. In wastewater filtra-tion, the carrier fabric, or backing,serves as an underdrain of sorts. It pro-vides support for the fiber bundleswhile offering the necessary porosity toallow free flow of backwash water, re-moving solids from the fiber mediaduring cleaning.

In its natural state, the fiber bundlesare full-bodied and protrude outward,perpendicular to the backing material.Once placed into operation, or wetted,the fibers relax and overlay one an-other, creating a barrier to solids.

There are two major advantages ofpile cloth media: 1) it offers a signifi-cant amount of surface area and, 2)depth. There are literally thousands offine fibers per square foot of media,each one capable of intercepting solid

Cloth Media Filtration For Wastewater TreatmentBy Edward W. Lang, Filtration Product Manager, Aqua-Aerobic Systems, Inc.

Figure 1. Pile Cloth Active Depth illustration

Figure 2 Pile Cloth Filtration Mode illustration

“R


particles, improving the probability ofsolids removal. Once intercepted, thedepth of the media provides solids stor-age capacity to help mitigate increasedheadloss, prolonging filter run timewhile reducing backwash frequencyand waste generation (Figure 1).

The pile filtration cloth is especiallyengineered for wastewater treatmentapplication and is available in a varietyof materials of construction and filtra-tion ratings (Figure 2).

Just as the pile filtration cloth is cus-tomized, so are the available mechanicalconfigurations in which it is utilized.

DISK CONFIGURATIONThe disk format is probably the

most recognizable mechanical form ofcloth media filtration. Besides provid-ing high quality filtrate, theAquaDisk® filter’s most significant at-tribute is its ability to offer more filtra-tion surface area in a much smallerfootprint than gravity flow, granularmedia filters. For example, the foot-print area of a disk filter consumes onlyabout ¼ the footprint area of a gravity

sand filter offering the same hydraulicthroughput.

Figure 3. shows a 12 Disk Configu-ration in Concrete Basin

The direction of flow through themedia is from the outside in. This fea-ture, combined with the vertical orien-tation of the media, results in a secondsubstantial advantage – high-appliedsolids loading capacity. Compared toother gravity flow filters, cloth disk fil-ters offer more than 2x the solids load-ing capacity.

The pile cloth media disk filter em-ploys an automatic vacuum cleaning or“backwash” function. As head lossthrough the cloth increases due tosolids deposition, the operating waterlevel in the tank rises. The differentialpressure is sensed until a predeter-mined set point value is reached, sig-naling the PLC based controls toinitiate a cleaning cycle.

Upon initiation, the backwashpump energizes and the disks begin aslow, 1 rpm rotation. As the clothmedia passes over the slotted openingin the backwash shoe, the fiber bundles

are extended into the slot due to thevacuum generated by the backwashpump. This serves to actively agitatethe fibers to induce dislodging of thesolids. Within a matter of minutes, theentire media surface area of the filter iscleaned. Once cleaned, defined by thereturn of the water surface in the tankto its normal operating level, the disksstop rotating and the pump is de-ener-gized. At no time during the cleaningcycle is the filter taken off-line. It isworth noting that the cloth disks arestatic during filtration, set in motiononly for cleaning. The result is a signif-icant savings in power consumptionover other technologies.

Because of the vertical orientation ofthe disks, suspended solids havinghigher specific gravity may settle to thebottom of the filter tank. These solidsare periodically removed via timedfunction, utilizing the same pump andmanifolding used for backwashing(Figure 4).

DIAMOND CONFIGURATIONAnother mechanical design utilizes


Water | Filtration

pile cloth media in a diamond format.The AquaDiamond® filter (Figure 5)embodies the same operational princi-ples as the AquaDisk filter, i.e., pilecloth filtration media; outside-in flowpath, vacuum backwash and solids dis-charge. Because it possesses a lower hy-draulic profile than the disk format, itcan be retrofitted easily into existingshallow filter basins, i.e., travelingbridge filters.

One of the featured benefits of thistechnology is its ability to offer morethan 2x the hydraulic capacity of thegravity sand filter that occupied thesame basin prior to replacement.

SMALL DISK CONFIGURATIONThe small disk format, or Aqua

MiniDisk® filter, is a smaller scaleversion of the full-sized disk formatdescribed previously. As such, it of-fers the same high performance fea-tures as the AquaDisk filter, but isused to treat smaller flows.

All of the above-described tech-nologies provide exceptional filtratequality. For example, effluent totalsuspended solids (TSS) and turbidity(NTU) are generally less than 5.0mg/l and 2.0 NTU, respectively. Thisperformance is achievable withcloths having fine pile fibers manu-

factured from nylon, acrylic or poly-ester. A unique cloth made of Mi-crofiber construction improves TSSand turbidity removal by approxi-mately 50%. This level of perform-ance rivals that of deep bed rapidgravity filters while minimizing foot-print and life cycle costs.

The impact of cloth media filtra-tion on the wastewater treatment in-dustry is widespread. Today, in themunicipal wastewater treatment mar-ket, cloth media filtration is consid-ered during design by plant ownersand consulting engineers for almostevery project. Many times, cloth

Figure 3. 12 Disk Configuration in Concrete Basin Figure 4. AquaDisk Backwash Mode


media filtration is used to replace oldsand filters. There are some applicationlimitations for cloth media filtration. Forexample, they are not generally used fordenitrification or as a final barrier for

potable water treatment. There is nodoubt, however, that cloth media filtra-tion provides high quality filtrate thatmeets, or exceeds, state regulatory require-ments with low cost of ownership.

For more information contact:AQUA-AEROBIC SYSTEMS, INC.Tel: 1-815-639-4483 Fax 815-654-2508Email: [email protected]: www.aqua-aerobic.com

Figure 5. AquaDiamond Overview with Diamond Lateral (inset).

FN


he 2012 London OlympicGames were as much aboutthe “green” as they were

about the “gold,” and described bysome as being the greenest Olympicsto date. Not only did the Olympic or-ganizing committee and sponsors dotheir parts in ensuring a green ap-proach to constructing and operatingthe Olympic venues, but the apparelcompanies designed sustainableclothing and accessories, which wereworn by the athletes.

According to the website of amajor apparel company, each uniformthat the USA men’s basketball team

wore was made from 22 recycled plas-tic bottles. Several countries andteams proudly wore uniforms featur-ing material that was largely madefrom recycled content. This was amajor accomplishment consideringthe importance given to the functionof the athletic wear.

Polyester fiber is the most com-mon building block for sustainableclothing and delivers high perform-ance for flexible, light-weight, re-duced-wind, and drag-resistantfabrics. However, in order to producesuch athletic garments from recycledmaterials, the quality of the recycled

polyester fiber needs to be on parwith that of virgin material.

Pall Corporation is a leader in fil-tration, separation and purificationand has been providing filtration so-lutions to the textile industry sincethe 1960s. In recent years, Pall’s tech-nology has extended into the recy-cling industry and has enabled theproduction of high-quality fibersfrom recycled feed stock. Pall helpsits customers to enable a greener,safer future and has once again beennamed one of the greenest companiesin America by Newsweek magazine.

Chung Shing Textile Company was

T


Advanced Filtration Technology Enables the Production of High-Quality Recycled PETFibers for the Textile IndustryBy Raj Shah, Pall Corporation

Advanced Filtration Technology Enables the Production of High-Quality Recycled PETFibers for the Textile IndustryBy Raj Shah, Pall Corporation


founded in Taiwan in 1949. It is afully integrated, large-scale textilemanufacturer engaged in chemicalfiber manufacturing, yarn spinning,weaving, dying & printing, and gar-ment manufacturing. Chung ShingTextile operates an 850-ton per daymanufacturing site at Yang-MeiChemical Fiber factory in Taiwan,where it produces virgin-grade poly-ester fibers and chips for textile use.

Synthetic fiber production and pro-cessing is a chemically intensiveprocess that is costly and draws onlimited natural resources. As an eco-conscious corporation, Chung Shing

Textile believes in contributing to en-vironmental sustainability and oper-ates under the 3R waste managementprinciple (Reduce, Reuse, and Recy-cle). In fact, in 2005 it started manu-facturing high-quality PET textilefiber from recycled plastic bottlewaste. These fibers are currently mar-keted under the “GreenPlus” brandand are used in a wide variety of tex-tile applications by leading manufac-turers of popular brands. GreenPlusfibers are certified by Oeko Tex Stan-dard 100 (Certificate Number: TPYO055042) and Greenmark (CertificateNumber: 3159).

GREENPLUS FIBER PROCESSPost-consumer PET bottles are col-

lected at communities and recyclingcenters throughout the world. The bot-tles are baled and brought to a process-ing facility, where they are sorted bytype (PET, HDPE, LDPE, etc.) andcolor. The PET bottles are thenstripped of their labels and caps andwashed multiple times to remove anyadhesives and other possible contami-nants. Next, the bottles are crushedand chopped into flakes. The smallflakes are fed into an extruder, filtered,and spun through spinnerets to pro-duce recycled PET fiber. The fiber is

Large photo shows used plastic bottles of various kinds, and after they are turnedinto bales (insert) from Chung Shing Textile.



crimped, cut, drawn, and stretchedinto required lengths for baling. Baledfiber can be processed into fabric for avariety of textile products.

CHALLENGE OF HIGH-QUALITY FIBERSPolyester fibers made from post-

consumer bottles are expected to be ofequal quality to those produced fromvirgin raw materials. These fibersshould possess the same desirableproperties including strength, abrasionresistance, flexibility, and moisture ab-sorption. While good for the environ-ment, recycled fibers present a realchallenge to manufacturers, as the pri-mary feed stock (recycled PET flakes)can vary considerably in quality.

There are several reasons why the

quality of recycled fibers may vary:

• The feed stock is from different sources (water bottles, soft drinks, detergents, and other packaging containers).

• Washing and other technologies used for converting the bottles into flakes can differ substantially between processors.

• Recycled flakes may contain impurities such as paper, metal, foil,other polymers, sand, or dirt.

As a result, melt filtration must playan important role in the recyclingprocess by removing contaminants andensuring consistent, high-quality feedstock. This crucial step is necessary to

eliminate variance in the feed stockquality, which ultimately will impactthe end fiber quality.

Two technologies are typically usedduring the melt filtration process:

1) Screen changers2) High-area duplex-style

continuous melt filter systems

Screen changers allow operators tocollect hard contaminants on wovenwire screens during the extrusionprocess. They are easy to use, butoffer limited filter area and thus plugup very rapidly, resulting in undesir-able polymer shearing and high dif-ferential pressure. They also requiremultiple daily interventions, result-

CPF System from Pall


Inside Chung Shing Textile plant


ing in an unstable operation thatlasts a few hours on-stream at best.Even the most expensive and sophis-ticated screen changers result in dis-continuous operation. In general,screen changers are considered basictechnology and are hardly ever pre-ferred by any fiber producer.

High-area continuous melt filtersystems allow operators to run sub-stantially longer with less downtimethan screen changers. These systemsoffer clear advantages when process-ing recycled materials, as well as ma-terials that require long run cycles.Continuous melt filter systems areoften the technology of choice.

Chung Shing Textile had beenrunning a duplex-style filter systemfor processing its recycled fibers. AEuropean textile company suppliedthe duplex filter system, which used

a plug-style diverter valve thatcaused polymer degradation andrapid plugging of the filter elements.The on-stream life of the filter wasonly 1-2 days, requiring expensivechangeovers and considerable downtime. More importantly, the quality ofthe resulting fibers was not compara-ble to that of fibers made from virginmaterial.

PALL’S ADVANCED FILTRATION TECHAfter reviewing the polymer feed

stock and operating conditions, Palloffered its duplex-style ContinuousPolymer Filter (CPF system®) cus-tomized to suit process requirements.Pall’s CPF technology uses apatented, contoured spool-type di-verter valve and is designed for usein various polymer melt filtrationprocesses. To date, Pall has sold over

2600 CPF systems, many of them inpolyester fiber production processes.

Chung Shing Textile has adoptedPall’s model 100 CPF system acrossits 11 chip spinning lines. Currently,five of the lines are used to produceGreenPlus fiber. The system was de-signed to use filter elements madewith Pall’s Dynalloy® filter media –a premium nonwoven type sinteredmetal fiber media suitable for remov-ing hard and soft gelatinous contentthrough its tapered pore geometry.The results were immediately notice-able – the operation became stableand on-stream filter life increased to7-8 days.

“Pall’s CPF technology enabled usto achieve the high-quality recycledpolyester fiber that is comparable tovirgin fiber,” said Mr. Dai, ChungShing Textile plant manager. “The

Chung Shing Textile operates an 850 ton per day manufacturing site at Yang-Mei Chemical Fiber factory in Taiwan, where itproduces virgin-grade polyester fibers and chips for textile use.


CPF system is a compact and provendesign ideally suited for such fiberprocesses. The system provides con-sistent fiber quality and improvedon-stream filter life with minimal op-erator intervention. This was funda-mental in lowering our cost ofproduction. We are proud of ourGreenPlus fiber product and its wide-spread use at the 2012 LondonOlympic Games.”

RESULTSSince its beginning in 2011,

GreenPlus fiber capacity has ex-panded to five production lines total-ing 56 MTD. Each production line isnow retrofitted with Pall’s CPF tech-nology for high-quality continuousfiber production. The next step is toextend the on-stream life of the fil-ters by introducing Pall’s innovativeUltipleat® Polymer Candle elementsinto the existing systems.

PALL CORPORATIONPall Corporation is a filtration, sep-

aration and purification leader provid-ing solutions to meet the critical fluidmanagement needs of customers acrossthe broad spectrum of life sciences andindustry. Pall works with customers toadvance health, safety and environmen-tally responsible technologies. Thecompany’s engineered products enableprocess and product innovation andminimize emissions and waste. PallCorporation is an S&P 500 company,serving customers worldwide. Pall hasbeen named by Newsweek magazine “atop green company.”

CHUNG SHING TEXTILE COMPANYChung Shing Textile, founded in

1949, is a fully integrated, large-scaletextile manufacturer based in Tai-wan. It includes five operating divi-sions: chemical fiber manufacturing,yarn spinning, weaving, dying &

printing, and garment manufactur-ing. All are vertically integratedthrough a comprehensive coverage ofthe upstream, midstream and down-stream operations. Its capital hasskyrocketed from the initialNT$40,000 to today’s NT$8.4 billion.

The company markets its productsboth at home and abroad underbrand names, which have becomesynonymous with quality.

For more information contact:Raj ShahPall CorporationTel: 1-386-822-8014Fax: 1-386-822-8010 Email: [email protected]: www.pall.com


FN

reservoir between the filter,which is cleaning thecoolant, and the high pres-

sure pump, which is using the coolant,is an important component to protectthe pump and the filter, regardless ofthe system’s size

The objective of this article is to ex-plain what happens in machining op-erations which use high pressure

pumps to feed coolant to flow-throughtools or other nozzles where a higherthan normal pressure is needed. Highpressure pumps are incorporated tomeet the needs, which can range from300 psi to as high as 5000 psi. Thesepumps have precision components andmust have cleaner coolant to mainlyprotect the pump as well as protect thesensitive tools. Applications needing

pressures just below 300 psi are usuallyhandled by pumps, which are more tol-erant of some contamination in thecoolant. But they still need better qual-ity fluid for the operations they serve.

The filter for the high-pressure sys-tem can be the primary filter for theprocess or could be a secondary “pol-ishing” filter, which enhances the clar-ity of the coolant received from a mainfilter. In either case, the filter discussedhere is dedicated to the needs of thehigh pressure pump.

Large systems serving several sta-tions are usually designed with a reser-voir because of the volume needed.Figure 1 shows a typical schematicwith the needed controls to insure safeoperation and easy start up.

However, individual machines maynot need all the elaborate controls butshould use a reservoir as part of thesystem’s design to serve the filter andpump.

TYPICAL EFFECTIVE SYSTEMFigure 2 shows a typical reliable

arrangement where the tank (sized forthe flow) helps the filter and the pumpperform their functions. The reliabilitycomes from:

•The filter sees a constant flow totally independent of the pump’s cycle, which usually is intermittent.Continuous flow does not constantly “pulse” the filter’s surfacewhich can adversely affect the element’s performance and life; particularly for bag filters.

•The continuous overflow from the reservoir to either the machine’s sump or systems main tank, allows



The Best Practice for Supplying Filtered Coolant to High Pressure PumpsBy James Joseph, Joseph Marketing

A


the filter to maintain the coolant’s clarity all the time. It is like a sidearm filtration loop. If overflow is not possible than level controls can be used in the reservoir. They will at least reduce the cycling of thefilter’s flow.

•The high pressure pump has a constant suction head of liquid so its output will be stable. A variablesuction head can cause starving or even cavitation, both of which can shorten pump life.

This is the best practice and beloware two schematics of familiar existingsystems applied to individual ma-chines. Their schemes are compared tothe Figure 2 layout to show their vul-nerability. This is not an indictment onthe designers of these systems. Manyof these designs were developed tostay within the limits of space andmoney. Others may have evolved asthe needs in the machine’s operationschanged and high pressure pumpswere added to the station. They allwork and serve needs. However, theydo have weaknesses, which everyoneshould be aware of and try to avoidwhere possible.

TWO PROBLEMATIC ARRANGEMENTSFigure 3 shows the most common

arrangement where the filter is tieddirectly to the suction of the highpressure pump. It is an in-line filtertrying to keep up with the demands ofthe pump.

Vulnerability1. As the filter loads, the flow

through it is throttled back and thepump is sensing a dropping suctionhead. The flow can be cut so low thatthe pump is starved and could cavitate,which shortens its life and creates prob-lems with the tools on the machine.Many systems have automatic by pass,which just sends dirty liquid to thepump. Some of these are fitted with vi-sual indicators that often go unnoticed.

2. The pump usually cycles on and

off or diverts flow as the station goesthrough its machining sequence.The constant change in flow and pres-sure can routinely pulse (flex) the filtereach time, and two things can happen:

• The element flexing can reach a point to possibly rupture the surface or cause channeling wherethe cake and media open up allowing dirty liquid to flow through uncontrolled


• When flow is stopped the cake canslide down on the media, which adversely affects the filters ability tooffer uniform cake filtration

Figure 4 reflects another commonarrangement where the filter is sand-wiched between the discharge of theprimary supply pump and the suctionof the high pressure pump.

This arrangement is similar to Fig-ure 3 except the difference is that Fig-ure 3 shows the filter receiving coolantfrom a common manifold or a pumpwhich is serving more functions andnot dedicated to the filter. This pump isconnected only to serve the filter.

Vulnerability

1. The same set of problems de-scribed for Figure 3 occurs here as well.

2. The problems above are furtheraggravated with the normal variancesoccurring in the pressure changes inthe pumps. The pressure differential

across the media can be generated bythe pressure changes between thepumps only. The element should onlybe affected by the force of one pump,not both. As the element gets dirty itcould easily be the variances in the twopumps’ pressures, which push the ele-ment to its set point and call for achange. This would be a prematurechange since the element itself is not“dirty” enough to be changed on con-tamination only.

SUMMARYThe basis of this article is to stress the

importance of an intermediate reservoirworking in conjunction with the filter toserve the high pressure pump. The keyis to filter the liquid for the reservoir andthen let the high pressure pump drawclean coolant from it.

Jim Joseph is a member of InternationalFiltration News' Editorial Board and an industry consultant for coolant filtration.Tel/Fax: 1-757-565-1549 Email: [email protected]

Filtration

Mergers, Acquisitions

and Divestures

GL Capital, LLC

We understand the nuances ofthe domestic and internationalfiltration industry and bringover 70 years of combinedbusiness, technical and finan-cial expertise. The current eco-nomic climate is an ideal timefor sellers to locate buyersseeking to diversify and forbuyers to identify growth op-portunities through acquisition.

For a confidential conversation contact:

Edward C. Gregor704-442-1940

[email protected]

P. John Lovell719-375-1564

[email protected]

FN


Read International Filtration News online: www.filtnews.com


FN

News | Briefs

he world of filtration and sep-aration will come to Germanyfor FILTECH 2013 from Oc-

tober 22nd through the 24th. Thelargest filtration show worldwide willfeature 300 exhibitors and will be ac-companied by a three-day conferencepresenting the latest filtration and sep-aration research to an international au-dience from around the world.

The FILTECH Congress will offera representative cross section of cur-rent research findings, global devel-

opments, and new approaches tosolving problems with respect to themethods for the classic mechanicalseparation of particles from liquids,the gas cleaning and membrane fil-tration methods. This ranges frommineral dressing to biotechnology,pharmaceuticals, and chemicalsright up to environmental technol-ogy and water purification. Specialhighlights are a plenary and six sur-vey lectures in which internationallyrenowned experts give a comprehen-

sive overview of state of the artknowledge and techniques concern-ing important aspects of separationtechnology. In addition, one dayprior to FILTECH 2013, two one-dayShort Courses will be held featuring“Fine Dust Separation” and “Solid-Liquid-Separation."

Congress language is English. Ab-stracts can be submitted until Febru-ary 14, 2013. Details for abstractsubmission and stand booking areavailable at www.filtech.de.

T

lugged nozzles, coated heatexchange surfaces and dirtychillers are not only a costly

maintenance item but result in higheroperating costs. The only way to pre-vent this potential is to remove sus-pended solids from the distributionsystem. The OR-Series of filters by Ori-val, Inc. are designed to reliably removeboth organic and inorganic suspendedsolids. With their highly efficient flush-ing systems and large screen areas, Ori-val OR Filters provide superiorperformance and quick payback. ORfilters are generally mounted in a hori-zontal configuration parallel to the pip-ing for quick and easy installation. TheORG-Series of Orival Filters offer thesame qualities and performance but ina vertical mounting configuration. Pay-back on investment has been docu-mented as quickly as 33 days for flowrates of 1100 gpm. Rugged OR andORG Filters, with their stainless steelscreens and rugged dirt collectors, donot rely on electricity for filter opera-tion. A simple integrated hydraulic sys-

tem manages the short cleaning cycletriggered by a predetermined pressureloss across the dirty screen. Completescreen cleaning takes only 5-15 sec-onds with no interruption of waterflow. Sizes are available from 1½” to

24” with screen openings from 3000microns down to 10 microns.

For more information: Email: [email protected]: www.orival.com

PEliminating High Maintenance Costs with Orival Filters

Orival Filters

FN

Call for Papers for FILTECH 2013

Did you know that...The American Filtration and Separations Society (AFS) Spring Conference is May 6-9th. The AFS is the largest Filtration Society in the world and the principal educator of the industry. AFS Corporate Sponsorships have increased 157 percent since 2009.For more information visit: www.afssociety.org


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ALL OTHER COUNTRIESKen NorbergEditor, International Filtration NewsPO Box 265Winchester, TN 37398 USATel: 1 202 681 2022Email: [email protected]

A2Z Filtration Specialities 11 www.a2zfiltration.comAFS Conference Inside Back Cover www.afssociety.orgAhlstrom 5 www.ahlstrom.comAir Filter, Inc. 9 www.airfilterusa.comAshby Cross Co. 10 www.ashbycross.comClack Corporation 35 www.clackcorp.comContract Pleating Services 29 www.solentech.comDexmet Corporation 21 www.dexmetfilter.comFerguson Perforating 21 www.fn.perfnow.comFlow Ezy 30 www.flowezyfilters.comIndustrial Netting 37 www.industrialnetting.comJCEM-USA 1 www.jcem.chMagnetool Inc. 27 www.magnetoolinc.comMetalex 39 www.metlx.comMetcom Inc. 37 www.metcomusa.comOrival Inc. 15 www.orival.comPerCor Mfg. 35 www.percormfg.comPerforated Tubes 19 www.perftubes.comRosedale Products 3 www.rosedaleproducts.comSealant Equipment 25 www.sealantequipment.comSolent Technology Inc. 31 www.solentech.comSonobond Utrasonics 23 www.sonobondultrasonics.comSpinTek Filtration Back Cover www.spintek.comXinxiang Tiancheng Aviation Inside Front Cover www.tchkjh.com

spintek filtration: improving aqueous coalescers · brane filter. she was fine, but asked john to...

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