Membrane System

Membrane
types
Membrane Shapes

To combine process requirements with economical aspects

membrane manufacturers have developed a multitude of
membranes in different shapes:

 Flat Sheet Membranes

 Cassette Membranes
 Spiral Wound Membranes
 Hollow Fibre Membranes
 Tubular Membranes
 Membrane Bags
Frame Systems
 Always the same principle but in different shapes
(round, square, oval)
 Some membranes directly on a support plate others self-supporting
  Tubes with different diameters
Spiral Wound Membranes in Tubes
(2.5, 4, 6 and 8 inches)
 Different Feed and / or permeate spacers (diamond or parallel)
Make up most of the membrane
filtration market today.
Allows for high density of membrane
area, ease of replacement, and a
durable construction.
Tubular Membranes in Tubular Housings
 Hollow Fibre Membranes
 Single Channel Tubular Membranes
 Multichannel Tubular Membranes

Used in applications where viscosity or

suspended solids limit crossflow in
spiral membranes.
Very popular in the juice industry due to
pulp and cellulose in the feed product.
Tubular membranes
Ceramic membranes, used
primarily in the pharmaceutical
industry because of their steam
sterilization tolerance

Available only in the

microfiltration range.
Very expensive installation.
 Utilize a sintered membrane
Stainless Steel Membranes
surface on a perforated
stainless steel substrate.
Used in corrosive applications,
or where absolute pore size is
needed.
Available only in MF or loose
UF cutoff.
Types of
filtration
Membrane Rejections
Bacteria
MF UF NF RO

Fat

Protein

Lactose

Minerals

Water

0.1 - 10.0 m 0.01 - 0.1 m 0.001 - 0.01 m <0.001 m

75 psi 45 - 150 psi 150 - 450 psi 450 - 600 psi
Micro Filtration (MF)
 Porous Filters for filtration by particle seize
 Applied Pressure 0.5 - 4 bars

Common applications:

 Removal of fat from dairy

streams.
 Removal of bacteria
(“Cold Pasteurization”)

REM picture of a MF-Membrane

Ultrafiltration (UF)

 Porous Filters for filtration by molecular seize

 Applied Pressure 0.5 - 4 bars
Common applications:
 Used primarily for protein
fractionation

REM picture of a UF-Membrane

Nanofiltration (NF)

 Diffusion Filters
 Applied Pressure 5 - 30 bars

Common applications:
 Used for demineralization of whey.
 Increased concentrate solids
Reverse Osmosis (RO)
 Diffusion Filters
 Applied Pressure 10 - 150 bars
Common applications:
 Pre-concentration
 Removal of water prior to evaporation.
 Fractionation
 Removal of specific solids from the feed stream.
 Solids Recovery
 Retention of product for re-introduction to the process.
 Clarification
 Removing soils from a re-used liquid.
 Water re-use
 Recovery of condensate for re-use as cleaning water.
 Chemical Recovery
 Recovery of spent caustic from CIP streams.
Osmosis

 … is the movement of Solvent from a Dilute Solution to a more

Concentrated Solution

 Osmosis in nature:

Evaporation of Water Mineral Concentration

Concentration of Salts at roots too high:
Water transport
reversed!
Transport of Water and
Nutrients Plant dries out!
The principle of Osmosis

The higher Chemical

Potential of the pure water
drives the water through the
membrane into the right
chamber until….

Semi permeable membrane Sugar Soln.

Pure Water
The principle of Osmosis
Atmospheric Pressure

Hydrostatic Pressure
compensates remaining
difference in Chemical
Potential

Hydrostatic = Osmotic
Pressure Pressure

Pure Water Sugar Soln.

The principle of Reverse Osmosis
Reverse Osmosis is the opposite of Osmosis:

 Solvent is moved from a Concentrated Solution to a

more Dilute Solution

This process counteracts the natural process:

 Solvent is moved from a Concentrated Solution to a more Dilute

Solution
 Therefore external energy has to be applied
 Pressure > Osmotic Pressure!
The Difference Osmosis – Reverse Osmosis

Osmosis Reverse
Osmosis

Pure Water
Sugar Soln. Sugar Soln.
Pure Water

The Membrane for RO requires the reverse permeability!

Reverse Osmosis Demonstration
(Begin) External
Pressure
=
Osmotic
Pressure

Osmotic
Pressure

Pure Water
Sugar Soln.
Reverse Osmosis Demonstration
(Cont.) External Pressure > Osmotic
Pressure

Concentration increases
Osmotic Pressure increases
Pure Water
Sugar Soln.
Reverse Osmosis Demonstration
(End) External Pressure = Osmotic
Pressure

Osmotic Pressure equals

maximum applicable External
Pressure

Pure Water Sugar Soln.

Trends during a Reverse Osmosis
Process
External Pressure

Osmotic Pressure

Concentration

Time
Batch Operation with complete Retentate Recycling

Feed
Back Pressure Valve

Permeate
Retentate
Tank

Membrane Module

Circulation Pump
Batch Operation with partial Retentate Recycling

Back Pressure Valve

Permeate
Feed
Tank Re-circulation loop
Return line

Membrane Module

Circulation Pump Re-circulation Pump

Single Path Operation

Concentrate

Back Pressure Valve

Permeate
Feed
Tank

Membrane Module

Circulation Pump
Feed and Bleed Operation

Concentrate
Back Pressure Valve

Permeate
Feed
Re-circulation loop
Tank

Membrane Module

Feed Pump Re-circulation Pump

Serial Multistage Feed and Bleed Operation

Feed
Concentrate

Tank Permeate

Re-circulation Pumps

Feed Line
Feed Pump
Application
areas
Applications for Membrane Filtration
Microfiltration
 Effluent Treatment

 Paint Recovering

 Cleaning Solutions

 Fat Removal (Whey Processing)

 Bacteria Removal ( Dairy “Bactocatch”)

 Fruit Juice Clarification

 “Sterile” Filtration of Beer

 Water Filtration

 Filtration of Latex Milk

 Sterile Filtration of Water

Applications for Membrane Filtration
Ultrafiltration
 Cheese Production

 Protein Processing /Fractionating

 Fruit Juice Concentration

 Production of Antibiotics

 Water Filtration

 Effluent Treatment

 Filtration of Photographic Emulsions

Applications for Membrane Filtration
Nanofiltration
 Cheese Production

 Effluent Treatment

 Water Treatment

 Whey Treatment
Applications for Membrane Filtration Reverse Osmosis

 Desalination of Sea Water

 Whey Concentration

 Effluent Treatment

 Filtration of Brackish Water

 Ultra clean water (Production of Semiconductors)

Requirements
on membrane
cleaners
Requirements on Membrane Cleaners

 Non aggressive regarding various membrane materials

 High chemical activity to provide cleaning power
 Easy to rinse, no residues on membranes
 Effective regarding a wide range of different soil
The use of Enzymes

Most enzymes work in ideal pH-ranges for

membrane cleaning, but their application also has limits:

 Persistence of Lipase
 Coating or carrier material (e.g. Titanium dioxide)
 Side activities of Amylase regarding Cellulose (Membranes!)
 Price and limited market segment for Pectinase, can be replaced by
oxidisers in many cases (ceramic or chlorine resistant polysulphone
membranes)
Typical problems when using straight caustic soda as a membrane
cleaner

 High pH - or little active material

 Precipitation of water hardness
 Not effective regarding many kinds of soil
 Not always inexpensive considering all process parameters as:
- time
- water
- energy
- life span of membranes
Concentration dependent cleaning effect of NaOH and a
Membrane Cleaner regarding different types of soil
[%] Removed soil
100
90
80
70
60
50
40
30
20
10
0
0 0.5 1 1.5 2 2.5 3 3.5 4
Membrane cleaner with all three kinds of soil [%] Concentration

NaOH with: Soil A, Soil B, Soil C

Membrane Cleaners

Membrane cleaners are different from standard industrial

cleaners because:

 Most membranes are rather sensitive regarding chemical

and physical impact

 Also during cleaning the membrane works as a filter

 ...
P3-ultrasil® Product Range
for Cleaning in Food and Beverage Industries

P3-ultrasil® 02 L P3-ultrasil® 65 L
P3-ultrasil® 10 S P3-ultrasil® 67 L
P3-ultrasil® 11 S P3-ultrasil® 69 New L
P3-ultrasil® 25 L P3-ultrasil® 73 L
P3-ultrasil® 41 S P3-ultrasil® 78 L
P3-ultrasil® 53 S P3-ultrasil® 110 L
P3-ultrasil® 54 S P3-ultrasil® 115 L
P3-ultrasil® 60 A L P3-ultrasil® 130 L
P3-ultrasil® 62 L P3-ultrasil® 141 L
P3-ultrasil® Product Range
for Cleaning in Food and Beverage Industries

P3-ultrasil® 02

P3-ultrasil® 02 is a surfactant-based cleaner used to remove tenacious

soil. Especially when dealing with vegetable fat and oil containing
soils,
P3-ultrasil® 02 shows best results.

P3-ultrasil® 02 may be used on its own or, if the nature of the soil
requires also other cleaning components than surfactants, in
combination with other neutral or alkaline P3-ultrasil products.
P3-ultrasil® Product Range
for Cleaning in Food and Beverage Industries

P3-ultrasil® 10

P3-ultrasil® 10 is a cleaner suited for cleaning any kind of alkaline

resistant filtration membrane. Another field of application is the
cleaning of organic TechSep-Membranes in dairies.
P3-ultrasil® Product Range
for Cleaning in Food and Beverage Industries

P3-ultrasil® 11

P3-ultrasil® 11 is a cleaner suited for highly alkaline resistant

membranes, especially Polysulphone, Polypropylene and
Ceramic Membranes used in food processing industries.
P3-ultrasil® Product Range
for Cleaning in Food and Beverage Industries

P3-ultrasil® 25

P3-ultrasil® 25 should be only used to clean membranes resistant

against available chlorine. In most cases it is advised not to
exceed a temperature of 35°C.
P3-ultrasil® Product Range
for Cleaning in Food and Beverage Industries

P3-ultrasil® 41

P3-ultrasil® 41 is a powder product based on alkaline substances in

combination with available chlorine.
P3-ultrasil® 41 is especially applied when cleaning chlorine resistant
spiral wound membranes used in dairy processes. Due to its high
amount of available chlorine (a 1% solution contains 540 ppm
available chlorine) it is sufficient to apply the product with an initial
concentration of 0.4 %. Due to the usual chlorine consumption
during the cleaning process the concentration should be maintained
at a level of 200 ppm available chlorine during the whole cleaning
time by adding P3-ultrasil® 41.
P3-ultrasil® Product Range
for Cleaning in Food and Beverage Industries

P3-ultrasil® 53
P3-ultrasil® 53 is a neutral, enzyme-based cleaner for cleaning pH-
sensitive membranes, e.g. cellulose acetate membranes. An
additional application is the soaking of membranes over night or
over the weekend to remove tenacious protein residues on
membranes.
P3-ultrasil® Product Range
for Cleaning in Food and Beverage Industries

P3-ultrasil® 54

P3-ultrasil® 54 is especially designed for the cleaning of electro-

dialysis (ED) plants. Consisting of a unique combination of
ingredients that will not adversely affect or foul ED-membranes,
P3-ultrasil® 54 is far more effective than any other product. By
using P3-ultrasil® 54 it is possible to replace a three-step-cleaning
(acid / alkaline / acid) by a single shot cleaning. The cost savings
can be easily calculated considering the gain of production time.
P3-ultrasil® Product Range
for Cleaning in Food and Beverage Industries

P3-ultrasil® 60 A

P3-ultrasil® 60 A is a buffer system that permits even to clean the

most pH sensitive cellulose acetate membranes. Usually it is
applied in combination with P3-ultrasil® 62. The product is
applied for cleaning membranes used in dairy, brewing and
potato starch manufacturing processes.
P3-ultrasil® Product Range
for Cleaning in Food and Beverage Industries

P3-ultrasil® 62
P3-ultrasil® 62 is an enzyme based cleaner containing both
protein and glucane removing enzymes. Due to its special
combination the product may be used to clean membranes in
dairies as well as membranes used in breweries. In contrast to
many other enzyme-based cleaners for removing glucanes, P3-
ultrasil® 62 does not adversely affect cellulose or cellulose acetate
membranes. Using tailor suited enzyme types, the undesired side
effect of the conventional enzyme glucanase is prevented.
Therefore P3-ultrasil® 62 may also be used for cleaning dialysis
(usually cellulose) membranes and sensitive cellulose acetate
membranes.
P3-ultrasil® Product Range
for Cleaning in Food and Beverage Industries

P3-ultrasil® 65
P3-ultrasil® 65 was especially developed for cleaning beer
filtration equipment. It may be used for cleaning cross flow
filtration membranes as well as dead-end filters. Due to its
enzyme activity P3-ultrasil® 65 destroys cellulose and cellulose
derivatives when regularly applied.
P3-ultrasil® Product Range
for Cleaning in Food and Beverage Industries

P3-ultrasil® 67

P3-ultrasil® 67 is a special new enzymatic cleaner enforced by

selected surfactants for cleaning whey and milk processing
filtration equipment in dairies. P3-ultrasil® 67 is suited for
cleaning micro-, ultra-, nanofiltration, reverse osmosis and
electro-dialysis plants.
P3-ultrasil® Product Range
for Cleaning in Food and Beverage Industries

P3-ultrasil® 69
P3-ultrasil® 69 is a buffering and sequestering system to be used in
combination with enzymatic P3-ultrasil 67 for cleaning of
filtration equipment in dairy applications.
P3-ultrasil® 69 maintains the pH value of the cleaning solution
within the optimum pH range of about 9, counteracting the effect
of a decrease in pH due to the formation of acidic components as a
result of the cleaning process. Depending on the amount of soil
further additions of P3-ultrasil® 69 during the cleaning process
may be required.
P3-ultrasil® Product Range
for Cleaning in Food and Beverage Industries

P3-ultrasil® 73
P3-ultrasil® 73 is an acidic cleaner providing antimicrobial effects. It
contains no phosphorus. The main field of application is the cleaning
of spiral wound membranes in dairies, but is also suited to clean
membranes in fruit juice manufacturing as well ceramic MF and UF
membranes. P3-ultrasil 73 may be also used as a preservative. In case
of long term soaking it is advised to follow the soak period with
P3-ultrasil® 73 by an alkaline cleaning step in order to re-establish full
permeate flux.
P3-ultrasil® Product Range
for Cleaning in Food and Beverage Industries

P3-ultrasil® 75
P3-ultrasil® 75 is a combination of phosphoric and nitric acid
that may be used for cleaning nearly all kinds of membranes
requiring an acidic cleaning step. The usually applied
concentration is 0.3 %.
P3-ultrasil® Product Range
for Cleaning in Food and Beverage Industries

P3-ultrasil® 110
P3-ultrasil® 110 is a liquid, moderate alkaline cleaner that may be
used on its own as well as in combination with peroxide-based
cleaning boosters. P3-ultrasil® 110 is a liquid alternative to
P3-ultrasil® 10.
P3-ultrasil® Product Range
for Cleaning in Food and Beverage Industries

P3-ultrasil® 115
P3-ultrasil® 115 is a liquid alternative to P3-ultrasil® 11. Therefore
it shows a very similar application profile.
P3-ultrasil® 115 is suited for highly alkaline resistant membranes,
especially Polysulphone, Polypropylene and Ceramic Membranes
used in the food processing industry.
P3-ultrasil® Product Range
for Cleaning in Food and Beverage Industries

P3-ultrasil® 130
P3-ultrasil® 130 is a liquid surfactant-free alternative to P3-ultrasil®
115. Therefore it shows a very similar application profile. P3-ultrasil®
130 is suited for highly alkaline resistant membranes, e.g.,
Polysulphone, Polypropylene and Ceramic Membranes used
especially in the beverage industry.
P3-ultrasil® Product Range
for Cleaning in Food and Beverage Industries

P3-ultrasil® 141
P3-ultrasil® 141 is a liquid, moderate alkaline cleaner that may be
used on its own as well as in combination with peroxide or
available chlorine-based cleaning boosters. Generally spoken
P3-ultrasil 141 may be considered as a substitute for the powder
product P3-ultrasil® 41.
Generally, products should be never mixed in their concentrated
form. To prepare combined solutions only blend in use solution!
Membrane cleaning
products
for pharmacos
P3-cosa FLUX, the Product Range
for Cleaning in the Pharmaceutical Industry

P3-cosa FLUX 22 L
P3-cosa FLUX 33 L

P3-cosa FLUX 44 L
L
P3-cosa FLUX 48
L
P3-cosa FLUX 55
P3-cosa FLUX, the Product Range for Cleaning in the
Pharmaceutical Industry

All P3-cosa FLUX products are strictly produced under GMP

guidelines. Assistance for validation procedures in form of detection
methods exclusively valid for the P3-cosa FLUX range is available
upon request.
P3-cosa FLUX, the Product Range
for Cleaning in the Pharmaceutical Industry
The Service Company

P3-cosa FLUX 22
P3-cosa FLUX 22 is a special blend of selected surfactants
supporting all other P3-cosa FLUX products to penetrate and
remove fat containing residues.
P3-cosa FLUX the Product Range for Cleaning in the
Pharmaceutical Industry

P3-cosa FLUX 33
The Service Company

P3-cosa FLUX 33 is a high alkaline cleaner removing organic foulants

on pH resistant membranes. In combination with P3-cosa FLUX 22 it
also can remove fat containing residues.
P3-cosa FLUX the Product Range for Cleaning in the
Pharmaceutical Industry

P3-cosa FLUX 44
P3-cosa FLUX 44 is a mild alkaline and surfactant-free product that can
be applied in combination with P3-cosa FLUX 22 or P3-cosa FLUX 48 to
remove all types of protein and fat containing residues. Used on its own,
P3-cosa FLUX 44 easily removes organic foulants from pH sensitive
membranes.
P3-cosa FLUX the Product Range for Cleaning in the
Pharmaceutical Industry

P3-cosa FLUX 48
P3-cosa FLUX 48 is a surfactant-containing blend of enzymes to
remove proteins and fat.
P3-cosa FLUX the Product Range for Cleaning in the
Pharmaceutical Industry

P3-cosa FLUX 55
P3-cosa FLUX is a blend of inorganic acids to remove salt residues
caused by water hardness or even nutrients for fermentation solutions.
Cleaning
conditions
Conditions to Clean a Membrane
Filter
 The best membrane cleaner will fail where the conditions for
a successful cleaning process are not present

 There are several rules that have to be followed to guarantee

the success of a cleaning process
Factors Influencing Membrane Cleaning

Soil

Water Quality Plant Design

Membrane Material
on cleaning
[%] Fat removal under standardised conditions
100
90
80
70
60
50
40
30
20
10
0
Glass Steel 304 PA PE PVC
Water Quality
Quality requirements for membrane cleaning and rinse water:

 Iron: 0.06 ppm or 0.5 ppm

 Manganese: 0.01 ppm 0.2 ppm
 Silica: 40.00 ppm 5.0 ppm
 Total hardness: 178.67 ppm
 Total bacteria count: 1000 / ml
 Total coliform count: < 1 / ml
 Non soluble matter: none ( see SDI )

Iron, Manganese and Silica have limits depending on their ratio to each other
The Salt
Determination:
Density Index
0.45 µm cellulose nitrate filter, 47 mm diameter
SDI
manometer with pressure control valve
filter cell

1. Put filter in filter cell and wet with water

2. Adjust water pressure to 2 bar and measure the time required to filtrate
500 ml of water (t1)
3. Allow water to flow for further 15 minutes
4. Measure again the time required to filter 500 ml of water (t15)
SDI
Manometer

Filter Cell
Water Mains
Permeate

Deaeration
Pressure Control Valve

500 ml Graduated Cylinder

The Salt Density Index SDI

The SDI is a measure to indicate solids and colloids in water

t1 100
SDI = 1- x
t 15 15

The SDI must not exceed 5.....

but already at values > 3 problems may occur !
Water Sources for Membrane Cleaning

 Well Water, Tap Water:

Hardness generally no problem when using proprietary
membrane cleaners. See Chart Water Quality.
 Evaporator Condensate:
Only if no organic impurities and/or residues of foam controlling
agents
 Water Treatment (e.g. filtration with common water filters)
Pre treatment of water for membrane cleaning generally
recommended for improving the cleaning process and
production performance of the equipment
 Preventive Maintenance of Water Filters !
 Regular Control of SDI
Membrane Filter

 Flow rate as in common cleaning to create a turbulent

flow but not to high to avoid erosion
 Special attention to pressure conditions
Membrane

Trans-membrane Pressure as low as possible

Flow as high as possible, approx. 2 m/sec

Trans-membrane Pressure as low as possible

Pressure Profile with Permeate Valve open

Only atmospheric pressure in

1.8 bar 1.0 bar 0.5 bar
Permeate Space

Permeate Valve open

Pressure Profile with Permeate Valve closed

≈1 bar
About 1 bar pressure in
1.8 bar 0.5 bar
Permeate Space

≈1 bar

Permeate Valve closed

The Membrane Cleaning Process

 In contrast to common cleaning often a complex system of

several interactive steps
 Often significant influence of pH sequence on production
performance and membrane fouling
 Cleaning sequence mostly dominated by membrane type,
not by nature of soil
Examples for Membrane Cleaning
Examples for Membrane Cleaning