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For airplane
For special vehicle
For coal machinery
For fluid cleaning system
For dust
collector
of cement
industry
For ultrafilter
2 February 2013 www.ltnews.com
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IN THIS ISSUE
January/February 2013, Vol. 32, No. 1
I8.?=><C E N/A=
Filtration...Perhaps the Greenest of All Industries 6
Environment Effort Boosts Filtration and Separation Industry 12
C9@/< #>9<C E #:38$/5 F36><+>398
CoMatrix and Aqueous Coalescer for Entrained Organic Removal 16
'+>/< E F36><+>398
Integrated Dual Membrane Systems for Drinking Water Production 20
Perforated Metals: Clarifying Options 24
Cloth Media Filtration For Wastewater Treatment 28
F36><+>398 E "/-C-6381
Advanced Filtration Technology Enables the Production of
High-Quality Recycled PET Fibers for the Textile Industry 32
C996+8> E F36><+>398
The Best Practice for Supplying Filtered Coolant to
High Pressure Pumps 38
N/A= E B<3/0=
Call for Papers for FILTECH 2013 41
Eliminating High Maintenance Costs With Orival Filters 41
I N T E R N A T I O N A L
Your G|oba| Source
FIL8AI0
w8
Jao0arylFebr0ary 2013
Vo|0me 32 ho. 1
www.I||toews.com

Spec|a| 8eports oo water F||trat|oo:
|otegrated 00a| Nembraoe Systems
Ior 0r|ok|og water Prod0ct|oo
PerIorated Neta|s: 0|ar|Iy|og 0pt|oos
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For wastewater Treatmeot
Sp|oTek F||trat|oo:
|mprov|og Ag0eo0s 0oa|escers
6reeoest

F||trat|oo...
Perhaps the 6reeoest
oI A|| |od0str|es

Cover courtesy of
SpinTek Filtration
Editorial Advisory Board
Editorial Board Chairman
Edward C. Gregor,
Chairman
E.C. Gregor & Assoc. LLC
Tel: 1 704 442 1940
Fax: 1 704 442 1778
ecg@egregor.com
M&A, Filtration Media
Haluk Alper, President
MyCelx Technologies Corp.
Tel: 1 770 534 3118
Fax: 1 770 534 3117
alper@mycelx.com
Oil Removal Water and Air
Jim Joseph
Joseph Marketing
Tel/Fax: 1 757 565 1549
josephmarketing@verizon.net
Coolant Filtration
Robert W. Mcilvaine
Tel: 1 847 272 0010
Fax: 1 847 272 9673
mcilvaine@
mcilvainecompany.com
www.mcilvainecompany.com
Mkt. Research & Tech. Analysis
Dr. Graham Rideal
Whitehouse Scientic Ltd.
Tel: +44 1244 33 26 26
Fax: +44 1244 33 50 98
rideal@
whitehousescientic.com
Filter and Media Validation
Tony Shucosky
Pall Microelectronics
Tel: 1 410 252 0800
Fax: 1 410 252 6027
tony_shucosky@pall.com
Cartridges, Filter Media,
Membranes
Scott P. Yaeger
Filtration and Separation
Technology LLC
Tel/Fax: 1 219 324 3786
Mobile: 1 805 377 5082
spyaeger@msn.com
Membranes, New Techn.
Mark Vanover
Bayer MaterialScience LLC
Key Account Manager
Tel: 1 314 591 1792
Email:
mark.vanover@bayer.com
Polyurethane Systems
Dr. Bob Baumann
Advisory Board
Member Emeritus
Andy Rosol
Global Filtration Products Mgr.
FLSmidth Minerals
andy.rosol@smidth.com
Tel: 1 800 826 6461/1 801 526 2005
Precoat/Bodyfeed Filter Aids
Clint Scoble
Filter Media Services, LLC
Ofce: 1 513 528 0172
Fax: 1 513 624 6993
cscoble@ltermediaservices.com
Fabric Filters , Filter Media,
Baghouse Maintenance
Gregg Poppe
The Dow Chemical Company
Tel: 1 952 897 4317
Fax: 1 942 835 4996
poppeg@dow.com
Industrial Water, Power,
and Membrane Technology
Henry Nowicki, Ph.D. MBA
Tel: 1 724 457 6576
Fax: 1 724 457 1214
Henry@pacslabs.com
www.pacslabs.com
Activated Carbons Testing,
R&D, Consulting, Training
Brandon Ost, CEO
Filtration Group
High Purity Prod. Div.
Tel: 1 630 723 2900
bost@ltrationgroup.com
Air Filters, Pharmaceutical
and Micro-Electronic
Dr. Ernest Mayer
E. Mayer Filtration
Consulting, LLC
Tel: 1 302 981 8060
Fax: 1 302 368 0021
emayer6@verizon.net
Wu Chen
The Dow Chemical Company
Tel: 1 979 238 9943
wuchen@dow.com
Process Filtration (liquid/gas)
Equipment and Media
Peter R. Johnston, PE
Tel/Fax: 1 919 942 9092
ddandp3@aol.com
Test procedures
Peter S. Cartwright, PE
Cartwright Consulting Co.
Tel: 1 952 854 4911
Fax: 1 952 854 6964
pscartwright@msn.com
Membranes, RO,
Ultraltration
Industry | News
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Ive been making the above state-
ment for 20 plus years and have never
had its veracity questioned or chal-
lenged. A few processes may not be 100
percent perfect yet, but the principal re-
mains and is hard to dispute.
Filtration, separations and coalesc-
ing companies are always on the
search for new opportunities and chal-
lenges, which brought to mind the
idea of exploring the broad world of
filtration, 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, academia
and companies have created to prevent
or resolve many pollution problems
that result in a higher standard of living
for us while also maintaining a cleaner
and safer world environment.
THE DAY BEGINS
John and Mary wake in the morn-
ing with the help of their digital alarm
clock whos acids, solvents and de-
ionized water were safely used to
make its microchip, and which was
filtered by prefilters, reverse osmosis
and microfiltration. John turns up the
thermostat, not giving a thought to
how their home air filters protect the
heating unit. The electricity being
provided by the local utility company
from a coal-fired power plant uses
scrubber technology and baghouse fil-
tration to remove particulate from the
exhaust stream. Mary heads to the
kitchen to make a pot of coffee,
pulling out a coffee filter, without
knowing the coffee had the caffeine
removed safely via super-critical fluid
extraction. Her water is pre-filtered
through a series of meltblown and
carbon prefilters as well as an RO unit
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Filters, separation or coalescing can solve any pollution or environmental challenge the world is facing.
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hidden under her sink. Now, Mary
heads back to the bathroom where
John is in the shower, using clean and
odorless filtered municipal water.
Mary applies her cosmetics, many of
which were filtered for purity. Getting
dressed, neither considers the poly-
ester fiber in their clothing that was
filtered during the fiber manufactur-
ing process. Included, were the man-
ufacture of Johns cotton/polyester
blend shirt and Marys dress, which
were both finished with a filtered anti-
microbial treatment. Running a bit
late for work, they quickly open
breakfast protein bars wrapped in
multi-layered plastic packaging used
to keep convenience-foods fresh, and
which have benefited from polymer
filtration once again. They drink their
coffee and orange juice, where pulp
has been removed using ultrafiltra-
tion. Being diabetic, John uses his
membrane diagnostic test kit and
gives himself an insulin shot, which
had been filtered by the pharmaceuti-
cal supplier.
OFF TO WORK
Time to leave and both jump in
their cars. Mary drives a hybrid, but
dislikes the odor of exhaust fumes and
pollutants and made sure a cabin air
filter came with her car. Its a foggy
winter morning as she leaves, not
thinking about a potential moisture
build-up in the head and tail lamps,
which evaporated overnight via the
oleophobic membrane media vents
embedded in the glass. These are sim-
ilar to the vents where water by-passed
the gaskets in the small motors con-
trolling the windshield wipers and
power windows in her car, which col-
lected when she was driving in the rain
the afternoon before. Johns a lead-foot
and an amateur racer, driving his pride
and joy muscle car with its high-per-
formance engine. In the back of his
mind, he knows he can rely on the gas
tank filter from monofilament and
www.ltnews.com February 2013 7
Industry | News
meltblown fabric and the fuel injector
filters of monofilament woven fabrics
to provide clean fuel, and that the en-
gine air-intake and lube oil wetlaid
media filters will provide peak per-
formance as well. Hes also confident
the space between the engine block
and the pistons, only a few microns
wide, are clean, thanks to two honing
coolant filtration systems at the en-
gine production plant that eliminated
shavings and other debris, using 25
micron bag filters, and the other line
with gradient density nonwoven fab-
ric roll stock to clear debris during
precision machining of both his en-
gine and transmission. Marys car has
an automatic transmission, which in-
corporates a transmission filter con-
taining needlefelt and/or
monofilament woven fabric. Both
Mary and Johns batteries also utilize
porous plastic media vents to prevent
a build-up of gasses, eliminating the
potential of a battery failure and even
an explosion. Before reaching the of-
fice John calls his mother on his cell
phone, which contains a microchip,
not all that dissimilar to the digital
clock. Mom is receiving hemodialysis
using a cleanable hollow fiber mem-
brane filter. She was fine, but asked
John to please come by over the
weekend to get her lawn mower ready
for the spring with a new paper fuel
and reticulated urethane foam air fil-
ter as well as to look at her gas dryers
lint filter screen, which might need
replacement.
As Mary reaches her office as VP of
OA/QC Manager at Living Well Phar-
maceutical & Medical Device Com-
pany, LLC, she turns on her computer
containing an e-PTFE disk-drive air
vent, but before she can remove her
coat, an anxious employee tells her
about problems on the production
line over night. The injectables pro-
duction line used to produce diabetes
medication was having problems. The
meltblown prefilter and membrane
sterilizing filter line might not be
working properly as the microbiology
test lab detected bacteria in the serum
on their membrane disk filter. Fur-
thermore, the insert molding lines
used to produce I.V. vent and in-line
bacteria medical filters were acting
up. Yesterday, they had a similar prob-
lem with the ophthalmic and pre-by-
pass filter line used in extracorporeal
open heart surgery.
In the meantime, John arrives at
his chemical plant where he is Direc-
tor of Operations. Unlike Marys situ-
ation, everything is running
smoothly. The filter presses using
woven fabric, flat bed filters with rolls
of nonwoven media and filters, and
leaf filters using filter aids are all op-
erating efficiently. However, one
chamber of the bag house needs to
have its filters replaced today as part
of routine maintenance along with all
the meltblown box air filters in the
offices. The new fleet of large diesel
trucks used to transport liquids and
powders produced at his facility had
Virtually every aspect of human life is touched by the principles of filtration.
Industry | News
finally arrived overnight. John feels
relieved, as he has had many com-
plaints about the diesel soot exhaust
from the neighbors. He is also pleased
to learn in the company newsletter,
printed using filtered ink, that the oil
and gas drilling operations the com-
pany owns elsewhere, has success-
fully installed improved coalescing
and absorption separation systems.
This was done to remove the higher
percentage of oil and fine droplet
chemicals from produced water in the
oil and gas recovery process.
TRAVEL TO HEADQUARTERS
The day goes smoothly for John,
before leaving for lunch and the air-
port and a flight to headquarters. At
lunch, John enjoyed a burger, fries
and sweet tea - the fry oil efficiently
filtered using a polyester media, and
the 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 his
replacement that had just installed
both tubular and RO crossflow mem-
brane systems to remove heavy met-
als before water disposal and
recycling. Once at the airport, John
boarded the aircraft confident the
FAA-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 fuel
being loaded onto the aircraft.
Upon arrival at the hotel, John had
supper, called Mary asking how things
went today. Mary said she had concerns,
but everything turned out well, relating
the microbiology lab diabetes report
proved to be a false-positive. John said
the same from his end and mentioned
his company has just uncovered a new
highly-efficient technology that sounds
capable of complete mercury removal
and direct recovery at the companys
huge natural gas drilling facility. Best of
all, there were no disposable absorbents
requiring post-cleaning. John said good-
night and hed call in morning. Before
turning out the lights, John watched the
news, where the TV had an LCD screen
made in a factory cleanroom using
HEPA filters to prevent surface contam-
ination during the manufacturing
process. And so it goes...another healthy
and trouble free day for John and Mary
as well as the rest of us, thanks to safe
and reliable filtration, separations and
coalescing technologies.
Ed Gregor is a specialist in ltration
technologies and media, and has both
Consulting and M&A businesses in ltration.
He can be reached by phone: 704-442-1940
or email: ecg@egregor.com
FN
Visit us
online
to read
more industry
news
www.filtnews.com
12 February 2013 www.filtnews.com
t the 4th Filtration & Separa-
tion Asia and the 7th China
International 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 and
separation industry. The participants
concluded that a strong market growth
would continue in the next few years,
which will continue to provide ongoing
momentum to innovation.
EXHIBITORS AND EXPERTS
The event was sponsored by the
China Technology Market Associa-
A
Industry | News
E8@3<987/8> E009<> B99=>=
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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 Filtration
News, the American Filtration & Sep-
arations Society (AFS), the Asia Non-
woven Fabrics Association (ANFA),
and the European Disposables and
Nonwovens 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, Hong
Kong, Japan, Germany, Taiwan, Bel-
gium, Finland and the United States
attended the FSA + CIFS 2013 at
INTEX Shanghai, covering exhibi-
tion halls of 6,000 square meters.
They included filtration materials
manufacturers, filtration and separa-
tion equipment producers, research
and development institutes, associa-
tions, and industrial publications.
Some of the exhibitors said that
the growing market demand was the
deciding factor in participating at
this biannual event. We expect a
growth of sales this and next year. So
we are here to look for more business
opportunities, 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 the
filtration and separation industry in
the forums of the FSA + CIFS 2012.
ENVIRONMENTAL PROTECTION EFFORTS
Some of these forums focused on
the market opportunities that will be
brought by the Chinese governments
environmental protection efforts.
One of these opportunities is cre-
ated by the Chinese governments
plan to improve the nations sewage
treatment and recycling system.
This effort will provide a strong mo-
mentum to the Chinese filtration and
separation industry in the next three
years or more, said Mr. Deng
Zhiguang, deputy president of the
China Central and Southern China
Municipal Engineering Design & Re-
search Institutes. He described the
Chinese governments policies and
targets for sewage treatment and re-
cycling by 2015, and the consequent
market demands and related oppor-
tunities. According to the targets,
Chinas sewage water treatment will
increase from 124.8 million cubic
meters to 208.1 million cubic meters
per day from 2010 to 2015, and
sewage sludge treatment will increase
5.18 million cubic meters per day in
the same period. In addition, recy-
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More than 300 exhibitors participated at Filtration & Separation Asia 2012, where experts predicted a strong growth for filtration in the coming years.
14 February 2013 www.filtnews.com
Industry | News
cling water will triple to reach 38.85
million cubic meters per day from
2010 to 2015.
Another opportunity is Chinas ef-
forts to reduce air pollution. The
Chinese central government has set
a plan to reduce the Chinese indus-
tries air emissions per metric ton of
production by 10% to 29% between
2010 and 2015. This plan will
strongly boost the consumption of
filtration fabric. According to Mr.
Sun Jinliang, member of the Chinese
Academy of Engineering (CAE), the
Chinese industries emit a total of
about eight million metric tons of
fine particles (PM2.5) a year, which
accounts for 80% of Chinas total air
pollution. The fine particles emission
is hard to be eliminated through tra-
ditional ways. The main solution is
filter bags made by filtration fabric.
Last year (2011), China pro-
duced about 120 million square me-
ters of filtration fabric, with a total
value of 20 billion yuan ($3.2 bil-
lion). In 2012, the market in value
terms will grow by 25% and reach 25
billion yuan ($4.0 billion), said Mr.
Jiang Shicheng, vice president of the
China Chemical Fiber Association
(CCFA).
But Mr. Jiang said that the Chi-
nese filtration fabric manufacturers
still had many problems. Among the
filtration fabric made in 2012, about
70 million square meters were com-
mon filtration fabric with poor heat-
and corrosion-resistance, and only
50 million were high-quality prod-
ucts. On the other hand, among
Chinas more than 200 filtration fab-
ric production lines, only 15 lines are
advanced lines introduced from
other countries, and more than 100
lines are low-quality ones. Overca-
pacity of low-quality products has
appeared in the industry and restruc-
turing will be required, explained
Mr. Jiang.
Other experts said that the rela-
tively high cost would be another
factor that retards the growth of filter
bags and filtration fabric. For exam-
ple, the investment on the filter bags
for a chimney in a steel plant could
cost 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 of
Chinas 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 increase
of the filtration products will be cru-
cial to our environmental protection
efforts, said Mr. Huang.
To reduce the environmental pro-
tection costs of the Chinese compa-
nies, the government has started to
subsidize the filtration fabric produc-
ers. For example, the government of
Chinas Funing County subsidizes
10% to 17% of the prices of new
equipment bought by local filtration
fabric manufacturers, which will re-
duce their cost of manufacturing ad-
vanced filtration fabric. Since 2011,
the Funing government has given
about $700,000 to 146 local filtration
fabric manufacturers. Supported by
the government, the Chinese filtration
fabric industry will have an average
annual growth rate (AAGR) of no less
than 15% in the next five years, said
Mr. Li Lingshen, president of the
China Nonwoven & Industrial Tex-
tiles Association (CNITA).
MATERIALS, APPLICATION, METHODS
In some other forums, experts dis-
cussed the applications of filtration
and separation technologies for vari-
ous industries. For example, Mr.
Liang Jinlong, researcher of Chinas
Nanchang Filter Machinery Research
Institute, described in a forum the re-
cent development of uranium separa-
tion and concentration technology;
Mr. Chen Gangjin, researcher of the
Laboratory of Electrets and Applica-
tion at Chinas Hangzhou Dianzi Uni-
versity, provided his recent findings
of melt-blown polypropylene elec-
trets web in medical applications.
New materials for filtration and
separation were discussed at the FSA
+ CIFS 2013 too. For example, Ms.
Bian Sisi, researcher of the Northeast-
ern University of China, described
her recent experimental research on
degradation of aramid filter media.
Some experts presented their re-
cent research on new manufacturing
methods for filtration materials. For
example, Mr. Lu Jiankang, researcher
of the Qidong Kanghui Coating &
Lamination Co Ltd, described their
recent research and development
(R&D) of the manufacturing tech-
nologies and equipment for multi-
layer filtration materials.
Cover Story | SpinTek Filtration
development and field-test-
ing program was undertaken
for an improved aqueous co-
alescer for produced water, oily water,
and electrolyte and raffinate streams.
The achievement of such a program
would provide low cost and effective
coalescence of entrained organics that
would 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 to
dual-media filters are to 1) improve
final effluent quality, 2) reduce back-
wash frequency of the filters, and 3)
provide a more easily recovered organic
then the reprocessing of backwash elec-
trolyte or water.
The system was shown capable of
operating at pressures under 140 kPa
and obtained entrained organic re-
moval of up to 95%. The low operat-
ing pressures allow for lower capital
costs and the ability to treat entire raf-
finate streams previously not feasible
due to extremely high capital and op-
erating costs.
This paper discusses the design and
basic operational considerations of this
improved coalescer and how it can be
applied to new construction as well as
operating plants. A unique feature will
be discussed as how the coalescer can
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Spence Copper Mine, Chile
be incorporated into existing dual-
media filters to significantly improve
organic removal, extend service runs
and reduce backwashing frequency.
INTRODUCTION
The removal of entrained organic
from aqueous streams is an essential
process to minimize plant operating
costs and maximize the quality of the
electrolyte. Current technology in-
cludes the CoMatrix filter and con-
ventional Dual-Media filters. The desire
is to produce a low operating and cap-
ital cost coalescer that can be used to
feed these media based systems. It is
desirable to remove high levels of en-
trained organic to provide a more con-
stant aqueous feed stream to this type
of equipment.
In addition, entrained organic re-
covery equipment has found very lim-
ited commercial implementation due
to the very high flow rates compared
to electrolyte and subsequent higher
than acceptable capital costs. Another
goal then is to produce a low cost but
very high flow rate system that can
consistently remove 75% or greater or-
ganic removal.
The following reports on the recent
study 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 design
produces an enlarged droplet size of the
organic for more efficient removal by
the subsequent filter. It is commonly
known that as modern SX-EW plants
become increasingly more advanced in
design, the organic droplet sizes de-
crease accordingly as a result of this en-
hanced mixer/settler operation. This
consequently causes lower efficiency in
the filters. Crud and organic loads as-
sociated with crud can also be reduced
from the electrolyte by placing less of a
load on the filters.
An added benefit is that a reliable
coalescer can smooth out levels of en-
trained organic to a media filter and
thus compensates for normal plant up-
sets that can cause excessive organic
levels from entering a filter. Stabilizing
the organic level to electrolyte filters re-
Cover Story | SpinTek Filtration
duces the chance of overrunning these
filters, which send organic to the tank
house. The service cycle of the filters
prior to backwash can be more accu-
rately predicted. The added benefit of
fewer backwashes is that filters are on
line for longer periods of time and the
amount of water or lean electrolyte
used for backwashing is minimized.
METHODOLOGY
The coalescer can be viewed as a
tank within a tank where the outer
tank can be pressurized up to 100 kPa
and has an access man-way and nozzles
for service inlet, service outlet and or-
ganic recovery. The inner tank is a
cylinder that is connected at the bottom
but open at the top. The flow path is up
through the center of this cylinder and
then the electrolyte changes direction
and flows down through the annulus
formed by the inner cylinder and the
inner walls of the outer tank. The or-
ganic floats to the top of the tank and
exits the system.
The operation of the system is en-
hanced by placing anthracite or poly-
ethylene beads in the cylinder and
putting a grid on the top of the cylinder
to prevent the escape of the coalescing
media. In the annulus area, SpinTek in-
stalls a Matrix packing that consists
of hydrophobic corrugated packing.
The distance between the corrugations
are typically 12 mm up to 17 mm. The
flow rate through the cylinder is in the
60 m3/hr-m2 range hence if anthracite
is used the flow velocity forces it to the
top of the cylinder and the containment
plate.
Free organic can be formed and flow
to the top of the cylinder. To further im-
prove organic removal efficiencies if
the organic touches the Matrix packing
the hydrophobic nature of the pack-
ing will cause the organic to stick to its
surface. This organic on the plates
eventually form larger droplets that
break free from the Matrix packing and
are buoyant enough to flow upwards
(counter flow to the electrolyte) and
migrate to the dome of the tank and
exit the coalescer.
A further enhancement is to intro-
duce air into the feed inlet. The air
provides lower surface tensions and
hence helps coalesce organic. The
air/organic then reaches the media
layer where larger organic droplets are
formed that will float up to the top of
the 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 feed
pumps and after usage the electrolyte
was returned to the same feed tank.
There was no loss of electrolyte from
the plant during operation of the pilot.
The coalescer was operated for 48
hours without sampling to stabilize op-
eration and to coat the system with or-
ganic from the feed electrolyte. It is
necessary to coat the coalescer with or-
ganic as this will be its normal operat-
ing condition.
RESULTS AND DISCUSSION
The chart shows the result of the
Matrix Tower coalescer over a contin-
uous five (5) day service run. As can
be seen, the results show low levels of
organic in the total effluent with the
vast majority of organic removed by
the 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 can
be seen with organic inlet concentra-
tions as low as 9 ppm the average en-
trained organic removal was 75%.
When the entrained organic level is
above 20 ppm, indicating less organic
associated with crud, the efficiency
rises to 88%.
CONCLUSIONS
The coalescer performed well even
with the presence of significant
amounts of crud (organic + sus-
pended solids), and the system was
never out of service during the five
(5) day test run.
The system consistently averaged
75% organic removal from the feed
electrolyte. When the organic present
in the feed was greater then 20 ppm the
efficiency rose to 88%. As the level of
organic is even higher in the 30 ppm
range removal efficiency rises to the
95% range.
The Matrix Tower has the ability to
significantly reduce the amount of or-
ganic in the electrolyte, which will ex-
tend the service run of CoMatrix or
Dual-Media filters used to polish and
filter the electrolyte.
The system is a low cost method of
entrained organic removal either as a
stand-alone system on raffinate or a
pre-treatment to polishing filters on
electrolyte. As an example, a 4872 mm
diameter Matrix Tower coalescer oper-
ates at 600 m3/hr and can be con-
structed of FRP or thin wall stainless
steel, which is enough for many elec-
trolyte or strip applications.
Large raffinate streams, for example,
at 2400 m3/hr could be configured as
follows:
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4872 77 .3+7/>/<
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SpinTek Filtration, Inc.
William A. Greene
10863 Portal Drive
Los Alamitos, CA 90720 USA
Tel: +714-236-9190
Email: wgreene@spintek.com
Website: www.spintek.com
DELKOR AMERICAS
Diego Rubio, Senior Sales & Process Engineer
Tel: Central: +56 (2) 650 4700, Direct: +56 (2) 650 4775
Fax: +56 (2) 650 4701
Email: diego.rubio@delkorglobal.com
Skype: Diego Rubio Delkor
Website: www.delkorglobal.com
For more information contact:
FN
Water | Filtration
he use of Ultrafiltration (UF) as
pretreatment 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 and
local particularities. When considering
surface water, the difficulty usually
comes from its fluctuating characteriza-
tion, being especially challenging dur-
ing periods with high natural organic
matter (NOM), high turbidity or high
suspended 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 in
severity over filtration cycles building
up and resulting in higher energy con-
sumption. Establishing a protocol to
optimize the type of cleaning and its re-
quired frequency is therefore of great
importance. Optimization allows for
more effective operational protocols to
be considered, providing an economi-
cally attractive alternative to conserva-
tive operating modes (Porcelli and
Judd, 2010 [2]). Non-optimized sys-
tems can lead to filtration cycles that
are too short, coupled with high back-
wash duration and higher chemical
concentrations during chemically en-
hanced backwashes (CEB) and clean in
place (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 brackish
under highly variable conditions of
turbidity (5 - > 1000 NTU) and tem-
perature (10 29C). In order to es-
tablish the feasibility of the process
consisting of a basic filtration (hydro-
cyclon and ring filter), Ultrafiltration
and Reverse Osmosis, the following
objectives 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
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Figure 1: Process flow diagram, Barcelona unit for drinking water applications.
T
plants (DWTPs)
Evaluation of the suitability of direct
UF as pretreatment step for RO from
a hydraulic and quality perspective
Determination of the sustainability
of the process (UF + RO) and
characterize its performance taking
into consideration various
parameters, such as water yield,
reagents consumption, energy
consumption, etc.)
Optimizing the performance of the
UF to increase the efficiency of the
process, 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 direct
surface water feed. Water was pumped
to the pilot plant from the Llobregat
River (Barcelona, Spain), and solely
pretreated by a combination of hydro-
cyclone and a ring filter. After primary
storage, the feed was sequentially
pumped to two parallel independent
DOW SFP - 2880 UF modules (pres-
surized outside-in PVDF hydrofilic
membranes with 30 nm pore size; 3.0
4.6 m3/h capacity each module). One
of the modules was employed as the
control line (Line 201) and the other
as the experimental line (Line 200).
To optimize the process, modifications
in the operating sequence were firstly
implemented in the experimental line.
The benefit of the change was then val-
idated from a process point of view and
the sustainability of the operation was
demonstrated by comparing with the
control line. The response of changing
operational parameters with respect to
variations in feed water quality was also
evaluated. The filtrate produced by the
UF 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/h
nominal capacity). Permeate from stage
one and two was stored in a permeate
tank, while the concentrate from both
stages was discharged (See Figure 1).
RESULTS AND DISCUSSION
Initially 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), backwash
bottom (BWB), forward flush (FF)
and draining (D) were set at 75, 60,
15, 20 and 30 seconds, respectively. As
these operating conditions demon-
strated stable membrane performance,
backwash frequency was decreased
from 30 to 60 minutes. Results of this
period also highlighted manageable
performance, allowing for further im-
plementation of constraints. However,
this time, a significant reduction in the
BW sequence was carried out to test
the performance outcome, so the only
functioning parameters were AS +
Water | Filtration
BWT (30 s) and FF (30 s), results in-
dicated a significant and irreversible
rise in fouling or TMP (Trans Mem-
brane pressure). Conditions were
then altered so that the default five
steps were implemented again but
each one with duration of 30 seconds.
Once these changes were imple-
mented, operation was stable at 30
minutes filtration cycles, which was
then increased to 60 minutes soon
after, showing a similar trend (Figure
2). Consequently, it was decided to re-
duce the CEB frequency in order to
minimize chemical usage, so an ad-
justment was made from 12 hour cy-
cles to once every 24 hours, yet again
implication of such a constraint
Figure 2: Normalized TMP variation along time both at the
experimental line (UF200) and the control line (UF201) at
60 and 30 minutes of filtration, respectively.
Figure 3: Normalized TMP variation along time both at the
experimental line (UF200) and the control line (UF201) at
24 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/m2h
with a 60 minute filtration cycle; both
UF modules continue to display satis-
factory operation, however, more test-
ing is required before a final
conclusion can be drawn.
Thanks to the optimization under-
taken, the recovery or water yield,
which is described as the ratio of water
produced and feed water has been in-
creased from 87% to 96.5%
PERMEATE QUALITY
The Llobregat River is known for
presenting a highly variable water
quality as highlighted in Figure 4,
which shows that turbidity during the
experimental period ranged from 5 to
over 1000 NTU. Despite the high vari-
ability of the influent water, the
volatile nature of the river has a very
minimal affect on UF filtrate quality:
from the middle of March 2012 until
the beginning of September 2012, the
feed turbidity has varied significantly,
whereas the filtrate turbidity averaged
0.06 NTU and deviated as little as
0.036 NTU.
CONCLUSIONS
Ultrafiltration demonstrated an
adept ability to deal with challenging
surface water conditions, becoming a
feasible solution to conventional pre-
treatment for drinking water treatment
plants (DWTPs). Direct UF sustain-
able performance was accomplished
even with reduced BW step duration,
increased flux, increased filtration
cycle and reduced CEB frequency,
achieving a water yield of 96.5% of
raw water intake for the tested condi-
tions. Furthermore, UF confirmed that
once an acceptable protocol has been
reached, a CEB and CIP could be ini-
tiated every 24 hours and 3 months,
respectively, ultimately reducing
chemical consumption, within the
tested conditions. Although the ultra-
filtration application was successful,
further optimization is believed still to
be 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 water
quality produced by the DOW Ultra-
filtration system, RO membrane life-
time may also be extended, benefiting
the overall treatment scheme.
For more information email:
vgarciamolina@dow.com
Acknowledgements
This work has been conducted under the -
nancial support of the LIFE+ Program of the
European Commission within the framework
of the UFTEC Project (LIFE09
ENV/ES/000467 UFTEC).
References
Pearce, G.K. (2008), UF/MF pre-treatment to
RO 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 cost
benet of optimization, Water Research 44,
Issue 5, 1389-1398.
FN
n many of the tough conditions
associated with water filtration
whether dealing with coarse sep-
aration, desalination, deionization or
other applications perforated metals
provide strength, structural integrity
and 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 of
applications 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 1-inch steel plate,
with holes punched in a wide array of
shapes, patterns and sizes from micro-
scopic up to 3 inches in diameter.
Cost-efficiency heavily influences
purchase decisions. Since engineers
have access to many alternative mate-
Drop in perforated stainless steel basket allows for easy removal and cleaning.
I
Water | Filtration
/<09<+>/. M/>+6=: C6+<30C381 O:>398=
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BC K/3>2 M+3669?B, IA $/-283-+6 C9773>>// C2+3<
rials, including wire mesh, expanded
metal, PVC or plastic screens, its im-
portant to know when and where per-
forated metals are the best choice. This
article will discuss the key functions
and advantages of perforated metals,
as well as considerations for specifying
the right hole configurations, metal
and options.
PRIMARY FUNCTIONS
Perforated Metals can be used in a
variety of ways in water filtration appli-
cations, but they generally serve two
functions better than competitive prod-
ucts: Primary Treatment (Coarse Sepa-
ration) and Support Cores.
C9+<=/ #/:+<+>398: Perforated met-
als are commonly used as primary
treatment filters. Wastewater is passed
through a perforated metal screen to re-
move large objects and/or a series of in-
crementally smaller screens to remove
grit that can cause excessive wear on
equipment. Typically, these filters arent
intended to be disposable; theyre used
in a system where theyre easy to clean
off with a scraper bar.
#?::9<> M/-2+83=7= 09< 9>2/< F36-
>/< M/.3+: Since pass-through open-
ings in perforated metal cant be made
much smaller than about 1/100th of an
inch, removing tinier particles requires
other filtration media. The second
common function of perforated metal
is as a support mechanism for these
more 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 as
the support core, perforated metal is
necessary when dealing with high pres-
sures or temperatures.
Another common application is to
combine the two functions. Many fil-
ters will have a perforated metal cylin-
der and an inner support core with an
inner filter media sandwiched in be-
tween, similar to an oil filter. The
outer core serves to filter out the
coarse materials, and the inner core,
usually permanently attached to the
filter material, keeps it from collapsing
on itself. This type of filter is com-
monly found in large commercial
buildings, factories, power generation
plants, hospitals or other buildings to
demineralize and deionize water up-
stream of ion exchange units or other
filtration systems.
STRENGTH AND DURABILITY
In general, perforated metal is
stronger and more durable than other
alternatives, such as wire cloth or ex-
panded metal. The perforation
process, usually accomplished
through punching holes out of a sheet
of metal, maintains much of the struc-
tural integrity of the original metal
sheet enabling the design to with-
stand high amounts of stress.
Because of its strength, perforated
metal handles high-temperature and
high-pressure applications much better
than its alternatives. For example, dem-
ineralization takes place in a high-pres-
sure tank. If that pressure builds up too
high or suddenly drops, wire cloth is
susceptible to bending or breaking.
Water | Filtration
Perforated metals provide the struc-
tural integrity to withstand the stress
without adding much weight.
Perforated metals are most often
used in commercial settings, where
pressure and temperature are a factor,
rather than in residential applications,
where lower-cost material functions
just as well.
DESIGN CRITERIA
Most filters are design-engineered
products, meaning their design must
meet certain known specifications. The
type of metal used, the hole design and
size, all impact the strength, flexibility
and capabilities. However, the science
behind filtration and water flow is ad-
vanced enough that engineers can calcu-
late pressure drop across a perforated
surface, 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 of
confidence how the part will function.
While hole patterns are fairly con-
sistent for water filtration applications,
most perforators have the flexibility to
customize tooling to meet customized
design requirements. They can also
provide recommendations for more
standard options that have similar
properties to help manage cost.
SPECIFYING MATERIALS
In the same way that the desired
flow rate and pressure gradient will
dictate the hole size, the environment
will dictate the type of metal needed.
For low-cost applications, it makes
sense to use as thin and inexpensive of
a material as possible. However, corro-
sive or high-pressures environments re-
quire more robust metals. Four of the
most common metals are Stainless
Steel, ETP, Brass and Titanium.
#>+386/== #>//6: Perforated stainless
steel sheet is essentially a low carbon
steel that contains chromium at 10% or
more by weight. The chromium con-
tent of the steel allows the formation of
a rough, adherent, invisible, corrosion-
Perforated filter core provides stable support and initial filter stages for outer
micro-filtration media.
resisting chromium oxide film on the
steel surface. If damaged mechanically
or chemically, this film is self-healing in
most environments.
A?=>/83>3-: Austenitic stainless
steels are non-magnetic, non-heat-
treatable steels that have excellent cor-
rosion and heat resistance with good
formability over a wide range of tem-
peratures. Additions of molybdenum
can increase the corrosion resistance.
F/<<3>3-: Ferritic stainless steels are
magnetic non heat-treatable steels that
contain chromium but not nickel. They
have good heat and corrosion resist-
ance, in particular to seawater, and
good resistance to stress-corrosion
cracking.
M+<>/8=3>3-: Martensitic grades are
magnetic and can be hardened by heat
treatment. They are not as corrosion re-
sistant as austenitic or ferritic grades,
but their hardness levels are among the
highest of all the stainless steels.
E$: Commonly called tinplate,
ETP is a coated steel product composed
of a thin sheet of steel, providing
strength and structural integrity, elec-
trolytically coated with a layer of tin for
corrosion resistance and other protec-
tive characteristics.
$3>+83?7: While its one of the most
expensive options available, Titanium
provides the best strength-to-weight ratio
among metals 40 percent lighter than
steel and 60% heavier than aluminum.
I8-98/6 A669C=: Inconel refers to a
family of high strength nickel-chromium-
iron alloys known for their resistance to
oxidation and their ability to maintain
their structural integrity in high-temper-
ature environments. While each variation
of Inconel has unique traits that make it
effective in a different circumstance, they
all stand up very well to caustic corro-
sion, corrosion caused by high purity
water, and stress-corrosion cracking.
B<+==: When zinc is added to copper,
it forms brass, which is stronger and
harder than either of the pure metals
and extremely useful for many perfo-
rated metal applications. As a general
rule, corrosion resistance decreases as
zinc content increases, so brass used for
water filtration applications usually re-
quires a copper content as high as 80
percent and 90 percent.
CHOOSING THE RIGHT OPTION
As mentioned earlier, there are many
different filtration options available to en-
gineers. Perforated metal, expanded
metal, wire cloth or plastic polymers all
present different advantages. Its impor-
tant to consider more than just price
when evaluating these options. Its also
crucial to understand the functional de-
mands of the application and find the ma-
terial that strikes the best balance between
long-term cost efficiency and utility.
For perforated metals, the main factors
influencing the cost are material cost, the
perforated patterns level of difficulty (hole
size versus material thickness, margins), tol-
erances and the quantity ordered. Working
with a member company of the Industrial
Perforators Association assures a reputable
perforator and a known standard of quality.
This can open up new avenues of cost sav-
ings through
alternative op-
tions, stan-
dardized hole
arrangements
or new tech-
nologies.
Today, the
water purifi-
cation uses of
per f or at ed
materials are
growing more
diverse, and
perforators are
helping push
the bound-
aries through
r e s e a r c h ,
knowl edge
sharing and
innovation.
They can be
an excellent
resource to
help over-
come many of
the tough
challenges. So
when consid-
ering water fil-
tration choices, reach out to experts in the
perforation industry. Theyll help identify
specific needs, consider options and em-
brace the proven benefits and boundless
potential 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 Association
continues to push the boundaries of what
these materials can do. Through extensive
research, knowledge sharing, standards set-
ting and more, the IPA provides members
with the tools to drive innovation and in-
crease utilization in perforation. In the
process, they act as an essential resource to
anyone who may benet from incorporating
perforated materials into their design.
For more information on perforated metals,
their applications and their benets, visit
www.iperf.org
FN
Water | Filtration
evolutionary and
New are adjectives
generally reserved for
the consumer products industry, not
for the traditionally conservative water
and wastewater treatment markets.
Conservative, by rights, since the pub-
lic welfare is the most important con-
sideration. However, there are few
words to describe the impact of Cloth
Media Filtration, the most revolution-
ary innovation to influence tertiary
treatment in decades.
Tertiary filtration of secondary
treated wastewater has become more of
a focus in recent years due to ever
tightening discharge limits on many
contaminants. For instance, the advent
of reclaimed wastewater for beneficial
reuse and the establishment of total
phosphorous 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 provide
these low filtered effluent discharge
levels. That is, until a technology was
introduced that provided the filtration
characteristics of deep bed filters but
offered many desirable advantages. The
technology is commonly referred to as
Cloth Media Filtration.
Textiles have been used for some
time as filtration media in a variety of
applications. Swiss manufacturer
Mecana Umwelttechnik developed
cloth media filter technology for
wastewater filtration in the 1980s. In
the early 1990s, Aqua-Aerobic Systems
of Rockford, Ill., utilizing the Mecana
design, introduced it to the United
States. Over the past 30 years, both
companies have improved the technol-
ogy and have combined for the instal-
lation of thousands of cloth media
filters in a variety of applications
around the world.
The key to the high performance of
the technology is the cloth. OptiFiber
cloth filtration media is a woven textile
having 13mm long bundles of fibers
that 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 bundles
while offering the necessary porosity to
allow free flow of backwash water, re-
moving solids from the fiber media
during cleaning.
In its natural state, the fiber bundles
are 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 of
pile cloth media: 1) it offers a signifi-
cant amount of surface area and, 2)
depth. There are literally thousands of
fine fibers per square foot of media,
each one capable of intercepting solid
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Figure 1.
Pile Cloth Active Depth illustration
Figure 2
Pile Cloth Filtration Mode illustration
R
particles, improving the probability of
solids removal. Once intercepted, the
depth of the media provides solids stor-
age capacity to help mitigate increased
headloss, prolonging filter run time
while reducing backwash frequency
and waste generation (Figure 1).
The pile filtration cloth is especially
engineered for wastewater treatment
application and is available in a variety
of materials of construction and filtra-
tion ratings (Figure 2).
Just as the pile filtration cloth is cus-
tomized, so are the available mechanical
configurations in which it is utilized.
DISK CONFIGURATION
The disk format is probably the
most recognizable mechanical form of
cloth media filtration. Besides provid-
ing high quality filtrate, the
AquaDisk filters most significant at-
tribute is its ability to offer more filtra-
tion surface area in a much smaller
footprint than gravity flow, granular
media filters. For example, the foot-
print area of a disk filter consumes only
about the footprint area of a gravity
sand filter offering the same hydraulic
throughput.
Figure 3. shows a 12 Disk Configu-
ration in Concrete Basin
The direction of flow through the
media is from the outside in. This fea-
ture, combined with the vertical orien-
tation of the media, results in a second
substantial advantage high-applied
solids loading capacity. Compared to
other 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 loss
through the cloth increases due to
solids deposition, the operating water
level in the tank rises. The differential
pressure is sensed until a predeter-
mined set point value is reached, sig-
naling the PLC based controls to
initiate a cleaning cycle.
Upon initiation, the backwash
pump energizes and the disks begin a
slow, 1 rpm rotation. As the cloth
media passes over the slotted opening
in the backwash shoe, the fiber bundles
are extended into the slot due to the
vacuum generated by the backwash
pump. This serves to actively agitate
the fibers to induce dislodging of the
solids. Within a matter of minutes, the
entire media surface area of the filter is
cleaned. Once cleaned, defined by the
return of the water surface in the tank
to its normal operating level, the disks
stop rotating and the pump is de-ener-
gized. At no time during the cleaning
cycle is the filter taken off-line. It is
worth noting that the cloth disks are
static during filtration, set in motion
only for cleaning. The result is a signif-
icant savings in power consumption
over other technologies.
Because of the vertical orientation of
the disks, suspended solids having
higher specific gravity may settle to the
bottom of the filter tank. These solids
are periodically removed via timed
function, utilizing the same pump and
manifolding used for backwashing
(Figure 4).
DIAMOND CONFIGURATION
Another 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., pile
cloth filtration media; outside-in flow
path, vacuum backwash and solids dis-
charge. Because it possesses a lower hy-
draulic profile than the disk format, it
can be retrofitted easily into existing
shallow filter basins, i.e., traveling
bridge filters.
One of the featured benefits of this
technology is its ability to offer more
than 2x the hydraulic capacity of the
gravity sand filter that occupied the
same basin prior to replacement.
SMALL DISK CONFIGURATION
The small disk format, or Aqua
MiniDisk filter, is a smaller scale
version of the full-sized disk format
described previously. As such, it of-
fers the same high performance fea-
tures as the AquaDisk filter, but is
used to treat smaller flows.
All of the above-described tech-
nologies provide exceptional filtrate
quality. For example, effluent total
suspended solids (TSS) and turbidity
(NTU) are generally less than 5.0
mg/l and 2.0 NTU, respectively. This
performance is achievable with
cloths having fine pile fibers manu-
factured from nylon, acrylic or poly-
ester. A unique cloth made of Mi-
crofiber construction improves TSS
and turbidity removal by approxi-
mately 50%. This level of perform-
ance rivals that of deep bed rapid
gravity 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 the
municipal wastewater treatment mar-
ket, cloth media filtration is consid-
ered during design by plant owners
and consulting engineers for almost
every project. Many times, cloth
Figure 3. 12 Disk Configuration in Concrete Basin Figure 4. AquaDisk Backwash Mode
media filtration is used to replace old
sand filters. There are some application
limitations for cloth media filtration. For
example, they are not generally used for
denitrification or as a final barrier for
potable water treatment. There is no
doubt, however, that cloth media filtra-
tion provides high quality filtrate that
meets, or exceeds, state regulatory require-
ments with low cost of ownership.
AQUA-AEROBIC SYSTEMS, INC.
Tel: 1-815-639-4483 Fax 815-654-2508
Email: elang@aqua-aerobic.com
Website: www.aqua-aerobic.com
Figure 5. AquaDiamond Overview with Diamond Lateral (inset).
FN
he 2012 London Olympic
Games were as much about
the green as they were
about the gold, and described by
some as being the greenest Olympics
to date. Not only did the Olympic or-
ganizing committee and sponsors do
their parts in ensuring a green ap-
proach to constructing and operating
the Olympic venues, but the apparel
companies designed sustainable
clothing and accessories, which were
worn by the athletes.
According to the website of a
major apparel company, each uniform
that the USA mens basketball team
wore was made from 22 recycled plas-
tic bottles. Several countries and
teams proudly wore uniforms featur-
ing material that was largely made
from recycled content. This was a
major accomplishment considering
the importance given to the function
of the athletic wear.
Polyester fiber is the most com-
mon building block for sustainable
clothing and delivers high perform-
ance for flexible, light-weight, re-
duced-wind, and drag-resistant
fabrics. However, in order to produce
such athletic garments from recycled
materials, the quality of the recycled
polyester fiber needs to be on par
with that of virgin material.
Pall Corporation is a leader in fil-
tration, separation and purification
and has been providing filtration so-
lutions to the textile industry since
the 1960s. In recent years, Palls tech-
nology has extended into the recy-
cling industry and has enabled the
production of high-quality fibers
from recycled feed stock. Pall helps
its customers to enable a greener,
safer future and has once again been
named one of the greenest companies
in America by Newsweek magazine.
Chung Shing Textile Company was
T
Filtration | Recycling
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founded in Taiwan in 1949. It is a
fully integrated, large-scale textile
manufacturer engaged in chemical
fiber manufacturing, yarn spinning,
weaving, dying & printing, and gar-
ment manufacturing. Chung Shing
Textile operates an 850-ton per day
manufacturing site at Yang-Mei
Chemical 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 intensive
process that is costly and draws on
limited natural resources. As an eco-
conscious corporation, Chung Shing
Textile believes in contributing to en-
vironmental sustainability and oper-
ates under the 3R waste management
principle (Reduce, Reuse, and Recy-
cle). In fact, in 2005 it started manu-
facturing high-quality PET textile
fiber from recycled plastic bottle
waste. These fibers are currently mar-
keted under the GreenPlus brand
and are used in a wide variety of tex-
tile applications by leading manufac-
turers of popular brands. GreenPlus
fibers are certified by Oeko Tex Stan-
dard 100 (Certificate Number: TPYO
055042) and Greenmark (Certificate
Number: 3159).
GREENPLUS FIBER PROCESS
Post-consumer PET bottles are col-
lected at communities and recycling
centers throughout the world. The bot-
tles are baled and brought to a process-
ing facility, where they are sorted by
type (PET, HDPE, LDPE, etc.) and
color. The PET bottles are then
stripped of their labels and caps and
washed multiple times to remove any
adhesives and other possible contami-
nants. Next, the bottles are crushed
and chopped into flakes. The small
flakes 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 turned
into bales (insert) from Chung Shing Textile.
crimped, cut, drawn, and stretched
into required lengths for baling. Baled
fiber can be processed into fabric for a
variety of textile products.
CHALLENGE OF HIGH-QUALITY FIBERS
Polyester fibers made from post-
consumer bottles are expected to be of
equal quality to those produced from
virgin raw materials. These fibers
should possess the same desirable
properties including strength, abrasion
resistance, flexibility, and moisture ab-
sorption. While good for the environ-
ment, recycled fibers present a real
challenge 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 play
an important role in the recycling
process by removing contaminants and
ensuring consistent, high-quality feed
stock. This crucial step is necessary to
eliminate variance in the feed stock
quality, which ultimately will impact
the end fiber quality.
Two technologies are typically used
during the melt filtration process:
1) Screen changers
2) High-area duplex-style
continuous melt filter systems
Screen changers allow operators to
collect hard contaminants on woven
wire screens during the extrusion
process. They are easy to use, but
offer limited filter area and thus plug
up very rapidly, resulting in undesir-
able polymer shearing and high dif-
ferential pressure. They also require
multiple daily interventions, result-
CPF System from Pall
Inside Chung Shing Textile plant
ing in an unstable operation that
lasts 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 basic
technology and are hardly ever pre-
ferred by any fiber producer.
High-area continuous melt filter
systems allow operators to run sub-
stantially longer with less downtime
than screen changers. These systems
offer clear advantages when process-
ing recycled materials, as well as ma-
terials that require long run cycles.
Continuous melt filter systems are
often the technology of choice.
Chung Shing Textile had been
running a duplex-style filter system
for processing its recycled fibers. A
European textile company supplied
the duplex filter system, which used
a plug-style diverter valve that
caused polymer degradation and
rapid plugging of the filter elements.
The on-stream life of the filter was
only 1-2 days, requiring expensive
changeovers and considerable down
time. More importantly, the quality of
the resulting fibers was not compara-
ble to that of fibers made from virgin
material.
PALLS ADVANCED FILTRATION TECH
After reviewing the polymer feed
stock and operating conditions, Pall
offered its duplex-style Continuous
Polymer Filter (CPF system) cus-
tomized to suit process requirements.
Palls CPF technology uses a
patented, contoured spool-type di-
verter valve and is designed for use
in various polymer melt filtration
processes. To date, Pall has sold over
2600 CPF systems, many of them in
polyester fiber production processes.
Chung Shing Textile has adopted
Palls model 100 CPF system across
its 11 chip spinning lines. Currently,
five of the lines are used to produce
GreenPlus fiber. The system was de-
signed to use filter elements made
with Palls Dynalloy filter media
a premium nonwoven type sintered
metal fiber media suitable for remov-
ing hard and soft gelatinous content
through its tapered pore geometry.
The results were immediately notice-
able the operation became stable
and on-stream filter life increased to
7-8 days.
Palls CPF technology enabled us
to achieve the high-quality recycled
polyester fiber that is comparable to
virgin fiber, said Mr. Dai, Chung
Shing Textile plant manager. The
Chung Shing Textile operates an 850 ton per day manufacturing site at Yang-Mei Chemical Fiber factory in Taiwan, where it
produces virgin-grade polyester fibers and chips for textile use.
CPF system is a compact and proven
design ideally suited for such fiber
processes. The system provides con-
sistent fiber quality and improved
on-stream filter life with minimal op-
erator intervention. This was funda-
mental in lowering our cost of
production. We are proud of our
GreenPlus fiber product and its wide-
spread use at the 2012 London
Olympic Games.
RESULTS
Since its beginning in 2011,
GreenPlus fiber capacity has ex-
panded to five production lines total-
ing 56 MTD. Each production line is
now retrofitted with Palls CPF tech-
nology for high-quality continuous
fiber production. The next step is to
extend the on-stream life of the fil-
ters by introducing Palls innovative
Ultipleat Polymer Candle elements
into the existing systems.
PALL CORPORATION
Pall Corporation is a filtration, sep-
aration and purification leader provid-
ing solutions to meet the critical fluid
management needs of customers across
the broad spectrum of life sciences and
industry. Pall works with customers to
advance health, safety and environmen-
tally responsible technologies. The
companys engineered products enable
process and product innovation and
minimize emissions and waste. Pall
Corporation is an S&P 500 company,
serving customers worldwide. Pall has
been named by Newsweek magazine a
top green company.
CHUNG SHING TEXTILE COMPANY
Chung Shing Textile, founded in
1949, is a fully integrated, large-scale
textile 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 integrated
through a comprehensive coverage of
the upstream, midstream and down-
stream operations. Its capital has
skyrocketed from the initial
NT$40,000 to todays NT$8.4 billion.
The company markets its products
both at home and abroad under
brand names, which have become
synonymous with quality.
Raj Shah
Pall Corporation
Tel: 1-386-822-8014
Fax: 1-386-822-8010
Email: raj_shah@pall.com
Website: www.pall.com
FN
reservoir between the filter,
which is cleaning the
coolant, and the high pres-
sure pump, which is using the coolant,
is an important component to protect
the pump and the filter, regardless of
the systems 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-through
tools or other nozzles where a higher
than normal pressure is needed. High
pressure pumps are incorporated to
meet the needs, which can range from
300 psi to as high as 5000 psi. These
pumps have precision components and
must have cleaner coolant to mainly
protect the pump as well as protect the
sensitive tools. Applications needing
pressures just below 300 psi are usually
handled by pumps, which are more tol-
erant of some contamination in the
coolant. 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 the
process or could be a secondary pol-
ishing filter, which enhances the clar-
ity of the coolant received from a main
filter. In either case, the filter discussed
here is dedicated to the needs of the
high 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 schematic
with the needed controls to insure safe
operation and easy start up.
However, individual machines may
not need all the elaborate controls but
should use a reservoir as part of the
systems design to serve the filter and
pump.
TYPICAL EFFECTIVE SYSTEM
Figure 2 shows a typical reliable
arrangement where the tank (sized for
the flow) helps the filter and the pump
perform their functions. The reliability
comes from:
The filter sees a constant flow
totally independent of the pumps
cycle, which usually is intermittent.
Continuous flow does not
constantly pulse the filters surface
which can adversely affect the
elements performance and life;
particularly for bag filters.
The continuous overflow from the
reservoir to either the machines
sump or systems main tank, allows
Coolant | Filtration
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the filter to maintain the coolants
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 the
filters flow.
The high pressure pump has a
constant suction head of liquid so
its output will be stable. A variable
suction head can cause starving or
even cavitation, both of which can
shorten pump life.
This is the best practice and below
are two schematics of familiar existing
systems applied to individual ma-
chines. Their schemes are compared to
the Figure 2 layout to show their vul-
nerability. This is not an indictment on
the designers of these systems. Many
of these designs were developed to
stay within the limits of space and
money. Others may have evolved as
the needs in the machines operations
changed and high pressure pumps
were added to the station. They all
work and serve needs. However, they
do have weaknesses, which everyone
should be aware of and try to avoid
where possible.
TWO PROBLEMATIC ARRANGEMENTS
Figure 3 shows the most common
arrangement where the filter is tied
directly to the suction of the high
pressure pump. It is an in-line filter
trying to keep up with the demands of
the pump.
&?68/<+,363>C
1. As the filter loads, the flow
through it is throttled back and the
pump is sensing a dropping suction
head. The flow can be cut so low that
the 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 the
pump. 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 goes
through its machining sequence.
The constant change in flow and pres-
sure can routinely pulse (flex) the filter
each time, and two things can happen:
The element flexing can reach a
point to possibly rupture the
surface or cause channeling where
the cake and media open up
allowing dirty liquid to flow
through uncontrolled
When flow is stopped the cake can
slide down on the media, which
adversely affects the filters ability to
offer uniform cake filtration
Figure 4 reflects another common
arrangement where the filter is sand-
wiched between the discharge of the
primary supply pump and the suction
of the high pressure pump.
This arrangement is similar to Fig-
ure 3 except the difference is that Fig-
ure 3 shows the filter receiving coolant
from a common manifold or a pump
which is serving more functions and
not dedicated to the filter. This pump is
connected only to serve the filter.
&?68/<+,363>C
1. The same set of problems de-
scribed for Figure 3 occurs here as well.
2. The problems above are further
aggravated with the normal variances
occurring in the pressure changes in
the pumps. The pressure differential
across the media can be generated by
the pressure changes between the
pumps only. The element should only
be affected by the force of one pump,
not both. As the element gets dirty it
could easily be the variances in the two
pumps pressures, which push the ele-
ment to its set point and call for a
change. This would be a premat ure
change since the element itself is not
dirty enough to be changed on con-
tamination only.
SUMMARY
The basis of this article is to stress the
importance of an intermediate reservoir
working in conjunction with the filter to
serve the high pressure pump. The key
is to filter the liquid for the reservoir and
then let the high pressure pump draw
clean coolant from it.
Jim Joseph is a member of International
Filtration News' Editorial Board and an
industry consultant for coolant filtration.
Tel/Fax: 1-757-565-1549
Email: josephmarketing@verizon.net
Filtration
Mergers, Acquisitions
and Divestures
GL Capital, LLC
We understand the nuances of
the domestic and international
filtration industry and bring
over 70 years of combined
business, technical and finan-
cial expertise. The current eco-
nomic climate is an ideal time
for sellers to locate buyers
seeking to diversify and for
buyers to identify growth op-
portunities through acquisition.
For a condential conversation contact:
Edward C. Gregor
704-442-1940
ecg@egregor.com
P. John Lovell
719-375-1564
glcapital@comcast.net
FN
Coolant | Filtration
Read International Filtration News
online: www.filtnews.com
FN
News | Briefs
he world of filtration and sep-
aration will come to Germany
for FILTECH 2013 from Oc-
tober 22nd through the 24th. The
largest filtration show worldwide will
feature 300 exhibitors and will be ac-
companied by a three-day conference
presenting the latest filtration and sep-
aration research to an international au-
dience from around the world.
The FILTECH Congress will offer
a representative cross section of cur-
rent research findings, global devel-
opments, and new approaches to
solving problems with respect to the
methods for the classic mechanical
separation of particles from liquids,
the gas cleaning and membrane fil-
tration methods. This ranges from
mineral dressing to biotechnology,
pharmaceuticals, and chemicals
right up to environmental technol-
ogy and water purification. Special
highlights are a plenary and six sur-
vey lectures in which internationally
renowned experts give a comprehen-
sive overview of state of the art
knowledge and techniques concern-
ing important aspects of separation
technology. In addition, one day
prior to FILTECH 2013, two one-day
Short 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 abstract
submission and stand booking are
available at www.filtech.de.
T
lugged nozzles, coated heat
exchange surfaces and dirty
chillers are not only a costly
maintenance item but result in higher
operating costs. The only way to pre-
vent this potential is to remove sus-
pended solids from the distribution
system. The OR-Series of filters by Ori-
val, Inc. are designed to reliably remove
both organic and inorganic suspended
solids. With their highly efficient flush-
ing systems and large screen areas, Ori-
val OR Filters provide superior
performance and quick payback. OR
filters are generally mounted in a hori-
zontal configuration parallel to the pip-
ing for quick and easy installation. The
ORG-Series of Orival Filters offer the
same qualities and performance but in
a vertical mounting configuration. Pay-
back on investment has been docu-
mented as quickly as 33 days for flow
rates of 1100 gpm. Rugged OR and
ORG Filters, with their stainless steel
screens and rugged dirt collectors, do
not rely on electricity for filter opera-
tion. A simple integrated hydraulic sys-
tem manages the short cleaning cycle
triggered by a predetermined pressure
loss across the dirty screen. Complete
screen cleaning takes only 5-15 sec-
onds with no interruption of water
flow. Sizes are available from 1 to
24 with screen openings from 3000
microns down to 10 microns.
For more information:
Email: lters@orival.com
Website: www.orival.com
P
E63738+>381 H312 M+38>/8+8-/ C9=>= A3>2 O<3@+6 F36>/<=
Orival Filters
FN
C+66 09< +:/<= 09< FIL$ECH 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
M
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To place a Mini Mart Ad
Email: joan@filtnews.com
M
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Mergers & Acquisitions
GL Capital, LLC
Specialists in Mergers, Divestitures
and Acquisitions of filtration
industry companies with sales of
between $10 and $300 million.
For a confidential discussion contact:
Edward C. Gregor
704-442-1940
ecg@egregor.com
Advertiser Index
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A%#$"IA, GE"MAN),
#'I$*E"LAND
Martina Kohler
Frank Stoll
IFF Media AG
Emmersbergstrasse 1
CH-8200 Schaffhausen,
Switzerland
Tel: 41 52 633 08 88
Fax: 41 52 633 08 99
Email: m.kohler@iff-media.ch
Email: f.stoll@iff-media.ch
BENEL%(, F"ANCE
Sabine Dussey
INTERNATIONAL JOURNALS
Duppelstr. 7
D-42781 Haan, Germany
Tel: 49 2129 348390
Fax: 49 2129 3483910
Email: Sabine.Dussey@dussey.de
CHINA
Mr. Zhang Xiaohua
Mobile: 0086 13522898423
Mr. Han Jiwei
Mobil: 0086 13810778772
Email: ifj_china@yahoo.com.cn
Beijing, China
INDIA
Yogesh Jog
BRIDGE MEDIA
D-302, Shiromani Complex
Nr Nehrunagar Satellite Road
Opp Ocean Park, Satellite,
Ahmedabad 380015.
Tel: 91 79 26752628
Telefax: 91 79 26762628
Mobile: 98242 31895
Email: media.bridge@gmail.com
I$AL)
Ferruccio Silvera
Silvera Pubblicit
Viale Monza 24, I-20127 Milano, Italy
Tel: 39 02 284 6716
Fax: 39 02 289 3849
Email: ferruccio@silvera.it
JAAN
Kenji Kanai
3-9-25, Wakamatsudai, Sakai
Osaka 590-0116, Japan
Tel: 81 6 6343 4513
Fax: 81 722 93 5361
Email: fwpb9629@mb.infoweb.ne.jp
KO"EA
Young-Seoh Chinn
JES MEDIA Inc.
2nd Fl.,
ANA Building
257-1, Myungil-Dong
Kangdong-Gu,
Seoul 134-070, Korea
Tel: 82 2 481 3411/3
Fax: 82 2 481 3414
Email: Jesmedia@unitel.co.kr
$AI'AN
Buildwell Intl. Enterprise Co. Ltd.
No. 120, Huludun 2nd St., Fongyuan City
Taichung County 42086, Taiwan
Tel: 886 4 2512 3015
Fax: 886 4 2512 2372
Email: buildwel@ms23.hinet.net
%NI$ED KINGDOM
Judy Holland
Textile Media Services Ltd.
Homerton House, 74 Cawston Road
Reepham, Norfolk NR10 4LT, UK
Tel: +44 1603 308158
Fax: +44 8700 940868
Email: jholland@textilemedia.com
%#A, CANADA
Bob Moore
RAMCO
P.O. Box 4032
Cave Creek, AZ 85327
Tel: 1 480 595 0494
Fax: 1 480 595 1749
Email: ramco@qwest.net
ALL O$HE" CO%N$"IE#
Ken Norberg
Editor, International Filtration News
PO Box 265
Winchester, TN 37398 USA
Tel: 1 202 681 2022
Email: ken@filtnews.com
A2Z Filtration Specialities 11 www.a2zfiltration.com
AFS Conference Inside Back Cover www.afssociety.org
Ahlstrom 5 www.ahlstrom.com
Air Filter, Inc. 9 www.airfilterusa.com
Ashby Cross Co. 10 www.ashbycross.com
Clack Corporation 35 www.clackcorp.com
Contract Pleating Services 29 www.solentech.com
Dexmet Corporation 21 www.dexmetfilter.com
Ferguson Perforating 21 www.fn.perfnow.com
Flow Ezy 30 www.flowezyfilters.com
Industrial Netting 37 www.industrialnetting.com
JCEM-USA 1 www.jcem.ch
Magnetool Inc. 27 www.magnetoolinc.com
Metalex 39 www.metlx.com
Metcom Inc. 37 www.metcomusa.com
Orival Inc. 15 www.orival.com
PerCor Mfg. 35 www.percormfg.com
Perforated Tubes 19 www.perftubes.com
Rosedale Products 3 www.rosedaleproducts.com
Sealant Equipment 25 www.sealantequipment.com
Solent Technology Inc. 31 www.solentech.com
Sonobond Utrasonics 23 www.sonobondultrasonics.com
SpinTek Filtration Back Cover www.spintek.com
Xinxiang Tiancheng Aviation Inside Front Cover www.tchkjh.com

FN Ja Fe 2013

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