Design of Ultra filtration

System

Sanjeev Srivastava

Sponsored by
Index of Presentation
o What is Ultrafiltration?
o How it is different from Sand Filtration?
o UF, Nano, RO – Differentiation
o Process Understanding
o Material of Construction – Strength & Hydrophilicity
o Internal Structure of UF module.
o Basic for Design of UF in waste water, Calculation, dosing calculation
o Valves & Pipes Design
o BOQ for UF plant.
o Instrumentation, Automation & Control Philosophy of Ultrafiltration plant
o Pre-treatment to UF systems
o Operation, CIP & Maintenance, Data Log & Performance Indicators
 What is Ultrafiltration?
Evaporation Gas
Floating
Dissolved

Suspended

Inorganic Organic

Ionic, Na+Cl-
X
Inter Molecular
Space Colloidal

Non Ionic, SiO2 Sediment

Dead, BOD, COD, TOC etc.

Live, Bacteria, Virus etc.
What is Ultrafiltration?

Tubular Module Spiral Wound

Module

Plate And
Frame
Capillary
Module
Module
Multibore Module
How it is different from Sand Filtration?
Lets understand few things first :

For Big Void Space the Pore Size is large and therefore poor Filtration.

Quality of
Treated
water

Void Space
For small Void Space the Pore Size is small and therefore good Filtration.
How it is different from Sand Filtration?
Now let us pass some water thru these medias :

The Pressure Drop across the Coarse Media shall be lower in comparison to the
fine media.

Pressure
Drop

Further, Fine Media will arrest most impurities at the surface, but the Coarse
Media will allow to get some in it’s depth.
How it is different from Sand Filtration?
The pore size of UF membrane ranges
from 0.001 micron -0.02 micron

. Filtration Back Wash During Back Wash

Water
Cross-Flow and Dead – End Filtration
o Unfortunately, we are yet to make UF membrane that changes its Pore Size during Backwash
o Thus We follow a different Technique, called Cross Flow Filtration

Cake thickness

Flux
Therefore;
Cake thickness
Flux
1. We will generate 5-10% Waste Stream
Time Time that can not be looped back
Concentrate
2. Can be sent to inlet of ETP

3. Use Dead End only for Very Clean

water e.g. Borewell
Permeate

Crossflow Deadend
UF, Nano, RO – Differentiation
Parameter Unit Feed UF NF RO
pH 7 ~7
TSS mg/l 35 1 0 0
Turbidity NTU 104 1 0 0 0 – means it will remove
Oil & Grease mg/l 12 1 0 0 but Foul
Colloids SDI >7 1 0 0
Color - Soluble Pt Co 83 40 35 15
Color - Pigment Pt Co 45 1 0 0 Gases : Will not be
Fe mg/l 6 1 0 0 removed by Any process
Pb mg/l 2 1 0 0
Zn mg/l 1 1 0 0 COD Removal : MWCO
Dependent
Ca & Mg mg/l 120 1 0
SO4, CO3 mg/l 125 1 0

Na, K mg/l 170 170 0

Cl, NO3, HCO3 mg/l 310 310 0

SiO2 mg/l 22 11 0
CO2 mg/l 6 6 6 6
COD - Organics Soluble mg/l 120 60 35 0
COD - Organics Particulate mg/l 10 1 0 0
Pathogens - Bacteria, Virus TBC / 1000 ml 10^5 1 0 0
Endotoxins - Bacteria Dead Body EU/100 ml 200 1 0 0
 Process Understanding FT

V2
IV2
V3 PT

B/W Inlet
FI
V4 V6 V8

Cross Flow out

B/W out
To Client

CIP out
HLS
Permeate Tank B/W
Pump
LLS

Drain
V5
Drain To ETP

Auto Ball Valve FT Flow Transmitter CIP CIP Tank

Manual Ball Valve Pum
IV1 CIP Inlet p
IV-Isolation Valve PT Pressure Transmitter
FT V7
FI PT
Flow Indicator LLS Low Level Switch V1

HLS High Level Switch

HLS
From Client
Feed Tank Feed
Feed
LLS
Pump
Pump
UF : Sequential Operation
Fig.1 : GRAFiL UF Sequence Diagram
Material of Construction – Strength
It’s often a Misunderstood Subject, we don’t hang on
fibers

The In and Out Dia is different

So In or Out surface is different

Outer surface is always high then

inner surface (πdh)

Velocity (Shear) across material is

thus a point of consideration of
strength of material.
Material of Construction – Hydrophilicity
Material of Construction – Hydrophilicity

❑ Since Water & Chemical need to be loved by membranes, they must be hydrophilic
for better cleaning during CIP.

❑ Do we clean our Eyes with HCl? Or NaOH? (NO)

❑ The higher the Hydrophilicity, better is cleaning and you can virtually clean your
membranes just by Water (We are yet to make such level of Hydrophilicity)
Internal Structure of UF module

Outer
skin

Microscope Image (to determine ID &

OD Inner
ID = 0.72-0.73 mm skin
OS = 1.13-1.14 mm
Wall thickness = 0.19-0.21 mm

SEM image
Design of UF – Before We design

o Type of Water –
1. Bore
2. Sewage
3. Effluent
4. With Solvents
5. Sea Water

o Remember: UF is never a stand alone plant, we

have either something Up Stream or Down
Stream
o m3/day .. Production need (nett)

Engineering Fact Request for

Sheet Design
Design of UF : Terminology
Is specific to the membrane manufacturer.
❖ Key words

- Batch Process (Filtration/Backwash/Drain/CEB)

- Cycle Time (30 or 60 min)

- Flux – Flow (rate lit/h) / m2 of membrane – LMH l/m2.h

- Backwash Flux l/m2/h

- TMP Clean = Avg Applied Pressure – Product Pr

- =[ (Feed Pr + Reject Pr)/2] – Product Pr

UF Software
Design of UF : CEB

Both duration are

Cake layer 60 sec Scaling
Pore blocking Adsorption

Backwash : Use UF Treated Product in Backwash : Use UF Treated Product in

reverse direction reverse direction + Add Chemicals

- HCl : 500 mg/l

- NaOH : 200 mg/l
- NaOCl : 1000 mg/l
Valves & Pipes Design
Sr No Parameter Unit Value
1 Feed Flow m3.h-1 6.43
2 Cross Flow m3.h-1 0.71 Consider Water Velocity in Pipe : 2 m/s
3 Feed Flow with Cross Flow m3.h-1 7.14
4 Permeate Flow (nett) m3.h-1 6 For CIP Tank Size :
5 BW In Flow m3.h-1 26.4
System Volume + 50% Extra for plant up to 2 m3/h
6 BW Out Flow m3.h-1 26.4
7 Filtration Flux l.m-2.h-1 40 System Volume + 15% Extra for plant up to 2 m3/h
-2 -1
8 B/W Flux l.m .h 160
9 CIP In flow m3.h-1 7.14
10 Membrane Type - GRAFil 8060
11 Membrane Nos Nos 3
12 Port Connection Size mm 50
13 CIP Tank Size - Calculated l 198
14 CIP Tank Size Provided l 250

Pipe & Valve

Valves & Pipes Design
Sr No Valve ID Valve Tag Calculated Size Selected Size Quantity Type of Valve
1 Feed Effluent V1 35.5 50 1 Auto
2 Permeate V2 33.7 50 1 Auto
3 BW In V3 68.3 80 1 Auto
4 BW Out V4 68.3 80 1 Auto
5 Cross Flow Out (Continueos) V6 11.2 20 1 Manual
6 Drain V5 35.5 50 1 Manual
7 CIP Chem In V7 35.5 50 1 Manual
8 CIP Chem Out V8 35.5 50 1 Manual
9 Module Isolation IsoVs NA 50 6 Manual

Consider Water Velocity in Valve : 2 m/s

For Plants > 35 m3/h, Valve Velocity may be 2.2 m/s

Selection of Components for UF plant.
Sr No Type Item Tag No. MOC Unit Size/ Capacity Quantity
1 Mech Feed Tank HDPE m3 1

2 Electro Mech Feed Water Pump P1 SS 316 7.14 m3/h @ 2 Kg/Cm2 1

3 Electro Mech Suction Valve UPVC-M 50 NB, Ball Valve 1
4 Electro Mech Discharge Valve UPVC-M mm 50 NB, Ball Valve 1
5 Electro Mech Discharge Valve - NRV UPVC-M mm 50 NB, NRV 1
6 Instrument Pressure Gauge SS Boudon 1
7 Electrical Motor KW 0.5 KW
1 Mech Product Tank HDPE m3 1
8 Electro Mech Backwash Water Pump P2 SS 316 26 m3/h @ 1.5 Kg/Cm2 1
9 Electro Mech Suction Valve UPVC-M 80 NB, Ball Valve 1
10 Electro Mech Discharge Valve UPVC-M mm 80 NB, Ball Valve 1
11 Electro Mech Discharge Valve - NRV UPVC-M mm 80 NB, NRV 1
12 Instrument Pressure Gauge SS Boudon 1
13 Instrument PG Isolation Valve SS Bourdon
14 Electrical Motor KW 0.5 KW
15 Electro Mech CIP Pump P3 SS 316 7.14 m3/h @ 2 Kg/Cm2 1
16 Electro Mech Suction Valve UPVC-M 50 NB, Ball Valve 1
17 Electro Mech Discharge Valve UPVC-M mm 50 NB, Ball Valve 1
18 Electro Mech Discharge Valve - NRV UPVC-M mm 50 NB, NRV 1
19 Instrument Pressure Gauge SS Boudon 1
20 Electrical Motor KW 0.5 KW
21 Mechanical CIP Tank Tank HDPE L 250 L 1
23 Module GRAFiL 8060 Module UF UF Membrane m2 55 m2 3
24 I/C Valves Feed Valve V1 Auto Ball Valve mm 50 mm 1
25 I/C Valves Permeate valve V2 Auto Ball Valve mm 50 mm 1
26 I/C Valves Backwash In Valve V3 Auto Ball Valve mm 80 mm 1
27 I/C Valves Reject Valve (BW Out Valve) V4 Auto Ball Valve mm 80 mm 1
28 I/C Valves Drain Valve V5 Manual Ball Valve mm 50 mm 1
29 I/C Valves Cross Flow Valve V6 Manual Ball Valve mm 20 mm 1
30 I/C Valves CIP In Valve V7 Manual Ball Valve mm 50 mm 1
31 I/C Valves CIP Out Valve V8 Manual Ball Valve mm 50 mm 1
33 I/C Valves Manual Isolation valve IV 1, IV 2 Manual Ball Valve mm 50 mm 4
34 Instrument Pressure Transmitter PT 2
35 Instrument Flow Transmitter/ IndicatorFT / FI 2
36 Instrument Control Panel - PLC 1
37 I/C Pipework Lot 1
38 Skids Lot 1
Instrumentation, Automation & Control Philosophy

Rule 1 : Instrumentation can never be more then expectation of process design engineer

At t = 0 : Plant goes in service by an operator and what would they like to know?

What How Log (Yes / No)

Feed Flow Manual Yes
Feed Pressure Manual Yes
Cross Flow Manual Yes
Product Flow Manual Yes
Reject Pressure Manual Yes
Product Pressure Manual Yes
Instrumentation, Automation & Control Philosophy

At t = 25 Sec : What will happen, off-course some deposition on membrane will result in

What How Observation Change

Feed Flow Manual Yes ↓
Feed Pressure Manual Yes ↑
Cross Flow Manual Yes →
Product Flow Manual Yes ↓
Reject Pressure Manual Yes ↑
Product Pressure Manual Yes →

Would you like to sit near plant and regulate it for 48 time a day * 7 days a week. NO
Instrumentation, Automation & Control Philosophy

Rule 2 : UF Plant is always Auto Operation wrt to Service Cycle

Filtration, Backwash & CEB (if Needed)

Rule 3 : Membrane shall not Foul, we should have Auto Cure or At-least Stoppage of Plant in case of
failure to our operational Idea.

1. Increase in TMP beyond the limiting no < 1.5 kg/Cm2 (Low Cost - DPT or Individual PTs)
2. Increase in Feed Pressure > 3.0 kg/Cm2 (Lowest Cost - Pr Switch)
3. Drop in Permeate Production? (High Cost – Flow Transmitters – recommend for large
Plants, connected with VFD to regulate Feed flow and allow to increase permeate
production till allowed by PT readings)
4. Etc.
Pre-treatment to UF systems

o Any thing that is needed to ensure Feed Limiting conditions are within limit wrt

1. TSS (Refer Individual Membrane Guideline)

2. Turbidity (No Thub’s Rule)
3. Temperature
4. COD Additionally for In to Out Membrane, we have limit on particle Size to
5. Oil & Grease enter in UF Fiber. One must put a Basket Strainer of Micron rating i.e =
6. Free Residual Chlorine Inner pore Dia in mm ÷ 8, i.e. if pore Dia is 2 mm or 2000 micron, the
basket strainer micron rating shall be 125 micron. Any larger particle
7. pH
entering the UF fiber(Inside) is not recommended.

For Out to In Filtration Basket Strainer of 200 micron is good.

Operation, CIP & Maintenance, Data Log &
Performance Indicators
Operation, CIP & Maintenance, Data Log &
Performance Indicators
 Operation, CIP & Maintenance, Data Log &
Performance Indicators

Level Pressure

Cartridge Filter UF
Permeate Delta P UF Feed UF Reject
Feed Tank Reject Tank Permeate TMP
Tank Max (Total) (Total)
(Total)
Inlet Outlet P

m m m Kg/Cm2 Kg/Cm2 Kg/Cm2 Kg/Cm2 Kg/Cm2 Kg/Cm2 Kg/Cm2

A B C D E F K P U V
5 3 2 10 8 2.00 10 0 10 5
 Operation, CIP & Maintenance, Data Log &
Performance Indicators

Flow

Permiability
(m3/hr)/(Kg/cm2)
UF Feed (Cumulative) UF Feed UF Reject UF Permeate
TMP UF F
(Total) (Total) (Total)
PLANT-1 PLANT-2 PLANT-3 PLANT-4

Kg/Cm2 m3/hr m3/hr m3/hr (m3/hr)/(Kg/cm2) PP

V W X Y Z AA AF AK AL AM
5 50 50 50 50 200 80 120 24 20
 Operation, CIP & Maintenance, Data Log &
Performance Indicators

TSS Turbidity BOD C

m2)
UF UF U
UF Feed UF Reject UF Feed UF Reject UF Feed UF Permeate UF Reject UF Feed
Permeate Permeate Perm

m2) PPM PPM PPM NTU NTU NTU mg/l mg/l mg/l mg/l m
AM AN AO AP AQ AR AS AT AU AV A
200 10 190 500 10 490 1000 70 930 200 1
 Operation, CIP & Maintenance, Data Log &
Performance Indicators

COD Oil & Grease

Remarks
UF UF
e UF Reject UF Feed UF Reject UF Feed UF Reject
Permeate Permeate

mg/l mg/l mg/l mg/l mg/l mg/l mg/l

AU AV AW AX AY AZ BA
930 200 10 190 400 0 400

Log Sheet
Operation, CIP & Maintenance, Data Log &
Performance Indicators
o During UF Operation the Foulants starts depositing on the surface of the membrane and If the Feed Energy is
constant:

o It will results drop in productivity (Flux).

o To restore productivity the operator shall increase the feed energy (throttle FC Valve of Feed Pump)

o Permeate is open to atmospheric pressure, this method will increase the Trans membrane pressure
differential (TMP). But the good thing is production will restore.
Operation, CIP & Maintenance, Data Log &
Performance Indicators
❑ Membrane performance indicator is Permeability

❑ (Can be calculated by Flux ÷ TMP), in Auto if you have FTs and PTs and can be fed to PLC

❑ When Fouling occurs Permeability decreases.

❑ To restore the membrane performance throttle Feed Valve (Additional Auto Valve)

❑ If it drops to 15% of Original Commissioning Values - must perform CIP.

❑ Be aware the TMP can not be higher than the maximum recommended TMP in Process Engineering
Datasheet
Thanks for your Attention

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