Membrane filtration
Product Centre Membranes
PC Membranes
Alfa Laval
Main Menu
Alfa Laval Nakskov A/S
What is membrane filtration?
Product range
Applications
References/case stories
Alfa Laval
Slide 3
www.alfalaval.com
One of the pioneers
Late 1950s
Membrane filtration introduced
1965
DDS Filtration
1989
Dow Liquid Separation Systems
1997
Danish Separation Systems AS
2002
Alfa Laval
Alfa Laval
Slide 4
www.alfalaval.com
Alfa Laval Nakskov A/S
In-house membrane production
Spiral membrane rolling
Customer test centre for application
development
Pilot equipment from few m to 200m
Plate-and-frame and spiral module
production
Copenhagen
Engineered membrane systems
R&D department
Complete separation solutions (synergy)
Alfa Laval
Slide 5
Nakskov
www.alfalaval.com
What is membrane filtration?
Membrane filtration is a physical
separation process and the driving
force is the pressure difference across
the membrane. It is characterised by
the ability to separate molecules of
varying sizes and characteristics by
using different membrane types.
Alfa Laval
Slide 6
www.alfalaval.com
Separation processes and mechanisms
Alfa Laval
Slide 7
www.alfalaval.com
Membrane filtration
Physical separation process
Semi-permeable barrier
One feed stream split into two individual
streams
Driving force is pressure
Either stream may contain the desired product
Feed . .
Membrane
Alfa Laval
. .
. .. .
.. .
. .. ..
.. . .
..
. .. .
. . .
.
. .
.
. . . .. .
. . .
.
.
.
. . . . . . . Retentate
. .
. . . . .
.
. . . .. ..... . . . Permeate
. .
.
Slide 8
www.alfalaval.com
Cross-flow filtration
Cross-flow filtration
No filter cake
No use of filter aids
Feed . .
Membrane
. .
. .. .
.. .
. .. ..
.. . .
..
. .. .
. . .
.
. .
.
.
.
.
. .. .. . .
.
.
. . . . . . . Retentate
. .
. . . . .
. . . . .. ..... . . . Permeate
. .
.
Uniform, controllable product quality
Continuous, automated process
Long membrane lifetime
CIP cleaning
Filter cake
Alfa Laval
Slide 9
www.alfalaval.com
Membrane structure
UF & MF membrane
Thin top layer (0.10.5 m)
Porous sub-layer (50150 m)
Support paper for mechanical
stability (100200 m)
Different polymers
Cellulose acetate/triacetate
Polysulphone/polyethersulphone
Fluoropolymers
Composite membranes
NF & RO - thin-film membrane
polymerization of barrier layer
Alfa Laval
Slide 10
www.alfalaval.com
The membrane
GR60PE surface, mag
100,000 x
High mechanical strength
High porosity
Sharp cut-off value
Excellent temperature, pH, and
chemical resistance
GRM 0.2m surface,
20,000 x
Easy to clean
Alfa Laval
Slide 11
www.alfalaval.com
Reverse osmosis
Only water will pass
NaCl rejection > 9596%
Typical operating pressure 1560 bar
Concentration of liquids with low molecular
compounds at low solid levels
Alfa Laval
Slide 12
www.alfalaval.com
Nanofiltration
Slightly more open than RO
MgSO4 rejection > 97%
Typical operating pressure 535 bar
Allows monovalent ions to pass
Rejects divalent and larger ions and most organic components
Alfa Laval
Slide 13
www.alfalaval.com
Ultrafiltration
MWCO: 1,000100,000
Typical operating pressure 110 bar
Allows salts, sugars, organic acids and smaller peptides
to pass
Rejects proteins, fats and polysaccharides
Alfa Laval
Slide 14
www.alfalaval.com
Microfiltration
Pore size 0.11 m
Typical operating pressure < 2 bar
Only suspended solids, bacteria and fat globules are
rejected
Alfa Laval
Slide 15
www.alfalaval.com
Operation
Batch
Continuous
Diafiltration
Batch
Pre-treatment
Automation and control
Cleaning
Alfa Laval
Slide 17
www.alfalaval.com
Batch operation
Retentate recycled until final concentration is reached
Minimum membrane area
Minimum automation
Used when holding time is not critical
Alfa Laval
Slide 18
www.alfalaval.com
Continuous operation
Multiple loops with own recirculation pumps
Module selected to fit actual viscosity
Low residence time
Can be fully automated
Permeate
Feed
Retentate
Alfa Laval
Slide 19
www.alfalaval.com
Diafiltration
To increase the purity of a given
product
Addition of water (or permeate) to retentate
to wash away impurities
Batch or continuous
Additional membrane area required to remove added water
Permeate
Feed
Retentate
Diafiltration water
Alfa Laval
Slide 20
www.alfalaval.com
Pre-treatment
To reduce fouling and ensure optimum plant
performance
Most common pre-treatment methods:
Centrifugation
Filtration
Heating/cooling
pH adjustment
Enzyme treatment
Alfa Laval
Slide 21
www.alfalaval.com
Automation and control
To secure overall plant
performance
To protect sensitive membranes
(temperature, pressure, pH)
Different levels of automation
Manual
Semi-automatic
Automatic
Alfa Laval
Slide 22
www.alfalaval.com
Cleaning
To promote the optimum membrane
performance
Cleaning In Place (CIP)
Typically once per day or batch
Chemical cleaning agents
Recycling through system
Given pH, temperature and pressure
Specific water quality requirements
Alfa Laval
Slide 23
www.alfalaval.com
Why use membrane filtration?
Lower cost of
production
Lower installation and energy costs
Increased yields
Environmentally responsible solution
Fewer processing steps
High end
product quality
Clean technology
Higher degree of purity
Compliance with stringent requirements
Flexibility
Alfa Laval
Range of viscosities
Continuous or batch
Modular structure
Slide 24
www.alfalaval.com
Major processes
Membrane filtration can sucessfully be used for the following
processes:
Concentration
Purification
Clarification
Recycling
Product upgrading
Extraction
Recovery
Effluent upgrading
Fractionation
Alfa Laval
Slide 25
www.alfalaval.com
Wide range of products
Membranes
Modules
Pilot equipment and test facilities
Systems and process lines
Spare parts and service
Alfa Laval
Slide 26
www.alfalaval.com
Membranes
For all filtration processes RO, NF, UF, MF
Different combinations of polymers and support paper
Resistant to high temperature and wide pH range
Compliance with EU and FDA
Flat sheet membranes
Available
by the metre
20 x 20 cm sheets
Rolls 500 750 metres
for all plate-and-frame configurations
Alfa Laval
Slide 27
www.alfalaval.com
Membrane overview
Membrane
process
RO
NF
Membrane
Series
Characteristics
pH
Pressure, bar
Temperature, C
CA995PE
Cellulose triacetate/diacetate
blend
NaCl rejection
95%
5-6.5
1-50
0-30
RO98pHt
Thinfilm composite on
polypropylene
NaCl rejection
96%
2-11
1-60
0-60
NF99
Thinfilm composite on polyester
MgSO4 rejection
99%
2-10
1-55
0-50
UFX5
Polysulphone permanently
hydrophilic
MWCO = 5,000
1-13
1-15
0-75
UFX10
MWCO = 10,000
1-13
1-15
0-75
GR40PP
MWCO = 100,000
1-13
1-10
0-75
2-8
1-10
0-50
1-11
1-10
0-60
1-10
1-10
0-60
1-11
1-10
0-60
1-11
1-10
0-60
1-13
1-10
0-75
Name
RO
NF
UFXpHt
GR51PP
UF
UF-pHt
UF-RC
UF-ETNA
MF-FSM
MF
MWCO = 25,000
MWCO = 20,000
Alfa Laval
CA600PP
FS40PP
FS61PP
RC70PP
ETNA01PP
ETNA10PP
FSM0.15PP
Polyethersulphone
Cellulose acetate
Fluoro polymer
Regenerated cellulose acetate
Composite fluoro polymer
Fluoro polymer
FSM0.45PP
MF-GRM
MWCO = 50,000
GR61PP
GR95PP
UF-FS
Polysulphone
GR60PP
GR81PP
UF-PP
Recommended operation limits - production
Membrane material
GRM0.1PP
GRM0.2PP
MWCO = 10,000
MWCO = 2,000
MWCO = 20,000
MWCO = 100,000
MWCO = 20,000
MWCO = 10,000
MWCO = 1,000
MWCO = 10,000
Pore size 0.15 m
Pore size 0.45 m
Polysulphone
Pore size 0.1 m
Pore size 0.2 m
Slide 28
www.alfalaval.com
Membranes
Feed spacer
Spiral membranes
Membrane
Permeate spacer
Cost-effective
Membrane
Permeate tube
Full-fit, sanitary design
Comprehensive range of elements
(membrane, diameter, length, spacer)
Alfa Laval
Slide 29
www.alfalaval.com
Membranes
Alfa Laval
Slide 30
www.alfalaval.com
Spiral membrane overview
Membrane
Series
RO
Membrane material
Pressure, bar
Temperature, C
NaCl rejection 95%
5-6.5
10-28
5-20
Thinfilm composite on
polypropylene support paper
NaCl rejection 97%
2-10
1-55
0-60
Thinfilm composite
NaCl rejection 98%
3-10
1-55
0-50
3-10
Max. 55
Max 50
2-10
1-10
0-75
2-10
1-10
0-75
1-13
1-15
0-75
3-9
1-10
0-50
Cellulose triaceate/diacetate
blend
RO98pHt
RO99
NF99
Polyamide type thinfilm
composite on polyester
NF99HF
UF
SSE20
Polyethersulphone
GR40PP
GR51PP
UF-pHt
UFX-pHt
UF-PE
MgSO4 rejection
97%
MgSO4 rejection
98%
MgSO4 rejection
98%
MWCO = 20,000. Inline sterilisable spiral
element
MWCO = 100,000
Polysulphone
MWCO = 50,000
GR60PP
MWCO = 25,000
GR61PP
MWCO = 20,000
GR81PP
MWCO = 10,000
GR95PP
UFX5 pHt
Polyethersulphone
Polysulphone permanently
hydrophilic
MWCO = 2,000
MWCO = 5,000
UFX10 pHt
MWCO = 10,000
GR60PE
MWCO = 25,000
GR61PE
Recommended operation limits - production
pH
CE4040C-30D
(based on CA995PE)
NF97
NF
Characteristics
Name
Polysulphone
GR70PE
MWCO = 20,000
MWCO = 20,000
GR81PE
Polyethersulphone
MWCO = 10,000
UF-FS
FS40PP
Fluoro polymer
MWCO = 100,000
2-10
1-10
0-60
UF-RC
RC70PP
Regenerated cellulose acetate
MWCO = 10,000
2-10
1-10
0-60
2-10
1-10
0-60
1-11
Max. 1.5
0-60
1-11
Max. 1.5
0-60
ETNA01PP
UF-ETNA
MF-FSM
ETNA10PP
FSM0.15PP
FSM0.45PP
MWCO = 1,000
Composite fluoro polymer
Fluoro polymer
GRM0.1PP
MF-GRM
Alfa Laval
GRM0.2PP
MWCO = 10,000
Pore size 0.15 m
Pore size 0.45 m
Pore size 0.1 m
Polysulphone
Pore size 0.2 m
Slide 31
www.alfalaval.com
Modules
Spiral modules
Compact
Inexpensive
Easy to use
Housing
ATD
Spiral element
Retentate
Permeate
Alfa Feed
Laval
Slide 32
www.alfalaval.com
Modules
Plate-and-frame modules
Wide viscosity range
Channel height to match
varying product characteristics
High tolerance to suspended
material, therefore less pretreatment required
Easy re-establishment of
membrane performance
Alfa Laval
Slide 33
www.alfalaval.com
Module range
Plateandframe
Spiral
- high viscosity and solids capability for max. concentration
- open channel sanitary design
- low running cost
- compliant with FDA and EEC regulations
- large membrane area per module for compact design
- resistant to high temperature and full pH scale
- low investment cost
- compliant with FDA and EEC regulations
Reverse Osmosis
Alfa Laval
Nanofiltration
Ultrafiltration
Slide 34
Microfiltration
www.alfalaval.com
Pilot laboratory equipment
To establish process feasibility
To determine design data for scale-up
final product composition
required operation parameters
necessary cleaning procedure
To demonstrate process solutions
To optimize existing production lines
For small-scale processing
Alfa Laval
Slide 35
www.alfalaval.com
From lab to pilot
Rental
equipment
Pilot plant
Nakskov
Capacity
Lab
tests
R&D
&
&
pilot
lab
tests
0
Alfa Laval
Scale
Slide 36
www.alfalaval.com
Pilot laboratory equipment
Rental equipment
For on-site testing
Close technical support
Wide range of equipment
Alfa Laval
Slide 37
www.alfalaval.com
Pilot laboratory equipment
Pilot plant Nakskov
State-of-the-art customer test
facilities
Production size modules
Large volumes
Expert technical staff
Joint tests with customers
Alfa Laval
Slide 38
www.alfalaval.com
Membrane filtration systems
Tailor-made solutions
Developed in close cooperation with
customers
application
process requirements
choice of membranes
Spiral, plate-and-frame or combined
systems
Batch and continuous operation
Sanitary and industrial design
Installation support and commissioning
Slide 39 installed world-wide
More than 2,000 membrane filtration systems
Alfa Laval
www.alfalaval.com
Plate-and-frame systems
Alfa Laval
Slide 40
www.alfalaval.com
Plate-and-frame systems
Alfa Laval
Slide 41
www.alfalaval.com
Spiral membrane systems
Alfa Laval
Slide 42
www.alfalaval.com
Spiral membrane systems
Alfa Laval
Slide 43
www.alfalaval.com
Process lines
One system one supplier
Heat Transfer
Separation
Membrane
Filtration
Fluid
Handling
Alfa Laval
Slide 44
www.alfalaval.com
Process lines
Synergies - Evaporator
Alfa Laval
Slide 45
www.alfalaval.com
Process lines
Synergies High speed separator
Alfa Laval
Slide 46
www.alfalaval.com
Process lines
Synergies Decanter
Alfa Laval
Slide 47
www.alfalaval.com
Spare parts and service
Membranes
Genuine spare
parts
Plates
System spares
Guarantee of
performance quality
Re-membraning
Day-to-day
support
Tailor-made
service
agreements
Alfa Laval
Emergency service
Troubleshooting
Training
Performance analysis
Upgrading
Preventive maintenance
Re-membraning
Training
Slide 48
Reduction of
downtime
Long-term cost
savings
www.alfalaval.com
Major applications
We help customers to
separate products such as
water, chemicals, beverages,
foodstuff, starch and
pharmaceuticals.
Alfa Laval
Slide 49
www.alfalaval.com
Major applications
Alfa Laval
Slide 50
www.alfalaval.com
Pharma and biotech
Antibiotics
UF and MF recovery and purification
NF and RO concentration and
desalting
For increased efficiency and higher
product quality
Enzymes
UF for concentration, purification, and
desalting
NF for recycling of water
For higher concentration and purity
with minimum loss of activity
Alfa Laval
Slide 51
www.alfalaval.com
Pharma and biotech
Polysaccharides
UF and NF concentration and purification
in one process at low cost
Amino acids
UF recovery and purification and RO
concentration
For high product quality and low costs
Yeast extract
UF for recovery and purification
RO for concentration
For high purity and reduced water
Alfa Laval consumption
Slide 52
www.alfalaval.com
Major applications
Alfa Laval
Slide 53
www.alfalaval.com
Food and beverages
Beer
RO for beer dealcoholization
Quality in line with standard beer
at low cost
Food gums
UF for concentration and purification
RO for recycling of permeate
High purity at minimum operating costs
Gelatine
UF for fractionation, concentration
and purification
For gentle processing to avoid
denaturation
Alfa Laval
Slide 54
www.alfalaval.com
Food and beverages
Juice
UF for clarification
RO for concentration
For greater profitability
and better quality
Eggs
UF for concentration of egg white and whole egg
RO for dewatering of egg white prior to drying
For gentle treatment and high-quality product
Alfa Laval
Slide 55
www.alfalaval.com
Food and beverages
Wine
RO for the concentration of grape juice
RO for colour concentration from red wine
NF for aciditiy reducation in wine
NF/RO for dealcoholisation of wine
Animal blood plasma
UF for concentration and purification
Vinegar
UF for clarification
Alfa Laval
Slide 56
www.alfalaval.com
Sugar and starch
Sugar industry
UF for removal of haze and colour from
sugar syrup
RO for concentration of sugarwater
Starch industry
MF/UF for mud removal after
saccarification
UF for polishing/pyrogen removal from
dextrose and HFCS
Sugar and starch industry
RO for evaporator concentrate polishing
RO for sweet water purification and
polishing
Alfa Laval
Slide 57
www.alfalaval.com
Pulp and paper industry
Paper industry
UF for colour recovery
UF & NF/RO for white water purification
Pulp industry
UF for the purification and concentration of
lignin from KBL and SSL
Pulp and paper industry
UF/NF/RO for evaporator condensate
polishing
Alfa Laval
Slide 58
www.alfalaval.com
References
Novo Nordisk
Glaxo SmithKline
Antibioticos
Milei GmbH
Arla Foods
Unilever
Citrosuco
Danisco Cultor
Lonza Biotec s.r.o
Biotech Paskov
Alfa Laval
Slide 59
www.alfalaval.com
Lonza Biotec s.r.o., Czech Republic
Reliable performance
Through 16 years of collaboration, Alfa Laval has installed, restored
and replaced a number of membrane filtration systems.
For us, the important things are an informal yet close collaboration,
mutual trust, willingness to cope with problems, and a
high degree of professionalism. It is a pleasure to work with a
company that acts like a real partner, rather than a mere supplier.
Its exactly what were trying to provide for our own customers.
Tomasz Cieslewski, site manager, Lonza Biotec, s.r.o., Czech Republic
Alfa Laval
Slide 60
www.alfalaval.com
Serum-Werk Bernburg, Germany
Easy expansion
Serum-Werk Bernburg installed its first membranes from Alfa Laval
in 1996. Advanced membranes ensure that only molecules of a
specific size are retained. It is also important that the processed
products are sterile, and ultrafiltration at high temperatures is how
we stop the growth of germs.
Due to the modular design of the membrane filtration system it was
easy to double the companys production capacity in 2002 and we
want to achieve another doubling of capacity next year
Werner Zimmermann, head of technology, Serum-Werk Bernburg,
Germany
www.alfalaval.com
Alfa Laval
Slide 61
Citrosuco, Brazil
Fruitful cooperation
Citrosuco installed an ultrafiltration plate-and-frame plant for orange
juice processing in 1996. However, peel oil is very aggressive, and
the oil was basically destroying part of our equipment. Alfa Lavals
engineers worked with us on a series of tests and experiments and
support plates were developed that could withstand the oil-rich juice.
The success of this innovation led to upgrading of all 16 modules in
2002, and the signing of a five-year service agreement.
Srgio Moretti, production manager, Citrosuco, Brazil
Alfa Laval
Slide 62
www.alfalaval.com
Edidan/Danish Crown, Denmark
Boosting capacity
When we reached our capacity limits, Alfa Laval gave us an
alternative to extending the dryer unit by installing a spiral
booster unit prior to the existing Plate & Frame unit.
This spiral unit undertakes preliminary concentration of blood
plasma. We can now boost production capacity by 50% with no
changes to the drying unit. Obviously, its much cheaper to remove
water by simply filtering it out.
Aage Christensen, plant manager, Edidan/Danish Crown, Denmark
Alfa Laval
Slide 63
www.alfalaval.com
BIOTECH Paskov,Czech Republic
Experience makes the difference
As it is fully automated, the ultrafiltration plant requires very little
attention from operators. They occasionally check the relevant
parameters, but do not generally have to take specific action.
Jan Jon, production manager, BIOTECH Paskov, Czech Republic
Alfa Laval
Slide 64
www.alfalaval.com
