Microfiltration

The water to be filtered by these water-treatment plants is relatively clean, so a microfiltration system called semi-dead-end filtration is often used. In these systems, the membrane unit is operated as an inline (dead-end) filter until the pressure required to maintain a useful flow across the filter reaches its maximum level. At this point, the filter is operated in a crossflow mode, while concurrently backflushing with air or permeate solution. After a short period of backflushing in crossflow mode to remove material deposited on the membrane, the system is switched back to dead-end operation. This procedure is particularly applicable in microfiltration units used as a final bacterial and virus filter for municipal water treatment plants. A photograph of a municipal microfiltration plant of this type is shown in Fig. 7.5. 

Microfiltration plants are also being installed in membrane bioreactors to treat municipal and industrial sewage water. Two types of systems that can be used are illustrated in Fig. 7.6. The design shown in Fig. 7.6(a), using a crossflow filtration module, was developed as early as 1966 by Okey and Stavenger at Dorr-Oliver [17]. The process was not commercialized for another 30 years for lack of suitable membrane technology. In the 1990s, workers at Zenon [15,16] in Canada and 

The first company to produce a successful membrane-based gas-separation process was Permea, now a division of Air Products, which introduced hollow-fme-fiber polysulfone membranes for the separation of hydrogen from ammonia reactor purge gas in 1980. This application was an immediate success the feed gas was clean and free of condensable components that might damage the membranes, and the value of the recovered hydrogen provided short payback times. Within a few years, many ammonia plants worldwide had installed these units. Several hundred hydrogen-separating systems have now been installed by Permea and its competitors. 

Following this success, Generon, now a division of MG Industries, introduced a membrane process to separate nitrogen from air. The first-generation mem- 

Other membrane-based gas-separation applications that developed in the late 1980s and the 1990s include the separation of carbon dioxide from natural gas, separation of organic vapors from air and nitrogen, and dehydration of air. Table 7.3 lists the major companies involved in the industry and their principal markets. Currently, total industry sales are estimated to be about US 200 million. Of all the industrial membrane-separation processes, gas separation is 

MF can be categorized between conventional filtration and UF. The process is used to filter very small particles (usually 10 pm in size) from a suspension, by using a membrane with very fine pores. Examples of MF include the separation 

The resistance of the cake can be correlated with the mass of cake per unit filter area  

The cells and cell lysates (fragments of disrupted cells) can be separated from the soluble components by using microfiltration (see Chapter 8) with membranes. This separation method offers following advantages  

MF units are widely used for turbidity removal (Hillis (1997), Tsatsaronis and Durham (1996), Ho et al. (1995)). Ho et al. (1995) installed a MF unit for turbidity and fine particles were removed satisfactorily. However, the true colour could not be removed completely without pretreatment. In the case of blue-green algae blooms, a GAC unit was used as post-treatment. 

with its high potential fot colloid removal, is an ideal pretreatment for processes using tighter membranes. Material removed will be held back by the membrane and pardy form a deposit. 

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The idea of ultrafiltration has been extended ia recent years to the filtration of particles ia the micrometer and submicrometer range ia porous pipes, usiag the same cross-flow principle. In order to prevent blocking, thicker flow channels are necessary, almost exclusively ia the form of tubes. The process is often called cross-flow microfiltration but the term cross-flow filtration is used here. 

A. E. Ostermann and E. Pfleiderer, "AppHcation of the Principle of Cross-Flow in SoHd/Liquid Microfiltration," in the Proceedings of the Symposium on Economic Optimi tion Strategy in SolidjFiquid Separation Processes, SocifitH Beige de Filtration, Louvaine-la-Neuve, Belgium, Nov. 1981, pp. 123-138. 

Phase Separation. Microporous polymer systems consisting of essentially spherical, intercoimected voids, with a narrow range of pore and ceU-size distribution have been produced from a variety of thermoplastic resins by the phase-separation technique (127). If a polyolefin or polystyrene is insoluble in a solvent at low temperature but soluble at high temperatures, the solvent can be used to prepare a microporous polymer. When the solutions, containing 10—70% polymer, are cooled to ambient temperatures, the polymer separates as a second phase. The remaining nonsolvent can then be extracted from the solid material with common organic solvents. These microporous polymers may be useful in microfiltrations or as controlled-release carriers for a variety of chemicals. 

The seminal discovery that transformed membrane separation from a laboratory to an industrial process was the development, in the early 1960s, of the Loeb-Sourirajan process for making defect-free, high flux, asymmetric reverse osmosis membranes (5). These membranes consist of an ultrathin, selective surface film on a microporous support, which provides the mechanical strength. The flux of the first Loeb-Sourirajan reverse osmosis membrane was 10 times higher than that of any membrane then avaUable and made reverse osmosis practical. The work of Loeb and Sourirajan, and the timely infusion of large sums of research doUars from the U.S. Department of Interior, Office of Saline Water (OSW), resulted in the commercialization of reverse osmosis (qv) and was a primary factor in the development of ultrafiltration (qv) and microfiltration. The development of electro dialysis was also aided by OSW funding. 

Ceramic, Metal, and Liquid Membranes. The discussion so far implies that membrane materials are organic polymers and, in fact, the vast majority of membranes used commercially are polymer based. However, interest in membranes formed from less conventional materials has increased. Ceramic membranes, a special class of microporous membranes, are being used in ultrafHtration and microfiltration appHcations, for which solvent resistance and thermal stabHity are required. Dense metal membranes, particularly palladium membranes, are being considered for the separation of hydrogen from gas mixtures, and supported or emulsified Hquid films are being developed for coupled and facHitated transport processes. 

The original expanded film membranes were sold ia roUs as flat sheets. These membranes had relatively poor tear strength along the original direction of orientation and were not widely used as microfiltration membranes. They did, however, find use as porous inert separating barriers ia batteries and some medical devices. More recentiy, the technology has been developed to produce these membranes as hoUow fibers, which are used as membrane contactors (12,13). 

In reverse osmosis membranes, the pores are so smaH, in the range 0.5— 2 nm in diameter, that they ate within the range of the thermal motion of the polymer chains. The most widely accepted theory of reverse osmosis transport considers the membrane to have no permanent pores at aH. Reverse osmosis membranes are used to separate dissolved microsolutes, such as salt, from water. The principal appHcation of reverse osmosis is the production of drinking water from brackish groundwater or seawater. Figure 25 shows the range of appHcabHity of reverse osmosis, ultrafiltration, microfiltration, and conventional filtration. 

Fig. 25. Reverse osmosis, ultrafiltration, microfiltration, and conventional filtration are related processes differing principally in the average pore diameter of the membrane filter. Reverse osmosis membranes are so dense that discrete pores do not exist transport occurs via statistically distributed free volume areas. The relative size of different solutes removed by each class of membrane is illustrated in this schematic.

Depth filters are usually preferred for the most common type of microfiltration system, illustrated schematically in Figure 28. In this process design, called "dead-end" or "in-line" filtration, the entire fluid flow is forced through the membrane under pressure. As particulates accumulate on the membrane surface or in its interior, the pressure required to maintain the required flow increases until, at some point, the membrane must be replaced. The useful life of the membrane is proportional to the particulate loading of the feed solution. In-line microfiltration of solutions as a final polishing step prior to use is a typical apphcation (66,67). 

Fig. 28. Schematic representation of dead-end and cross-flow filtration with microfiltration membranes. The equipment used in dead-end filtration is simple, but retained particles plug the membranes rapidly. The equipment required for cross-flow filtration is more complex, but the membrane lifetime is...

Whereas many of these technologies are not really new, they have never had the regulatory and economic justification for their use in metallizing. Each of these general methods has many variants. Some may be directed to waste treatment, some to recycle, and some to reclaim. An example is filtration, used to prevent release to air of zinc particles from flame spraying, microfiltration of cleaners to extend hfe, in combination with chemical precipitation to remove metal particles from wastewater, and many other uses. 

Ultrafiltration separations range from ca 1 to 100 nm. Above ca 50 nm, the process is often known as microfiltration. Transport through ultrafiltration and microfiltration membranes is described by pore-flow models. Below ca 2 nm, interactions between the membrane material and the solute and solvent become significant. That process, called reverse osmosis or hyperfiltration, is best described by solution—diffusion mechanisms. 

Membrane Filtration. Membrane filtration describes a number of weU-known processes including reverse osmosis, ultrafiltration, nanofiltration, microfiltration, and electro dialysis. The basic principle behind this technology is the use of a driving force (electricity or pressure) to filter... 

The individual membrane filtration processes are defined chiefly by pore size although there is some overlap. The smallest membrane pore size is used in reverse osmosis (0.0005—0.002 microns), followed by nanofiltration (0.001—0.01 microns), ultrafHtration (0.002—0.1 microns), and microfiltration (0.1—1.0 microns). Electro dialysis uses electric current to transport ionic species across a membrane. Micro- and ultrafHtration rely on pore size for material separation, reverse osmosis on pore size and diffusion, and electro dialysis on diffusion. Separation efficiency does not reach 100% for any of these membrane processes. For example, when used to desalinate—soften water for industrial processes, the concentrated salt stream (reject) from reverse osmosis can be 20% of the total flow. These concentrated, yet stiH dilute streams, may require additional treatment or special disposal methods. 

U.S. EPA, SITE Demonstration Bulletin Microfiltration Technology, EPOC Water, Inc., EPA/540/MR-93/513, Cincinnati, Ohio, 1993. 

Polymer Membranes These are used in filtration applications for fine-particle separations such as microfiltration and ultrafiltration (clarification involving the removal of l- Im and smaller particles). The membranes are made from a variety of materials, the commonest being cellulose acetates and polyamides. Membrane filtration, discussed in Sec. 22, has been well covered by Porter (in Schweitzer, op. cit., sec. 2.1). 

Cross-flow-elec trofiltratiou (CF-EF) is the multifunctional separation process which combines the electrophoretic migration present in elec trofiltration with the particle diffusion and radial-migration forces present in cross-flow filtration (CFF) (microfiltration includes cross-flow filtration as one mode of operation in Membrane Separation Processes which appears later in this section) in order to reduce further the formation of filter cake. Cross-flow-electrofiltratiou can even eliminate the formation of filter cake entirely. This process should find application in the filtration of suspensions when there are charged particles as well as a relatively low conduc tivity in the continuous phase. Low conductivity in the continuous phase is necessary in order to minimize the amount of elec trical power necessaiy to sustain the elec tric field. Low-ionic-strength aqueous media and nonaqueous suspending media fulfill this requirement. 

Basic Equations AU of the processes described in this sec tion depend to some extent on the following background theory. Substances move through membranes by several meoianisms. For porous membranes, such as are used in microfiltration, viscous flow dominates the process. For electrodialytic membranes, the mass transfer is caused by an elec trical potential resulting in ionic conduction. For aU membranes, Ficldan diffusion is of some importance, and it is of dom-... 

Membrane Porosity Separation membranes run a gamut of porosity (see Fig. 22-48). Polymeric and metallic gas separation membranes, electrodialysis membranes, pervaporation membranes, and reverse osmosis membranes are nonporous, although there is hnger-ing controversy over the nonporosity of the latter. Porous membranes are used for microfiltration and ultrafiltratiou. Nanofiltration membranes are probably charged porous structures. 

Pores Even porous membranes can give very high selectivity. Molecular sieve membranes exist that give excellent separation factors for gases. Their commercial scale preparation is a formidable obstacle. At the other extreme, UF,3 separations use Knudsen flow barriers, with aveiy low separation factor. Microfiltration (MF) and iiltrafiltra-tion (UF) membranes are clearly porous, their pores ranging in size from 3 nm to 3 [Lm. Nanofiltration (NF) meiTibranes have smaller pores. 

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