ipc membranes results on brewery waste … support specially developed spacer-fabric support for ipc...

IPC MEMBRANES

RESULTS ON BREWERY WASTE WATER

OUTLINE

» IPC Concept

Support

Membrane layers

Manufacturing

» Application tests Pilot-scale

• Municipal

• Brewery

» Position versus competition

» Conclusions

IPC CONCEPT

Best of both worlds:» combination of advantages of capillary (CAP) and flat sheet (FS)

MBR technology:

Backwashable No need for extensive pre-filtration

High packing density No braiding

No clogging

Low fouling

Flat sheet membrane envelopes were developed with:» well-anchored & robust membrane layers

» open internal structure

» reduced thickness (≤ 4 mm) for high packing density

» reduced number of manufacturing steps for low cost of the

manufacturing process

Development goals for a novel flat sheet MBR

IPC CONCEPT

Membrane envelope with 2 adjacent membrane layers» nicely “spaced-apart”

» inseparably connected with each other

» comprising an Integrated Permeate Channel (IPC)

Key elements: » dedicated support structure

» membrane layers made from dope used for making self-supporting CAP membranes

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IPC SUPPORT

Specially developed spacer-fabric support for IPC

» Flat-sheet textile with typically 3 parts (2 faces and a hollow-space)

» Internal hollow-space composed of multitude of spacer thread

monofilaments

» High internal porosity (≥ 95%)

» Textile can be made either by knitting (1st generation) or by weaving

(2nd generation)

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IPC SUPPORT

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Specially developed 3D spacer-fabrics!

Special attention given to:

» Open-faces structure

» No loose hairs;

» Small face thickness;

» High internal “porosity”

» Low elongation in both X and Y direction

» Low compressibility

» High explosion pressure

IPC generation Type of spacer fabric Type of filaments Properties

in faces as spacer filament elongation in X- and Y Explosion pressure Compressability

% bar bar

1st Knitted multifilament monofilament > 5 > 5 ˂ 0,5

monofilament

2nd Weft monofilament monofilament ˂ 0,1 > 5 > 5

AVAILABLE MEMBRANE LAYERS

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IPC MANUFACTURING

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OUTLINE

» IPC Concept

Support

Membrane layers

Manufacturing


• Municipal

• Brewery


» Conclusions

APPLICATION TESTS PILOT-SCALE WITH IPC/MMF MODULE

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IPC 2nd generation PVDF/UF

APPLICATION TESTS PILOT-SCALE

Equipment pilot-scale:

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CRITICAL FLUX MUNICIPAL WASTE WATER

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CRITICAL FLUX MUNICIPAL WASTE WATER @ PILOT-SCALE

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SUMMARY CRITICAL FLUX MUNICIPAL WASTE WATER

Cycle time

(minutes)

Recovery

(%)

Gross critical

flux (l/h.m²)

Net critical

flux (l/h.m²)

5 90 55 49,5

10 80 50 40

20 80 50 40

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MARTENS BREWERY

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» Location: Bocholt (BE)

» Capacity: 3 M hl per year

» Brands:

Private brand partnership

Own brands: Martens pils, Sezoens, Kristoffel Witbier, Kristoffel blond en donker

» Ultra-modern brewery lowest CO2 footprint in the world

innovative in technologies, processes and products

MARTENS BREWERY

» Two-stage UNITANK comprising:

• Sieve

• Buffer and alarm tank (1.600 m³)

• Heavily loaded stage (active volume 1.600 m³)

• Low loaded stage (active volume 1.600 m³)

• Fine bubble aeration

• Sludge stabilization and thickener

• Filter press for sludge treatment

» Operational data:

• Sludge load: 0,15 kg COD/kg MLSS.day

• Influent:

35-50 m³/h

COD 2.500-5.500 mg/l

N shortage dosage of ureum

P elimination dosage of FeCl3

Specifications waste water treatment plant

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MARTENS BREWERY

Influent

COD (ppm) 4755

TN (ppm) 53

TP (ppm) 14,6

pH 6,7

Cond. (mS/cm) 3,13

Analyses: mean values during test period

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Membrane tank

MLSS (g/L) 14,7

SVI (mL/g) 58

MBR effluent

COD (ppm) 27,9

TN (ppm) 25,2

TP (ppm) 6,4

pH 8,7

Cond. (mS/cm) 3,10

FLUX RESULTS @ MARTENS BREWERY (BOCHOLT)

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AERATION DEMAND @ MARTENS BREWERY

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ROBUSTNESS TESTS @ MARTENS BREWERY

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OUTLINE

» IPC Concept

Support

Membrane layers

Manufacturing


• Municipal

• Brewery


» Conclusions

SOME KEY DATA

» Membrane pore size: 0,08 µm

» Membrane material: PVDF

» Clean water permeability: 1500 l/h.m².bar

» Net flux: 40 – 50 l/m².h

» Packing density for triple deck U-90 module: 512 m²/m²

» Permeate production per m² projected area: 20,5 – 25,6 m³/m²

» Aeration demand (16,8 Nm³/h = optimized SAD @ Martens Brewery fornet flux = 40 l/m².h):

SADm 0,062 Nm³/m².h

SADp 1,55 Nm³/m³

» Pretreatment 3 mm

» Backwashability up to 2 bar

Triple deck U-90 module (based on pilot trials)

(U-90: 90 m², Width = 736 mm, Height = 1070 mm, Depth = 716 mm)

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POSITION BFM VS COMPETITION

FLUX COMPARISON

0

10

20

30

40

50

60

70

80

GE Zenon-ZW500

Kubota- RW400 Koch Puron-PSH1800MBR

Koch Puron-PULSION LE44

Pentair- Skid Pentair-Megablock

Bluefoot- U100-1

Bluefoot- U100-2

Bluefoot- U100-3

Mem

bra

ne

flux (

l/(m

2h))

Competitive performance: Membrane flux

Average design flux Max. design flux

IPC 1 IPC 2 IPC 3

POSITION IPC VS COMPETITION

The IPC membrane operates at a high flux rate, aproximately

twice as high as most competitors.

For a given capacity the installed membrane area is potentially

50% less than that of most competitors

FLUX COMPARISON


PACKING DENSITY COMPARISON

0

100

200

300

400

500

600

GE Zenon-ZW500




Bluefoot- U100-1

Bluefoot- U100-2

Bluefoot- U100-3

Packin

g d

ensi

ty (

m2

mem

bra

ne /

m2

footp

rint)

Competitive performance: Packing density --> m2 membrane area / m2 footprint

Packing density (max.) Packing density (in reality)

Higher

is better


SPECIFIC PERMEATE FLOW COMPARISON

0,00

2,00

4,00

6,00

8,00

10,00

12,00

14,00

16,00

18,00

GE Zenon-ZW500




Bluefoot- U100-1

Bluefoot- U100-2

Bluefoot- U100-3

Perm

eate

flo

w (

m3/h/m

2fo

otp

rint)

Competitive performance: Specific Permeate Flow

Permeate flow (normal conditions) Permeate flow (max. conditions)

Higher

is better



IPC’s packing density (membrane area per m2 footprint) depends

heavily on the capability to stack modules:

without stacking this value is rather low

with a triple stack this value is the highest amongst the competition

The more relevant parameter is specific flow (m3 per hour

produced per m2 of footprint).

The specific flow is:

equal with the competition without stacking

by far the highest amongst the competition with a triple stack


SPECIFIC AERATION DEMAND (M) COMPARISON

0

0,1

0,2

0,3

0,4

0,5

0,6

GE Zenon-ZW500




Bluefoot- U100-1

Bluefoot- U100-2

Bluefoot- U100-3

Specif

ic A

era

tion D

em

and (

Nm

3/h/m

2m

em

bra

ne)

Competitive performance: Specific Aeration Demand per m2 membrane area

SAD_m (normal conditions) SAD_m (max. conditions)

Lower

is

better


SPECIFIC AERATION DEMAND (P) COMPARISON

0,0

5,0

10,0

15,0

20,0

25,0

30,0

GE Zenon-ZW500




Bluefoot- U100-1

Bluefoot- U100-2

Bluefoot- U100-3

Specif

ic A

era

tion D

em

and (

Nm

3/m

3)

Competitive performance: Specific Aeration Demand per m3 water treated

SAD_p (normal conditions) SAD_p (max. conditions)

Lower

is

better



IPC’s aeration demand (Volume of air per hour per m3 filtrate),

which typically counts for 30-40% of the energy consumption in an

MBR is for good quality sludge:

The lowest amongst the competition without stacking

Up to 80% less than the submerged competition with a triple

stack and good quality sludge (eg. @ Martens Brewery)

OUTLINE

» IPC Concept

Support

Membrane layers

Manufacturing

» Application tests Lab-scale

Pilot-scale

• Municipal

• Brewery


» Conclusions

CONCLUSIONS

» IPC concept allows for fully backwashable flatsheet membranes

» efficient backwashing is key in fouling control!

» 50-100 % flux improvement demonstrated at pilot scale

» highest specific flow rate amongst competitors for double and

triple deck

» excellent robustness

» Good quality sludge low aeration demand

» IPC manufacturing at competitive price thanks to integrated

concept

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CONCLUSIONS: USP

» The combination of:

High operating flux,

High packing density,

Low aeration demand

Ability to stack 2 or even 3 modules on top of one other

Provides the IPC MBR concept a strong competive postion!

BLUE FOOT MEMBRANES (BFM) SPIN-OFF

IPC membranes and modules are commercialized by

Blue Foot Membranes

Pantarein is our preferred partner in Belgium and

European brewery market

Voorstelling VITO 35

BLUE FOOT MEMBRANES (BFM) SPIN-OFF

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Current BFM production facility in Lommel

Come and visit us at booth 64 !!!

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ipc membranes results on brewery waste … support specially developed spacer-fabric support for ipc...

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