Membrane Filtration For Sanitary Use - Alfa Laval
Membrane filtration for sanitary useThe complete line
Fine-tuned filtrationAlfa Laval is one of the world’s major suppliers of industrialseparation technologies. We have a proud tradition ofproviding virtually all industries with separation equipmentbased on centrifugal and mechanical principles.Dead-End-FiltrationHowever, there are many processes in which thesubstances involved are too delicate to be able towithstand such treatment.The gentle alternativeMembrane filtration separates out the different componentsin a feed stream on the basis of the size and shape of themicro-particles within it. And the better the filtration, thebetter the quality and value of your end product.This separation takes place by pumping the feedstream across the surface of a membrane with pores somicroscopic that they are measured in angstroms (1 x 10-10 m).Some components pass through – others cannot.Membrane filtration is often used to supplementconventional centrifugal separation processes based ongravity differences. Membrane filtration can also be usedfor concentration prior to evaporation and spray drying.The Alfa Laval take onmembrane filtrationAlfa Laval is the world’s leading supplier of filtrationmembranes for sanitary use.High-hygiene Alfa Laval membranes are the preferredchoice for many leading users of membrane filtrationtechnology, as well as for OEM suppliers of membranefiltration modules and systems.End-to-end focusAlfa Laval is unique in mastering the full spectrumof membrane filtration know-how. In addition tomanufacturing and supplying membranes, we arealso responsible for developing and designing thesetechnically advanced products.As a result, we are in a position to apply unparalleledend-to-end quality assurance procedures that greatlybenefit every membrane user.Selecting the right type of sanitary membrane, with themost appropriate configuration and specifications, is essentialfor making filtration processes as effective as possiblein terms of hygiene levels, operating costs and yield.Schematic cross-section of a thin-film membrane used in reverse osmosisSupport layerPolysulphone (PS)Thickness 40–100 micronsThin-film membrane layerPolyamide (PA)Thickness 0.25 micronsMeeting high-hygienerequirementsMembrane filtration is becomingincreasingly popular in high-hygieneprocesses that include: Concentration and purification Clarification and fractionation Extraction Product recycling and recovery Product and effluent upgrading.Support paperPolyester (PE) orpolypropylene (PP)Thickness 100–200 microns3
How membrane filtration worksThe basic technology behind membrane filtration involves using a semi-permeablemembrane to separate a liquid into two distinct streams.Pumping this liquid across the surface of the membrane creates a positivetrans-membrane pressure that forces any components smaller than the porosity ofthe membrane to pass through, forming the permeate. Any components larger thanthe pore size simply cannot pass through, and remain behind in what is called theretentate.The surface of the membrane is kept free of blockages by the force of the liquidflow moving parallel to the membrane surface.FDA complianceAlfa Laval manufactures membranesfor use in an extensive range ofprocesses used in the food, beverage,dairy, biotech and pharmaceuticalindustries.All Alfa Laval membranes – in bothspiral-wound and flat-sheet designsand configurations – are thereforemade to comply with the relevantFDA regulations.This compliance also extends tothe equipment and fittings relatedto membrane filtration operations,including items such as plate-andframe units, element housingsand pumps.4
MicrofiltrationAlfa Laval microfiltration (MF)membranes are extremely cost-effectiveto operate, largely as the result of the low energy consumption involved. They alsohave the advantage of eliminating the frequent replacement and disposal of thecartridges and other consumables used in traditional dead-end filtration.Alfa Laval microfiltration membranes are extremely durable, with service livesthat can extend over more than five years.Microfiltration is used on feed streams where the aim is to remove smalldiameter dispersed solids such as bacteria, fat and oil globules without affectingthe balance of the components dissolved within the stream.UltrafiltrationUltrafiltration (UF) uses membranes in which the pores are somewhat smaller,with a cut-off range from 1,000 to 100,000 Molecular Weight (MWCO), andwhere the applied pressure is relatively low.Salts, sugars, organic acids and smaller peptides pass through the poresof the membrane, whereas proteins, fats and polysaccharides do not.Using appropriate ultrafiltration membranes also makes it possible to fractionatea feed stream into two distinct streams. Each contains dissolved components withdifferent molecular weights.NanofiltrationNanofiltration (NF) uses membranes with pores that are even smaller – down to300 daltons. Operating at pressures of up to 50 bar, small ions pass through,whereas larger ions and most organic components do not.Alfa Laval nanofiltration elements are used for the high-yield concentration anddemineralization of products such as whey and ultrafiltration permeate. Thesespecial membranes are used for filtering out large salts with a divalence in excessof 2, while small monovalent salts pass into the permeate. They can also be usedin producing low-alcohol beverages, because the alcohol component passesthrough the membrane, while the colour and aroma remain in the retentate.CleanabilityMost types of membranes are castonto a backing material made ofpolyester.Certain special membranesare available using polypropyleneinstead, making them capable ofwithstanding high temperaturesand high pH values.These so-called pHt membranetypes can operate continuouslyat high temperatures and alsowithstand high-temperature (60 C)cleaning with pH values in the range1–12.5. They can also be sanitizedusing water at temperatures ashigh as 90 C.Reverse osmosisReverse osmosis (RO) uses membranes with pores so minute that only smallfractions of salts can pass through, along with the water that is the primecomponent of the permeate.Certain organic compounds with low molecular weights can also pass through– but only to a limited extent. However, it is impossible for any other componentssuspended or dissolved within the liquid flow (salts, sugars, etc.) to do so.Alfa Laval reverse osmosis membranes are used for the high-flux concentrationof either the direct feed stream, or permeates from ultrafiltration and nanofiltration.5
Spiral-wound membranesThe unique design of Alfa Laval spiral-woundmembrane elements makes sure the feed streampasses through the element under the bestpossible flow conditions. This ensures the mostefficient separation and superior flux, and thateach element has a long service life and is easyto clean.The core of each spiral element is a perforatedcentral tube, with large membrane pocketsattached. Each of these contains a spacer netthat transports the permeate out of the membranepocket and into the central tube.Different thicknesses of spacer net betweeneach pocket make sure the feed is evenlydistributed over the entire surface of themembrane.The special tight-rolling technique used inAlfa Laval spiral-wound membrane elementsprovides the maximum possible active membranearea, which provides correspondingly highpermeate capacity. The exceptional firmnesscharacteristics of Alfa Laval spiral-woundmembrane elements ensure long service lifeand fewer channelling problems, even if thereis a high pressure drop across the element.These membrane elements are also availablein special configurations that withstand cleaningat high temperatures and extreme pH values.Flow pattern in a spiral-wound membrane element.Red is feed/retentate. Yellow is permeate.6
Plate-and-frame membranesBasic membrane filtration principles are the sameregardless of whether the membrane is rolled intoa spiral element or cut into flat sections to fit intoplate-and-frame units.The types of membranes used for spiral-woundelements are therefore also available as flatmembranes for use in the unique plate-and-frameunits manufactured by Alfa Laval. Such units aremost appropriate when the retentate has a highviscosity.A plate-and-frame unit is designed with openchannels across the membrane surface. Thefeed stream/retentate flows through these. Themembrane itself is supported by hollow plateswith numerous slots that allow the permeate tocollect and be removed from the unit via thepermeate collecting tubes.Plate-and-frame units use the membrane itself,aided by lock rings or strips, to seal off the feed/retentate from mixing into the permeate channels.This also prevents any leaks from the platestack itself.A plate-and-frame installation normally has ahigher permeate capacity per unit of membranearea compared with what can be achieved usingspiral-wound membrane elements. Industrial-scaleplate-and-frame units have active membranesurface areas that range from 1.65 sq m to60 sq m. These can in turn be combined intolarger systems using several units placed either inseries or parallel to achieve the required capacity.Flow pattern in a plate-and-frame unit. Red is feed/retentate. Yellow is permeate.7
Getting the pressure rightThe efficiency of membrane filtration systemsdepends heavily on the reliable, uninterruptedapplication of consistent pressure. High-pressurepumps make the feed stream flow across thesurface of the membrane and through itsmicroscopic pores at a consistent rate, boostingboth reliability and efficiency. Such pumps alsohave to maintain exceptional levels of hygiene.Alfa Laval is unique in being able to also provideour customers with a wide selection of high-pressure pumps of sanitary standard as wellas a comprehensive range of other sanitaryequipment. This includes valves, membranehousings, installation material, tank equipment,heat exchangers and control instruments.You benefit from efficient logistics, from allthe components dovetailing perfectly, and theadvantages of purchasing the full spectrum ofsanitary equipment and fittings from one singleexpert source.Alfa LavalLKHPF-High Pressure PumpAlfa LavalLKH-Multistage PumpSpecifically designed for high outletpressures, and used as feed pumps inreverse osmosis and nanofiltrationinstallations. Pressure range up to 40 bar.Used in both spiral and plate-and-framefiltration installations.Used as feed and recirculation pumps ininstallations requiring both high pressuresand high flow rates, such as reverseosmosis and nanofiltration. Pressurerange up to 40 bar.Used in both spiral and plate-and-framefiltration installations.Alfa Laval LKHCentrifugal PumpUsed as feed and recirculation pumps inboth spiral and plate-and-frame filtrationinstallations. Ideal for when combinationsof low pressures and high flow ratesare required, as in microfiltration andultrafiltration. Pressure range up to 10 bar.8
Alfa Laval SRURotary Lobe PumpUsed as feed and recirculation pumpsfor filtration of high-viscosity products.Used in conjunction with microfiltrationand ultrafiltration in plate-and-frame filtrationinstallations. Pressure range up to 20 bar.Alfa Laval SXRotary Lobe PumpFor use in conjunction with processes thatrequire absolutely sterile conditions, includingmany pharmaceutical applications.Used as feed and recirculation pumpsfor filtering high-viscosity products. Used formicrofiltration and ultrafiltration in plate-andframe installations. Pressure range up to 20 bar.Alfa Laval OptiLobe PumpOptiLobe is a rotary lobe pump for generalapplications. Available in an optimized rangewith fewer options. It combines cost-effectivesimplicity with Alfa Laval quality and reliability.Pressure range up to 8 bar.Everything you need for a complete membrane systemAlfa Laval also provides a wide range of the special ancillary equipment, fittingsand accessories needed for installing the membranes used in spiral-wound andplate-and-frame systems, and for operating them safely and efficiently.These items must be approved for pressure classifications of as much as60 bar in cases where the membrane filtration process requires high operatingpressures.All these components are also designed to maintain the best possiblehygiene conditions, and to comply in full with FDA and EU regulations, as wellas 3A sanitary standards and USDA requirements.Make the connectionSpecial couplers are needed to install a membrane element in its housing, tolink individual elements and to connect these elements to the permeate outleton the housing. These Alfa Laval ATD couplers also prevent the elements fromtelescoping due to the pressure created by the cross-flow feed stream passingthrough the element.A special ESA coupler is used to ensure that the elements in a housingachieve the tight fit required for maximum efficiency. This coupler uses aperipheral seal ring to minimize any bypass around the element, while alsomaking sure the appropriate sanitary and hygienic conditions are maintainedat all times.An important additional benefit of using ESA couplers is that they providereductions of up to 30% on the energy consumption of the recirculation pumps.9
Solutions for your applicationAlfa Laval provides high-hygiene membranes for all needs, from microfiltration to reverseosmosis. Every type ensures you an efficient, reliable product that does its job effectivelyand for a long time. Our experience extends over many different industries in which sanitarystandards and exceptional levels of hygiene are important.We can supply both general-duty membranes and solutions designed to tacklespecialist assignments. And we have both the know-how and the products to provide youwith the best solution across a wide spectrum of viscosities, pH values and temperatures.Food and beveragesThe gentle separation that Alfa Laval membranes provide helps preserve thenatural flavours and delicate aromas of foods and beverages.Their exceptional levels of hygiene help you maintain the high quality of yourproducts, while their efficiency helps keep costs down.Dairy productsExceptionally high levels of hygiene are essential when processing dairy products,and it is vital that the membranes are easy to clean and keep clean.Alfa Laval membrane filtration equipment enables you to maintain these highstandards, and special units are available that can be sanitized with hot water attemperatures of up to 90 C.Biotech and pharmaceuticalsUsing Alfa Laval membrane filtration equipment makes it easy to comply with thestringent hygiene standards and certification requirements that characterize thebiotech and pharmaceutical industries.In addition to providing sterility, these sanitary-standard products safeguardyour installation against cross-contamination.10
Service that boosts efficiencyWe have most types of membrane – for both spiral and plate-and-frame installations – in stockat all times. This means rapid dispatch and short delivery times.Easy and straightforwardPurchasing Alfa Laval membranes is an easy, rapid and straightforward process.A specialist sales team deals promptly with any enquiries you may have. This givesyou direct, easy access to the advice and in-depth know-how crucial in helpingyou run your membrane filtration operations efficiently.You can contact us directly for advice, and order via our special web-basede-Channel catalogue for sanitary parts and equipment.Single-source purchasingWe can also provide all the fittings, ancillary equipment, accessories andconsumables you need to set up and operate membrane filtration facilities,or to revamp, retrofit and extend existing systems.A single-source purchasing strategy provides you with rapid return oninvestment because: Fewer engineering hours are needed Procurement is cheaper and faster, with lower logistics costs Using one single supplier ensures well-coordinated efficiency Sourcing all sanitary products from the same manufacturer makes surethey all fit together All documentation and certification are coordinated and standardized.We also provide service visits to carry out re-membraning, to help you optimizeyour membrane filtration processes and for troubleshooting any specific problemsyou may have. We can also provide any operator training you might require.11
Alfa Laval in briefAlfa Laval is a leading global provider ofspecialized products and engineeredsolutions. Our equipment, systems andservices are dedicated to helpingcustomers to optimize the performanceof their processes. Time andtime again.We help our customers to heat,cool, separate and transport productssuch as oil, water, chemicals,beverages, foodstuffs, starch andpharmaceuticals.Our worldwide organization worksclosely with customers in almost 100countries to help them stay ahead.ESE00613EN 1706Alfa Laval is a trademark registered and owned by Alfa Laval Corporate AB, Sweden. 2007 Alfa Laval.How to contact Alfa LavalUp-to-date Alfa Laval contact details forall countries are always available on ourwebsite at www.alfalaval.com
The basic technology behind membrane filtration involves using a semi-permeable membrane to separate a liquid into two distinct streams. Pumping this liquid across the surface of the membrane creates a positive trans-membrane pressure that forces any components smaller than the porosity of the membrane to pass through, forming the permeate.
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Introduction to membrane filtration Membrane filtration is a pressure driven technology with pore sizes ranging from 100 molecular weight to 5 microns. Cross-flow membrane filtration technology is quickly gaining global acceptance as an important manufacturing step in many of the process lines in the biotechnological, chemical, starch and sweet-
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the bulk phase through the membrane into the permeate stream (Di et al., 2017). 3. Membrane Integration on chip It is crucial to apply a membrane (i.e. material and type) that best fits the targeted application. Membrane properties differ from one membrane to another and they greatly affect the overall membrane separation efficiency.
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