OUTLINE
» IPC Concept
Support
Membrane layers
Manufacturing
» Application tests Pilot-scale
• Municipal
• Brewery
» Position versus competition
» Conclusions
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
5
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)
6
IPC SUPPORT
7
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
OUTLINE
» IPC Concept
Support
Membrane layers
Manufacturing
» Application tests Pilot-scale
• Municipal
• Brewery
» Position versus competition
» Conclusions
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
15
MARTENS BREWERY
16
» 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
17
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
18
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
OUTLINE
» IPC Concept
Support
Membrane layers
Manufacturing
» Application tests Pilot-scale
• Municipal
• Brewery
» Position versus competition
» 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)
23
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
POSITION IPC VS COMPETITION
PACKING DENSITY COMPARISON
0
100
200
300
400
500
600
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
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
POSITION IPC VS COMPETITION
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
Kubota- RW400 Koch Puron-PSH1800MBR
Koch Puron-PULSION LE44
Pentair- Skid Pentair-Megablock
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
POSITION IPC VS COMPETITION
SPECIFIC PERMEATE FLOW COMPARISON
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
POSITION BFM VS COMPETITION
SPECIFIC AERATION DEMAND (M) COMPARISON
0
0,1
0,2
0,3
0,4
0,5
0,6
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
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
POSITION BFM VS COMPETITION
SPECIFIC AERATION DEMAND (P) COMPARISON
0,0
5,0
10,0
15,0
20,0
25,0
30,0
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
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
POSITION BFM VS COMPETITION
SPECIFIC PERMEATE FLOW COMPARISON
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
» Position versus competition
» 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
33
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