Commissioning Training - Nov. 29th

Page
Reiner Eisenring | Michiel van Ettinger | 29-11-2017
Commissioning
Training
www.berghofmembranes.com
Page 2
Agenda
Berghof introduction
Product range
Basics of Cross-flow Ultrafiltration
BioFlow & BioPulse system
Control philosophy
Biopulse operation in detail
Case study
Commissioning Training | www.berghofmembranes.com
Page 3

Page 4
Products & instruments
Automation &
Fluoroplastics control
Membranes
Engineering & management

Products & instruments
Page 5

Page 6
Product range
• Tubular membranes
• Low solids (5 mm)
• High solids (8 mm)
• Chemical Resistant
• Membrane skids
• Pilot units/ piloting
• Engineering & Commissioning
• Project management
Page 7
What is a membrane doing?

Permeate
Feed Concentrate
Membranes separats a Feed (stream) into a higher concentrated

Retentate (or Concentrate) and a lower concentrated Permeat

Page 8
How can a membrane do this?

Page 9
Source: Visual Encyclopedia of

Chemical Engineering
Membranes are simple walls with many holes!

Page 10

Very tiny holes!

Page 11

The holes are called pores!

Page 12
Membrane types

Page 13
How does membranes looks like?
Flatsheet (outside – in)
Hollow fibre (outside – in)
Tubular (inside – out)

Page 14
How are membranes operated?
2 basic principels: Dead-end and Cross-flow Filtration

Page 15
Dead-end
Page 16
Dead-end Cross-flow
Page 17
For MBR-application only Cross-flow-Filtration is

suitable. Why?
1. Dead-end-Filtration is a discontinuous filtration mode
2. Only cross-flow filtration guarantees control of the filter cake
3. High solid content of Bioreactor would immediately bloc Dead-end

filtration membranes

Page 18
Control of filter cake – cross-flow velocity

Page 19
Function of membranes in Bioprocess
Bioreactor Secundary Sand filters &

Pre- Primary
Clarifier Desinfection
treatment Clarifier
Influent Effluent
Thickener
Dehydration
system

Page 20
Membrane Bioreactor treatment
Pre- Bioreactor
Treatment
Influent Effluent
Membrane filtration
system
Dehydration
system

Page 21
MBR treatment (submerged and external)

Page 22
MBR treatment (submerged and external)

Page 23
Submerged Influent
Permeate
Bioreactor

Waste sludge
Page 24
External Influent Retentate Recycle
Bioreactor
Permeate

Waste sludge
Page 25
External
EXTERNAL ULTRA FILTRATION
BASED ON
Influent Retenate Recycle
INSIDE-OUT PRINCIPLE.
The solution for
fouling sensitive
Bioreactor applications
Permeate
Waste sludge

Page 26
External
BASED ON
The solution for
fouling sensitive
Permeate
Easy accessibility for
cleaning & maintenance
Waste sludge

Page 27
External
BASED ON
The solution for
fouling sensitive
Permeate
Easy accessibility for
cleaning & maintenance
Higher fluxes with

a smaller footprint
Waste sludge

Page 28
Comparison
Design Advantages Disadvantages
Flat Sheet Wide choice of membranes High costs
(Submerged)
Can be dissembled and cleaned Membrane replacement process is time
consuming
Low energy requirement
Hollow Fiber Very compact system Can get fouled with particulates
(Submerged)
Low liquid hold up Not suitable for viscous liquids
Low capital costs Comparatively limited range of products
Tubular Can tolerate feeds with high suspended solids High energy requirements?
(External)
Can work with viscous liquids High capital costs?
Easy to clean Requires large space?
Page 29
Important parameters
Pressures
• Pressure drop over a module: ∆P = Pin – Pout
• Permeate pressure: Pperm
• Av. Pressure over a module: Pav = (Pin + Pout)/2
• TMP = Pav - Pperm
Keep it constant in the range of 1 – approx. 2.5 bar
During backwash: negative TMP!
Concentration factor
• Flow feed/ Flow concentrate: Cf = Ffeed/Fconcentrate
Keep it 1.1-1.15 or maybe 1.2 depending on application
Page 30
Important parameters
Flux
• Flux = Qpermeate/Amembrane (L/m² x h)
Typical values: 55 – 100 L/m²*h

Page 31
Berghof tubular membranes
Operation parameter:
pH-Value: 5–9
Max. Inlet Pressure (inside): 7 bar
Max. negative TMD: - 0,6 bar (during Back-wash)
Max. Temperature: 40 °C
No use of silica containing Anti-foam agents in Bioreactor!

Page 32
Berghof tubular membranes
Parameter during cleaning:

pH-Value: 2 – max. 10 (exceptional 11)
Max. Inlet Pressure (inside): 7 bar
Max. Temperature: 40 °C
Max. concentration of free chlorine: 200 ppm (Natriumhypochlorite contents
59% aktive Chlorine!)
Caution: Operation outside the defined parameter will lead in loss of guarrantee!

Page 33
Berghof solution for tubular MBR external systems
BioFlow
BioPulse

Page 34
BioFlow technology
High turbulent flow parallel among the membrane surface

Excellent fouling control results in high flux rates
Efficient and easy to clean
Reliable and robust process
Optimized energy consumption due to optimization of process and membrane – and module
design.

Membrane Technology Page 35
External Berghof MBR concepts

Bioflow: robust, high reliability
• Treatment of liquids with extremely high fouling potential

• Low investment cost (high permeate flux rate 75 – 120 l/m²h)
• Small footprint
• Easy cleaning & maintenance
Waste water Berghof BioFlow
BIO-
High Energy Consumption
5m
Reactor 2,2 - 7,0 kWh/m³ permeate
Permeate
Feed Recirculation
pump pump
3,5 - 4,5 m/s
Page 36
Bioflow
Flux: 75- 120 l/m2h
Permeate
Feed Concentrate
3.5 – 4.5 m/s

Membrane Technology Page 37
External Berghof MBR concepts

Biopulse: Low energy, high flexibility
• Innovative self-regulating side stream concept

• Most economical treatment at any time
• Intelligent fouling control software
Waste water Berghof BioPulse
Permeate
BIO-
Permeate Low Energy Consumption
5m suction pump
Reactor 0,4 – 1,0 kWh/m³ permeate
Feed pump Backwash

1,0 - 2,0 m/s pump

Page 38
Berghof Biopulse system

Page 39
Biopulse technology
Modular design
Engineering innovation by smart control:
System checks the individual TMP of the membranes
If TMP is changing the system automatically reacts with:
1. Increasing crossflow
2. Permeate backwash
3. Permeate backwash + chemicals
4. Flushing (after every stop, periodically)
5. Cleaning In Place

Page 40
Biopulse
Flux: 40 - 80 l/m2h
Permeate
Feed Concentrate
1 - 2 m/s

Page 41
Bioflow energy consumption
10,00
60 l/m²h
9,00 l/m²h
8,00
BioFlow 70 l/m²h
80 l/m²h
7,00
90 l/m²h
6,00
100 l/m²h
kWh/m³
5,00
4,00
3,00
2,00
1,00
0,00
2,5 3 3,5 4 4,5 5
m /s

Page 42
Biopulse energy consumption
7 45 l/m²h
50 l/m²h
6
55 l/m²h
60 l/m²h
5
Biopulse 70 l/m²h
80 l/m²h
kWh/m³
4
90 l/m²h
3 100 l/m²h
0
0,5 1 1,5 2 2,5 3 3,5 4
m/s

Page 43
Fouling sources

Page 44
Fouling process

Page 45
Actions for maintaining permeate production

Page 46
1. Increase crossflow
Permeate
Feed Concentrate
2 - 3 m/s ↑

Page 47
2 Backwash
Backwash
Feed Concentrate
1.0 - 1.5 m/s

Page 48
3. Chemical Enchanted Backwash (CEB)

Backwash
Feed Concentrate
1.0 - 1.5 m/s

Page 49
4. Flushing
Water Water
2 - 3 m/s ↑

Page 50
5. Cleaning in Place (CIP)

Permeate
Circulation 1.0 - 3.0 m/s

TMP 0.5 – 3.0 bar Concentrate

Page 51
CIP procedure
1. Drop down of Flux (permeat flow)

Increase of TMP:
Reason: Blocking of the pores Action: -> Cleaning at higher Baseline
Build up of Filter cake pressure (> 1 – 1,5 bar)
Stronger infiltration of cleaning
agent through pores
2. Increase of pressure drop/ module

Reason: accumulation of biomass Action: -> Cleaning at low Baseline
inside of tubes pressure and high flow rate
(high turbulence)

Page 52
Cleaning

Page 53
Cleaning Transmembrane Pressure

Page 54
Focus of operators
In order to prevent decreasing membrane performance and/or taking the right
actions operators should monitor and always b informed about development of
1. permeate Flux (permeat flow)

2. pressure drop/ Module
3. TMP
4. spec. energy consumption

Page 55
Cleaning Agents
Type of Foulant Cleaning Agents

Mineral Deposits/Precip. Salts Acids
Organic Foulants Alkalis
Micro-organisms Enzymes
Oils, Fat and Grease Detergents

Page 56
Matten
• BioPulse
• 6 modules + 1 dummy = 7 module positions
• Feed/ Bleed
• Permeate flow: 20 m3/h
• Circulation flow: 96 - 240 m3/hr (crossflow 1.0 - 2.5 m/s) estimated
• Pressure drop/ module: approx. 0.5 bar
• pH: 2 - 10 (max!) during cleaning

Page 57
Feed skid

Page 58
UF skid
Page 59
CIP skid

Page 60
Operation Mods/Sequences:
Filtration -> Production of clear water/ Product

Flushing -> Removing sludge from membrane
Preparing Stand-by situation
Special Flushing -> Emergency flushing in case of blocked
strainer
Back-wash -> Filtration with periodical displacement of filter
cake from permeate side
can be done with or without chemicals
Cleaning in Place (CIP)-> indroduction of cleaning agends from concentrate
side to membranes
Page 61
Filtration

Page 62
Operation sequences:
Filtration

Page 63
Filtration

Page 64
Filtration

Page 65
Filtration

Page 66
Filtration

Page 67
Filtration
Page 68
Filtration
Page 69
Filtration
Page 70
Filtration
Page 71
Filtration
Page 72
Filtration
Page 73
Filtration
Page 74
Filtration
Page 75
Filtration
Page 76
Filtration
Page 77
Filtration
Page 78
Filtration
Page 79
Filtration
Page 80
Filtration
Page 81
Flushing

Page 82
Flushing

Page 83
Flushing

Page 84
Flushing

Page 85
Flushing

Page 86
Flushing

Page 87
Flushing

Page 88
Flushing

Page 89
Flushing

Page 90
Flushing
Page 91
Flushing
Page 92
Flushing
Page 93
Flushing
Page 94
Flushing
Page 95
Flushing
Page 96
Flushing
Page 97
Flushing
Page 98
Flushing
Page 99
Flushing
Page 100
Flushing
Page 101
Flushing
Page 102
Flushing
Page 103
Filtration with Back-wash

Page 104
Filtration
with BW
Page 105
Filtration
with BW
Page 106
Filtration
with BW
Page 107
Filtration
with BW
Page 108
Filtration
with BW
Page 109
Questions?

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Page

Reiner Eisenring | Michiel van Ettinger | 29-11-2017

Commissioning Training | www.berghofmembranes.com

Products & instruments

Engineering & management

Commissioning Training | www.berghofmembranes.com

Commissioning Training | www.berghofmembranes.com

What is a membrane doing?

Membranes separats a Feed (stream) into a higher concentrated

Commissioning Training | www.berghofmembranes.com

How can a membrane do this?

Commissioning Training | www.berghofmembranes.com

How can a membrane do this?

Source: Visual Encyclopedia of

Membranes are simple walls with many holes!

Commissioning Training | www.berghofmembranes.com

How can a membrane do this?

Source: Visual Encyclopedia of

Very tiny holes!

Commissioning Training | www.berghofmembranes.com

How can a membrane do this?

Source: Visual Encyclopedia of

The holes are called pores!

Commissioning Training | www.berghofmembranes.com

Commissioning Training | www.berghofmembranes.com

How does membranes looks like?

Flatsheet (outside – in)

Hollow fibre (outside – in)

Tubular (inside – out)

Commissioning Training | www.berghofmembranes.com

How are membranes operated?

2 basic principels: Dead-end and Cross-flow Filtration

How are membranes operated?

2 basic principels: Dead-end and Cross-flow Filtration

How are membranes operated?

2 basic principels: Dead-end and Cross-flow Filtration

For MBR-application only Cross-flow-Filtration is

1. Dead-end-Filtration is a discontinuous filtration mode

2. Only cross-flow filtration guarantees control of the filter cake

3. High solid content of Bioreactor would immediately bloc Dead-end

Commissioning Training | www.berghofmembranes.com

Control of filter cake – cross-flow velocity

Commissioning Training | www.berghofmembranes.com

Function of membranes in Bioprocess

Bioreactor Secundary Sand filters &

Commissioning Training | www.berghofmembranes.com

Membrane Bioreactor treatment

Commissioning Training | www.berghofmembranes.com

MBR treatment (submerged and external)

Commissioning Training | www.berghofmembranes.com

MBR treatment (submerged and external)

Commissioning Training | www.berghofmembranes.com

Commissioning Training | www.berghofmembranes.com

External Influent Retentate Recycle

Commissioning Training | www.berghofmembranes.com

Commissioning Training | www.berghofmembranes.com

Commissioning Training | www.berghofmembranes.com

Higher fluxes with