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FILTRATION NEWS

May/June 2011Volume 30 No. 3

www.filtnews.com

Rosedale Products

Single or Dual Stage MunicipalDrinking Water Filters

Rosedale Products

Single or Dual Stage MunicipalDrinking Water Filters

Show Report: Filtech 2011 - Largest Event

Since Beginning

Filtration – A Growth Market for Synthetic Fibers

Membrane Filter Rating

2 • June 2011 • www.filtnews.com

Filtration | MarketingFiltration - A Growth Market for Synthetic Fibers 4

Association | NewsAFS Dixie Chapter Spring Meeting Held in North Carolina 11

Cover Story | Rosedale Products Inc.Single or Dual Stage Municipal Drinking Water Filters 12

Membranes | TechnologyNew Methodology for “Hyperfine” Membrane Filter Rating 14

Membranes | WastewaterNew Membrane Bioreactor System Eliminates Municipal Surcharges with Onsite Wastewater Treatment Facility 22

Filter | TestingMeasuring the Performance of a Filter Medium 28

Show Report | Filtech 2011Filtech 11 - Largest Event Since Beginning 31

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Editorial DepartmentKen Norberg, Editor in Chief, [email protected]

Adrian Wilson, Intl. CorrespondentChen Nan Yang, China CorrespondentEditorial Advisory Board, See page 3

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Publication DataFiltration News (ISSN:1078-4136) is publishedbi-monthly by International Media Group, Inc.Printed in U.S.A., Copyright 2011.This publication has a requested and controlledsubscription circulation - controlled by the staff ofFiltration News; mailed bi-monthly as PeriodicalsPostage Paid (USPS 025-412) in Novi MI andadditional mailing offices.Filtration News is not responsible for statementspublished in this magazine. Advertisers, agenciesand contributing writers assume liability for allcontent of all submitted material printed andassume responsibility for any claims arisingthere-from made against publisher.

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IN THIS ISSUEMay/June 2011, Vol. 30, No. 3

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Cover courtesy ofRosedale Products

Editorial Advisory Board

www.filtnews.com • June 2011 • 3

Editorial Board ChairmanEdward C. Gregor, ChairmanE.C. Gregor & Assoc. LLCTel: 1 704 442 1940Fax: 1 704 442 [email protected]&A, Filtration Media

Haluk Alper, PresidentMyCelx Technologies Corp.Tel: 770.534.3118Fax: [email protected] Removal – Water and Air

Jim JosephJoseph MarketingTel/Fax: 1 757 565 [email protected] Filtration

Robert W. McilvaineTel: 1 847 272 0010Fax: 1 847 272 [email protected]. Research & Tech. Analysis

Dr. Graham RidealWhitehouse Scientific Ltd.Tel: +44 1244 33 26 26Fax: +44 1244 33 50 [email protected] and Media Validation

Tony ShucoskyPall MicroelectronicsTel: 1 410 252-0800Fax: 1 410 [email protected], Filter Media,Membranes

Scott P. YaegerFiltration and SeparationTechnology LLCTel/Fax: 219-324-3786Mobile: [email protected], New Techn.

Mark VanoverBayOne Urethane Systems LLCMarketing ManagerTel: 1- 314-591-1792Email:[email protected] Systems

Dr. Bob BaumannAdvisory Board Member Emeritus

Andy RosolGlobal Filtration Products Mgr.FLSmidth [email protected]: 1 800 826 6461/1 801 526 2005Precoat/Bodyfeed Filter Aids

Clint ScobleFilter Media Services, LLCOffice: 1 513 528 0172Fax: 1 513 624 [email protected] Filters , Filter Media, Baghouse Maintenance

Gregg PoppeThe Dow Chemical CompanyTel: 1 952 897 4317Fax: 1 942 835 [email protected] Water, Power,and Membrane Technology

Henry Nowicki, Ph.D. MBATel: 1 724 457 6576Fax: 1 724 457 [email protected] Testing and Training

Brandon Ost, CEOFiltration GroupHigh Purity Prod. Div.Tel: 1 630 723 [email protected] Filters, Pharmaceuticaland Micro-Electronic

Dr. Ernest MayerDuPont Co.Tel: 1 302 368 0021Fax: 1 302 368 [email protected] Solid/Liquid Separationsin All Areas

Wu ChenThe Dow Chemical CompanyTel: 1 979 238 9943Fax: 1 979 238 0651Process Filtration (liquid/gas)Equipment and Media

Peter R. Johnston, PETel/Fax: 1 919 942 [email protected] procedures

Peter S. Cartwright, PECartwright Consulting [email protected], RO,Ultrafiltration

Filtration | Market


t may surprise many to learn that thefiltration and separation industry isa growth industry and synthetic

fibers have played a major role in its suc-cess. Over the last 20 years the filtrationand separations industry has grown at asteady rate of 2-6 percent per year be-

yond the economy, whether the econ-omy is up, down or stagnant. Certainmembrane market segments have a his-torical growth of 5-10 percent, whereasothers are growing at 25 percent per year.Synthetic fibers for use in filtration maynot be as glamorous as medical devices

or the information technology marketwith computers, iPods, cell phones,biotechnology and all the other growthindustries. However, few other manufac-turing industries hold a candle to filtra-tions consistent year-over-year growthand predictable profitability.

INDA, the principal nonwoven in-dustry trade association in the USA,identified North American filtrationnonwoven roll good sales at $735 mil-lion in 2007, as the largest nonwovenmarket segment in North America. In2011, sales are now approaching $800million in spite of the economic envi-ronment. Few would image that non-woven fabrics for filtration marketshave actually surpassed hygiene ormedical drapes and gowns sales. Oneonly need look at what Fortune 500companies have and are paying to ac-quire filtration and separations compa-nies in terms of multiples tounderstand the magnitude and on-going strength of the filtration industry.

INDUSTRY MEGA TRENDSLeading trends include:

• Finer filtration, which continuously creates opportunities for wider use and refinements of filtration media and new materials of construction

• Steady predictable long-term growthfor most filter makers and suppliers

• Consolidation has accelerated in the last 4-5 years

• Fibers are used widely in filtration media

• Environmental consciousness as users seek solutions to contain contamination

•One world business as technology grows and easily transcends borders;including emerging markets

I

Filtration – A Growth Market for Synthetic FibersBy Edward C. Gregor

Filter Cartridge from Meltblown Nonwoven Fabric Filter with FluoropolymerFibers. Photo courtesy of Pall Corporation.

• Legislation and regulatory controls are increasing by the United States Congress, State and local officials with enforcement by the EPA and other agencies

LEGISLATING GROWTHTraditional drivers of industry

growth revolve around the need toimprove product quality in manufac-turing processes, prevention of unde-sirable containment and pollutionbefore it occurs and remediation ofenvironmental damage. However, inrecent years, local, State and federalgovernment lawmakers and regula-tors have enacted legislation at an ac-celerating rate. The CongressionalClean Air Act of 1990, with enforce-ment by the EPA, was the first majorpiece of broad legislation with realteeth. It provided new regulations forparticulate and other contaminantcontrol. Since then, there has been

enforcement of coal-based power gen-eration facilities including mercury,SOX and CO2 exhaust. Other legisla-tion controls include oil and greasecontainment from parking lot stormwater runoff. Beginning in 2007,OEM diesel vehicle soot and NOxemissions were regulated in the USAand by most other major territoriesworldwide commencing in 2008. En-forcement accelerates again in the2014 time frame with vehicle retrofitlegislation in California and imple-mentation across the USA for use intug boats, locomotives, etc. Sepa-rately, the United States EPA enforce-ment of Superfund Site cleanup andother less publicized enforcementshave also become important factors.In addition to traditional industrygrowth, including emerging coun-tries, legislation has become an im-portant factor and best friend of thefiltration and separations industry.

FUNDAMENTAL CHARACTERISTICS• Industry growth out-paces the

economy by 2-6 percent per year with certain segments perennially growing at higher levels

• Many filtration and separation companies achieve 25-50 percent gross profit margins

• The customer base is extremely diversified with over 30 major market segments

• It’s still largely a razor blade type business with extensive replacementof filters

• Liquid filtration and separation, as arule, tends to be more profitable thanair or gas filtration, although there are exceptions in specific situations

• Product cycles are long, often 10 - 20years and more

• Upstream product development withcustomers is common, especially forhigh-performance end-uses

• The better performing companies


Filtration | Market

Filtration | Market


have been acquired at 8-16 times EBITDA over the last 10 years.

MEDIA - THE HEART AND SOULMicroporous membrane filtration

media roll stock is a $2.5 - $3 billiondollar worldwide industry, dependingupon whose report one buys. Mem-brane media is but one component andabout 10 percent of the cost of an all-plastic filter cartridge, yet uses 2 layersof nonwoven fabric as pleat support forevery one layer of membrane in the fil-ter cartridge. This has an enormous im-pact on the use of nonwovens andhighlights synthetic fiber contributionsto the filtration and separations indus-try. Synthetic nonwoven filtrationmedia roll stock sales are approxi-mately $2 billion dollars worldwide.This value does not include in excess of$1 billion worldwide for cellulosic wet-laid filtration media, typically used inautomotive and truck engine air intake,fuel and oil filters and a variety of otherapplications. Add in the hundreds ofmillions if not billions of dollars in syn-thetic monofilament and multifilamentyarns, roving and staple fibers, plasticcartridge support frames, end caps,

housings, piping and othersystem materials and one be-gins to realize why polymercompanies have paid atten-tion to opportunities in thismarket.

POLYPROPYLENE FIBERS Polyolefin, and in particu-

lar, polypropylene, is one ofthe three main workhorsesynthetic fibers of the indus-try. Polypropylene fibers arewidely specified in filtrationmedia where chemical or sol-vent resistance is important.Polypropylene monofilamentand multifilament woven fab-rics, meltblown, spunbondand thru-air bonded fabricsand spray spun (meltblown)cartridges are widely usedwith a variety of constructionsin coolant filtration, paint

spray booths, demisters, filter presses,spring wound cartridges, dewateringbelts and meltblown fabrics for vacuumcleaner bags. Wetlaid polypropylenefabrics are used as membrane sub-strates for certain cleanable RO/UFmembranes spiral wrap modules.Polypropylene is a leading polymer andwidely used fiber component of HVACair filters, taking advantage ofpolypropylene’s negative triboelectricproperty for enhanced particle capture.

POLYESTER FIBERSPolyester fibers are used primarily in

nonwoven fabric and monofilamentwoven fabric for a variety of applica-tions, including filtration media mu-nicipal sludge dewatering to criticalmedia applications from open heart by-pass surgery to hernia patches. Poly-ester and co-polyester fibers in the formof a wetlaid substrate are used as sup-port material for RO/UF membranesand/or binder fibers combined with cel-lulose or glass fibers for specialty ap-plications. Polyester yarns dominateknitted channel fabrics in spiral woundmodules. On the nonwoven fabric side,polyester-based media is used in swim-

Baghouse Filters from Hydroentangled Nonwoven using PET Fibers. Photo courtesy of PGI Nonwovens.

ming pool and spa filters and widelyused as pleat separators and mem-branes substrate for microporous mem-brane liquid filters, a substantial marketmentioned earlier. On the air filtrationside of the business, polyester fibershave a leading and substantial positionin the form of staple fibers in needlefeltfabrics such as baghouse filters anddust collection cartridges used in gran-aries, cement production, kaolin pro-cessing, foundries, abrasive manu-facturing and other industries. PTFEmembranes are laminated widely topolyester fabrics for use in hydropho-bic air vents for dozens of small motorsin automobiles, in addition to spikevents for intravenous drip chambers,urine drain bags, vacuum canisters andrelated uses.

FLUOROPOLYMER FIBERSThe third most important fiber in fil-

tration with likely the highest percent-age rate of growth in the future isfluoropolymer fibers. Fluoropolymersoccupy a unique position in the filtra-

tion business with many diverse mate-rials and applications. Because of theirinert nature and higher temperatureproperties, fluoropolymers are the mostwidely deployed filtration mediathroughout the microelectronics indus-try to filter acids and aggressive chem-icals during the etching and washingsteps in the manufacture of wafers andmicrochips. The cartridge assemblyoften has a PTFE or PVDF microporousmembrane and PFA flouropolymersupport fabrics. PVDF is also used inthe chemical industry as monofilamentwoven fabrics for chemical processbelts and as ultrafiltration membranesfor separations where aggressive chem-icals. E-CTFE meltblown fabrics have aspecial ability to coalesce difficult liq-uids and can withstand the piranha ef-fect in filtering ozonated ultrapurewater and tend to be non-protein bind-ing in medical uses.

SPECIALTY POLYMER FIBERSWith all the success of polypropy-

lene, polyester and emerging fluo-

ropolymer fibers over the years, engi-neering polymers are growing andopening new opportunities as savvypolymer manufacturer’s step up theirfocus on the filtration and separationmarket. Examples include polyether-sulphone (PES), which has replacedlarge quantities of cellulous acetate,nylon and to a lesser degree PVDF inRO/UF, all traditional membrane mediapolymers. It is only a matter of timeuntil PES finds additional markets asfibers as pre-filters in water and phar-maceutical filtration and pleat separa-tors and filtration media in cartridgesand dewatering. Polyphenylene Sulfide(PPS) has roared ahead in recent yearsas a new polymer with use as fibers inbaghouse filters where high-tempera-ture and chemical resistance are impor-tant. Producers of other engineeringpolymers and fibers, such as Polyether-imide (PEI) Polyetheretherketone(PEEK) and liquid crystal polymers(LCP) suppliers are also making effortsto gain a larger toehold in the lucrativeand growing filtration and separations



Filtration | Market

market. The sleeper plastic may be bio-polymers with considerable opportuni-ties in the future. Currently, polylacticacid (PLA) fibers have the edge, as thepolymer of choice, especially for use assustainable, compostable and/or incin-erateable filters, but other emergingbiopolymers will surely challenge asmore companies perfect their offerings.

CONCLUSIONThe use of fibers as filtration and sep-

aration media has enabled the filtrationand separations industry to achieve con-sistent annualized growth. For the last15-20 years the filtration and separationindustry has generated steady profitabil-

ity and the prospects for continued fu-ture growth are based on identifiable,predicable and proven factors; a brightlight for fiber producers, whether it beas nonwoven fabrics, monofilament ormultifilament yarns, roving, staple fibersor any other fiber form best suited to aparticular end use.

Edward C. Gregor, Edward C. Gregor &

Associates, LLC (www.egregor.com) is a

co-founder of the American Filtration &

Separations Society and a specialist in

creating growth for companies in the spe-

cialty polymer, fibers and filtration industries.

He can be reached by phone: 1-704-442-

1940 or email: [email protected]

Pleated Ceramic Filter with Silicon Carbide Wetlaid Fibers. Photo Courtesy of Industrial Ceramic Solutions, LLC.

FN


Association | News

he Dixie chapter of the Ameri-can Filtration and SeparationsSociety (AFS) held a two-day

spring chapter meeting and conferenceMarch 9-10 at Purolator-Facet in Greens-boro, North Carolina. The event wasmarked with a good dose of networking,camaraderie and the opportunity to makenew industry acquaintances in the best ofsouthern fashion. The event had 12 pre-sentations over both days covering thetopic of Self-Cleaning, Cleanable andReusable Filters for Liquids and Gas.

Chapter members went on a very in-formative tour of the Childress Wineryand had a unique educational experience.Interestingly, participants learned how fil-ter presses are being replaced by ceramictangential (crossflow) filtration in winemaking, even with smaller wineries, suchas Childress, who share the equipmentduring the season. The head wine makerwas every bit as much of a “filter man” asanyone of the visitors, with his in-depthknowledge of the vast variety of industryfilters and filtration processes. This obvi-ously contributed greatly to the experi-ence and appreciation of the tour andwinemaking process. Of course, few ofthe participants left without a chance totaste the wine and a visit to the wine shop,taking home the fruits in a bottle or two.

A networking reception followed laterin the day with a Dixie chapter meetingincluding the election of three new offi-cers going forward: Todd Furbee, DeltaPure Filtration as Dixie chapter president;Rob Prichard, Fiberweb, chapter vicepresident; and Brad Zeigler, Sefar, chaptersecretary/treasurer. An in-depth slide pres-entation followed on the topic of reusablefiltration media, covering six of the mostcommon choices and end use market op-portunities. For those who thought theindustry was largely made up of dispos-able filters, a dose of just how broad the industry is and how many opportunitiesexist for higher-margin business wasgleaned, and perhaps a new mindset from

the comments after the meeting.On the second day, participants met in

the conference room at Purolator-Facetwith 11 presentations on reusable and“green” filtration media, filters and sys-tems including insight into two brand-new emerging technologies, beyondtraditional industry offering with plenty ofchances for Q&A. One of the speakers ranfor the U.S.House of Repre-sentatives in2010, but lost, al-though he said hewould try againin 2012. Most at-tendees left thetwo days with anumber of newprofessional con-tacts with severalasking about fu-ture Dixie chap-ter meetingsand/or AFS Cor-porate Sponsor-ship for theirc o m p a n i e s ,which was an all-around positivesign of success.

Special thanksgo to exiting offi-cers – Cecil Baty,H.C. Warner,chapter presi-dent; Don Olds,Olds Filtration,vice president;

and George Stone, Jack Daniels (retired),secretary/treasurer – for their dedicated ef-forts and stewardship over the years inkeeping the Dixie chapter strong and oneof the leading AFS chapters.

AFS’ next calendar event is the 2011

Fall Focus Conference in Houston, TX,

October 17-20.

For more information visit: www.afssociety.org

AFS Dixie Chapter Spring Meeting Held in North Carolina

By Ed Gregor

T

Members of the Dixie chapter of the AFS at the spring meeting.

FN

Cover Story | Rosedale Products Inc.


Single or Dual Stage Municipal Drinking Water FiltersBy Dan Morosky, Rosedale Products, Inc.

ost Americans take safe,contaminant-free drink-ing water for granted. Yet

waterborne disease outbreaks dooccur, with most directly related tocontaminated surface water orgroundwater with surface watersources. Violations of the Safe Drink-ing Water Act affect millions of Amer-icans through water provided to thepublic in restaurants, hotels, camp-grounds and, of course, our homesfrom our municipal water system.

Organisms such as cryptosporidiumand Giardia Lamblia can cause diar-rhea, abdominal cramps, nausea, occa-sional vomiting, and low-grade fever.Surface water is exposed to contamina-tion by cryptosporidium and Giardiafrom sewage and animal wastes.

Additional organisms, such as Cryp-tosporidium, threaten water suppliesand produce diseases with serioussymptoms. Particularly at risk, are thevery young, the aged, and the im-munologically challenged.

The federal government has pro-vided the Surface Water Treatment Rule(SWTR), which specifically requiresthe control of Giardia in public watersupply systems. The SWTR establishesperformance criteria for water treat-ment to ensure a 99.9 percent reduc-tion of cysts in water supplies.

TWO FILTRATION SYSTEMSRosedale has developed two long-

lasting, effective water filtration sys-

tems that meet the SWTR and proto-cols for most states. The Single StageSystem is excellent for smaller applica-tions. The Dual Stage System can be de-signed to filter water up to 500 GPM.

Single Stage Giardia Cryptosporidium Removal

The Model 8302P and NCO8135high-capacity filter housings offer anexceptional value in Giardia Cryp-tosporidium Removal applications. Thesystem is approved for use in Oregonand has met all the EPA LT2 guidelines.

The single housing and element pro-vide a large containment capacity com-

bined with a rugged stainless steel designrated to 150 psi. It incorporates an eye-nut cover that is easily removed, reduc-ing time spent on cartridge change-out.

SINGLE STAGE FILTER ELEMENTSPS-740-PPP-356 elements are man-

ufactured in a unique “Y” pleat arrange-ment that optimizes physical size andmaximizes effective surface area. Thelarge surface area provides a low fluidflux rate maximizing dirt containment.

This provides a 3 LOG cryptosporid-ium removal (see chart) when usedalone. The optimum flow rate for thesystem is 10 gallons per minute (GPM).

The element fits into the RosedaleNCO8135 housing or can retrofit ex-isting 8302P housings with an adaptorbasket. The end caps are heat sealedfor high efficiency performance. Theo-ring seal insures sealing and elimi-nates bypass.

M

Left to right: Single Stage Model 8302P; Single Stage Model NCO8135; Cutawayof 740 Cartridge –The “Y” pleat maximizes effective surface area.


FN

Retrofit Current SitesExisting installations using the

Rosedale 8302P and PS-520-PPP-241or GLR-PO-825-2 can easily convert toa single housing by installing the PS740 adaptor basket.

This is accomplished by replacingthe perforated filter basket with theadaptor. The solid side basket acceptsthe new PS 740 cartridge and directsthe flow through the unit.

Dual Stage Giardia Cryptosporidium Removal

Rosedale has developed an effectivewater filtration system that meets theSWTR and protocols for most states. Twostage systems are approved in California,Washington, Oregon, Vermont, Maineand Minnesota. This system offers adual-stage design that filters out largercontaminants before filtering out dis-ease-producing microorganisms. Thisextends the life of the element that filtersout the Giardia and Cryptosporidium.

The system consists of two high-quality Rosedale Model 8 housings(pressure vessels), placed in series.

• The first stage is fitted with a PS-520-PPP-241 bag/cartridge.

• The second stage is Rosedale’s GLR-PO-825-2 bag/cartridge.

An optional third Roughing Filter isrecommended, and helps extend ele-ment life for all the filters (see TypicalApplication photo).

This provides a 2 LOG cryp-tosporidium credit (see chart) whenused in tandem. The optimum flow ratefor the system described is 13 gallonsper minute (GPM).

DUAL STAGE FILTER ELEMENTSPre-filter (Optional)All graded-density bags are con-

structed of nine-layers of polypropy-lene micro fibers and standard fibersthat are variably calendered. Heavy-duty handles are sewn and turned in-side out to avoid leakage and enhancetheir pressure capacities.

Final Filter (2 Choices)1. The Rosedale GLR-PO-825-2 ele-

ment has 26 layers of high-efficiencypolypropylene micro fiber material, en-cased in a rigid support cage. The initiallayers are pre-filtration levels, while thenext several layers filter the cystpathogen itself. The final barriers pre-

vent any material from migrating intothe effluent. All GLR units have a spe-cially designed gasket to assure a by-pass-proof seal. All seams and joints areheat sealed to prevent leakage. The in-side-out flow design traps contami-nants on the inside, reducing thepossibility of downstream contamina-tion during change-out and simplifyingthe service process. NSF 61 listed.

2. The PS-520-PPP-241 filters aremanufactured in a “Y” pleat arrange-ment that optimizes physical size andmaximize effective surface area. Thelarge surface area provides a low fluidflux rate maximizing dirt containment.This means element life is extended(NSF 61 listed).

Rosedale manufactures filtration sys-tems for larger applications that can filterwater up to 500 GPM. Multiple designsare available to meet clients needs.

For more information contact:

Rosedale Products Inc.

P.O. Box 1085

3730 West Liberty Road

Ann Arbor, MI 48106

Tel: 1-800-821-5373, 1-734-665-8201

Fax:1-734-665-2214

Website: www.rosedaleproducts.com

Typical application, from left to right (below): Optional Roughing Pre-Filter Bag, Filter PS-520-PPP-241, Final Filter GLR-PO-825-2.

Membranes | Technology


here are a number of indus-tries in which microporousmembrane filtration is an en-

abling technology. Membrane filtersallow users to remove microscopic“killer” particles that would other-wise be detrimental or even destruc-tive to their processes. A primeexample is leading edge integratedcircuit production. Particles as fine as20 nanometersi can intrude fromprocess streams contacting semicon-ductor wafers and potentially causingfailure of chips produced from thesewafers. Manufacturers of filters in-tended for these processes must pro-duce filters capable of capturing suchfine particles, as well as providingsome quantitative indication of cap-ture efficiency at these small sizes.The current state of particle countingtechnology exhibits suitable sensitiv-ity only down to about 30 nm. Thislimits the extent to which membraneproducers can provide a product witha reliable rating finer than 30 nm.

Membrane producers have com-monly addressed this obstaclethrough the use of indirect methodsof assessing particle retention below30 nm. For example, determinationof the pressure (usually referred to asthe “KL” value) at which liquid re-tained in the porous structure by sur-face tension is expelled has beenshown to correlate with retentionii.Other methods include determina-tions of pore size distribution byporosimetry or actual measurementsof pore size by microscopyiii,iv. Evenwhere there is a sound physical ra-tionale for such methods, they areonly capable of providing a rough,qualitative indication of the size ofparticle the membrane can capture.There is a need to develop new tech-

niques that circumvent the limita-tions of particle counters and permitquantitative filter rating. This paperdescribes a new technique that candemonstrate quantitative membraneretention of particles as fine as 10 nmusing colloidal gold as a model parti-cle for challenging the membrane.

This new method makes use ofthese key facts regarding colloidalgold:

1. It is available in a variety ofsizes from < 5 nm to > 200 nm.

2. It can be obtained as suspen-sions of particles that are very nearlyspherical.

3. As the colloid particles consistof essentially pure gold, their level insuspension can be measured accu-rately and over a wide dynamic rangeby inductively coupled plasma massspectrometry (ICP-MS).

4. Suspensions of colloidal goldexhibit the necessary degree of col-loidal stability required for testingmembrane retention.

5. Because gold is conductive, it isnot necessary to apply a potentiallysize-altering conductive coating forelectron microscopy imaging, whereneeded.

In developing this technique, PallMicroelectronics addressed the fol-lowing questions that are importantwith respect to the testing and ratingof filters:

• Do the particles exhibit the requisite uniformity of shape andsize required?

• Does the technique show comparability with other more established techniques, e.g., the use of single-sized PSL beads?

• Does the technique produce results that are consistent with expectations based on predictivetechniques, e.g., correlation of retention to membrane KL values?

• Is it possible to apply the technique reliably for membranes produced from various materials (e.g., PTFE, polyamide, polyethylene)?

• Can unintended adsorptive or agglomerative effects that artificially enhance retention efficiency be avoided through identification of proper test conditions?

As described below, the company’sevaluation of the new technique hasdemonstrated its viability in terms ofall of these issues.

EXPERIMENTALColloidal Gold: Materials and Characterization

All of the testing described herewas conducted using colloidal goldobtained in various sizes (EMGCgrade: 10, 20, 30 nm), from BBI(Cardiff, U.K.). The actual particlesize distribution for the differentsizes used was determined using dy-namic light scattering (DLS, modelZetasizer Nano ZS, Malvern, Worces-tershire, U.K.), with supplementalconfirmation of size and shape viafield emission scanning electron mi-croscopy (FESEM, model S-5200, Hi-tachi, Tokyo, Japan). For referencepurposes, 33 nm PSL beads were ob-tained from Duke Scientific (PaloAlto, CA, U.S.). Detection of the levelof elemental gold in suspensions ofcolloidal gold in deionized water wasdetermined using ICP-MS (model

New Methodology for “Hyperfine” Membrane Filter RatingBy Tony Shucosky, Patrick Connor and Takehito Mizuno, Pall Microelectronics

T

HP-4500, Agilent, SantaClara, CA, U.S.), usinga standard solution ofchloroauric acid,HAuCl4 (Wako, Osaka,Japan) for calibration.

Membrane TestingRetention testing of

filtration membraneswas carried out using47 mm disks of varioustypes of media: polyte-t r a f l u o r o e t h y l e n e(PTFE) possessing rat-ings of 20 nm and30 nm, high density polyethylene(HDPE) with ratings of 10 nm and30 nm, and nylon-6,6 rated at 20 nmand 40 nm. Where any medium isdesignated as having a rating finerthan 30 nm, this value was obtainedby extrapolating the correlation ob-served between KL value of themedium (in pure isopropanol) andsize rating as determined by quanti-tative counting methods available at30 nm and larger. This is depicted in

Figure 1 for the specific caseof PTFE.

As necessary to achievewettability of the medium,disks were prewet with pureisopropanol and installed in astandard 47 mm disk holder. Thedisk holder was plumbed to a 10” fil-ter housing, functioning as a pressurevessel, which contained the colloidalgold suspension challenging themembrane. The disk holder, pressure

vessel, and all other wetted surfaceswere of perfluoroalkoxy (PFA) con-struction to avoid potential electro-chemical interactions that mightoccur between gold and metal sur-faces. A constant pressure was main-

Figure 1. Rating of Membrane via Extrapolationof Curve for KL Data vs. Measured Retention

Figure 2. Schematic of test set-up



tained above the suspension in thevessel, adjusted to an appropriatelevel to allow a constant flow rate of5 mL/min to pass through the mem-brane, as established by monitoringthe weight of effluent from the mem-brane over time. The experimentalset-up is depicted schematically inFigure 2.

The typical concentration of goldemployed for testing was 500 µg/L(500 ppb or 0.5 ppm), although ad-ditional tests were run at lower con-centrations where evaluation of theimpact of particle level (which can beeasily shown to be proportional tolevel of elemental gold for single-sized particles) on membrane reten-tion characteristics. The actual levelof elemental gold in the challenge so-lution was confirmed by ICP-MS. Inconducting actual tests, an initialvolume of effluent was discarded soas to ensure that results reflectedonly steady-state operation. Afterthis initial period, sufficient effluent

was collected for analysis of goldlevel by ICP-MS. Particle removal ef-ficiency is defined as:

where Cpart. refers to the concentra-tion of particles in the influent to oreffluent from the filter membrane.For challenge testing involving sin-gle-sized particles, Cpart. can be re-placed by CAu the level of goldmeasured by ICP-MS, as the parame-ters relating Cpart. to CAu cancel in theequation above.

Evaluation of Chemical Modificationof Colloidal Gold on Particle Capture

With respect to HPDE andnylon-6,6 membranes, it was recog-nized that colloidal gold might ex-hibit excessive adsorption on thesematerials, thereby leading to artifi-cially high degrees of particle re-moval. To evaluate this aspect, aseries of colloidal gold suspensionswere prepared to which was added

between 0.5 and 10 ppm of two dif-ferent stabilizers known to be capa-ble of bonding to the surface of thegold colloid particle. Based on infor-mation gleaned from studies of thebehavior of colloidal gold in the pres-ence of various stabilizing ligands,Pall chose to evaluate the impact ofmercaptosuccinic acid (Wako) oncapture of colloidal gold by HDPE,and of 2-amino-2-hydroxymethyl-1,3-propanediol (Wako) for the case

Figure 3. Particle size distribution ofvarious sizes of colloidal gold andPSL beads


of nylon-6,6. Membrane testing withstabilized suspension of colloidalgold was otherwise conducted in thesame manner as described earlier.(Based on the known properties ofPTFE, it was not considered neces-sary to employ stabilizers in tests in-volving PTFE membrane.)

RESULTS AND DISCUSSIONSize Distribution and Morphologyof Colloidal Gold

As depicted in Figure 3, the parti-cle size distributions of the colloidalgold suspensions used in this studyexhibit minimal variation from thevalues provided for them by the man-ufacturer, when analyzed by DLS. Inthis graph, the PSD of 33 nm PSLbeads has been overlaid, and is found

to exhibit more variation than thecorresponding size of colloidal gold,and even of the smallest size of col-loidal gold employed. Collections ofcolloidal gold deposited onto asmooth surface, for each of the threesizes used, when imaged by FE-SEM,

were found to be very uniform, withminimum deviation from spherical,as seen in Figure 4 (a,b,c).

These evaluations demonstratethat colloidal gold as fine as 10 nm insize exhibits the requisite character-istics in terms of approach to

Figure 4. FE-SEM Images, 500kX magnification, of 10 nm (top), 20 nm(middle), and 30 nm (bottom) colloidalgold particles

Figure 5. Comparison of Removal Efficiencies of 20 nm PTFE Membrane Testedwith Various Concentrations of 30 nm Colloidal Gold and 33 nm PSL Beads


Membranes | Technologymonodispersity of particle size anduniformity of particle morphology tobe used in a successful manner forthe rating of filtration membranesexpected to be capable of retentiondown to 10 nm.Comparison of Retention Testing Using Colloidal Gold and PSL Beads

While the aforementioned limita-tions in terms of suitable sub-30 nmPSL beads precludes comparison ofretention test results below that size,it was considered appropriate to es-tablish comparability of the gold col-loid technique to the existing PSLmethodology that uses standard lightscattering particle counting instru-mentation at 30 nm. For this com-parison, PTFE medium which hadbeen assigned a 20 nm rating (per theKL correlative method mentionedearlier) was tested at various incidentparticle levels between about 1�108and 4�108 particles/cm2 of 33 nmPSL beads and 30 nm colloidal gold.As depicted in Figure 5, the twomethods yield essentially identicalresults, an indication that the goldcolloid method is suitable in terms ofquantitative testing of particulate re-tention as compared to a well estab-lished technique.

Comparability of Gold Colloid toPredictive Techniques

It has been noted that in the ab-sence of definitive means of estab-lishing the quantifiable removal ofparticles of a given size, membraneproducers may utilize indirect tech-niques to assign a size rating atwhich some reasonable reduction inlevel of particles ought to occur. Forsome of these methods, most espe-cially the extrapolation of ratingbased on membrane KL, the strongdegree of correlation over a wide sizerange within which direct determina-tion of particle removal is possiblesuggests that predicted values oughtto have some validity, even if onlysemi-quantitative.

PTFE membrane exhibiting a KLvalue suggesting that the membrane

Figure 6. Removal Efficienciesfor VariousPTFE MembranesChallengedwith 20 nmColloidalGold

ought to provide reasonable reten-tion at 20 nm was subjected to test-ing with a 500 ppb suspension of20 nm colloidal gold without the ad-dition of any stabilizers. It was foundthat essentially 100 % removal wasachieved for the membrane assigneda 20 nm rating by indirect means.Furthermore, a PTFE membrane ofsimilar type, but possessing lower KLvalue and for which a rating of 30 nmhad been previously assigned usingdirect particle counting methodology,was also tested using 20 nm colloidalgold. In this testing, retention at20 nm was found to be 82%. Re-searchers additionally tested twoother PTFE membranes that hadbeen assigned 30 nm ratings, but forwhich no information was availablewith respect to assignment of thisrating, with 20 nm colloidal gold re-tention found to be 71% and 55% forthese two membranes. These results,depicted in Figure 6, indicate thatthe colloidal gold technique pro-duces results that are in line with ex-pectations with respect to particleremoval of filters known by othermeans to possess intrinsically differ-ent retention characteristics. Theyalso suggest that, there can be somevariation in actual performanceamong membranes given the samerating, even at 30 nm.

Applicability of Gold Colloid Tech-nique for Different Membrane Ma-terials

The gold colloid technique has

been applied to the testing of PTFE,HDPE, and nylon-6,6 membranesthat have been assigned ratings finerthan 20 nm based on indirect tech-niques. For all of these media, it wasfound that the technique returned anindication of essentially complete re-tention of the 10 nm (for HDPE) or20 nm (for PTFE and nylon-6,6) col-loidal gold with which they werechallenged. These results indicatethat the technique is suitable for es-

tablishing retention characteristicsbelow 30 nm for various membranematerials known to have disparatechemical nature and morphology oftheir porous structure.

Additionally, Pall compared the re-tention of the 10 or 20 nm gold col-loid particles for two different gradesof each material. As shown inTable 1, the technique was capable ofshowing a difference between reten-tion characteristics for all three typesof material. This is further indicationof the general applicability of thetechnique for a variety of differentmembrane materials.

For the HDPE and nylon-6,6 mem-branes, the listed value in Table 1. wasthe lowest observed in testing withvarious levels of stabilizer added, asdiscussed in the next section.

Effect of Ligand Addition for Avoidance of the Impact of Adsorption

The typical manner in which col-loidal gold are prepared tends to pro-duce particles that will possess anadsorbed layer of citric acid, a condi-tion that enhances their colloidal sta-

Figure 7. Schematic representation of mercaptosuccinic acid (left) and 2-amino-2-hydroymethyl-1,3-propanediol (right) covering surface of colloidalgold particles (CH bonds omitted for clarity)




bilityv. As such, no special additivesare necessary to maintain their sus-pension in water. In spite of this col-loidal stability away from themembrane surface, colloidal and in-terfacial chemical considerations pre-dict that for the sizes of particleencountered here, HDPE andnylon-6,6—but not PTFE—could be

expected to have some adsorptive ef-fect on the colloidal gold particles.This condition might tend to resultin artificially high retention levels forparticles smaller than the assignedrating of a membrane.

Various studies have shown thatthe surface properties of colloidalgold can be modified through the ad-sorption of thiol or amino functionalgroupsvi,vii,viii,ix. In evaluating severalpossible candidates it was found thatmercaptosuccinic acid (MSA) wouldbe the most appropriate stabilizer fortesting of the HDPE membrane,while 2-amino-2- hydroxymethyl-1,3-propanediol was suitable for test-ing of the nylon-6,6 membrane.Figure 7 provides a schematic repre-sentation of the adsorption of theseligands via sulfur and nitrogen, re-spectively, for the two compounds.

As can be seen in Figure 8, the

presence of stabilizer had a significantimpact on retention, with 30 nmHDPE membrane and 40 nmnylon-6,6 membrane capable of ex-hibiting very significant retention ofcolloidal gold smaller than the mem-brane rating in the absence of stabi-lizer, but exhibiting a reduction in thepresence of stabilizer. On the otherhand, the 10 nm HDPE membraneand 20 nm nylon-6,6 membranes eachexhibited minimal reduction of reten-tion when challenged with 10 nm and20 nm colloidal gold, respectively, re-gardless of the level of stabilizer pres-ence. These findings are significant inthat they suggest that the techniquecan be optimized to minimize the un-predictable impact of chemical effectsand provide a conservative indicationof capture that is primarily based onthe typical filtration mechanisms(e.g., sieving and inertial impaction).

Figure 8. Impact of addition of stabilizer on retention of colloidalgold particles smaller than assigned rating of membrane

Figure 9. Impact of the addition of stabilizer on retention of col-loidal gold particles of the same size as assigned filter rating


CONCLUSIONSPall Microelectronics has developed

a technique involving colloidal goldthat allows quantitative determinationof the removal by membrane of parti-cles as fine as 10 nm. This permits theassignment of size ratings below30 nm by a direct, operational meas-urement technique for today’s next-generation filtration membranes. Thisrepresents a significant advancementover the indirect membrane ratingmethods that analytical limitationshave necessitated to this point for as-signing ratings finer than 30 nm. Thetechnique has been shown i.) to utilizea material available with the necessaryuniformity of size and shape to be ap-propriate for the rating of filtrationmembranes, ii.) to provide resultsconsistent with expectations based onother direct and indirect methods, iii.)to be applicable to a variety of differ-ent membrane materials and iv.) to becapable of optimization to ensure thatadsorption effects that might lead toartificially high retention are ad-dressed, thus providing a suitably con-

servative indication of membrane rat-ing expected to be based on typicalparticle capture mechanisms.


Tony Shucosky, Pall Microelectronics

Email: [email protected]

REFERENCES i) International Technology Roadmapfor Semiconductors, 2009 edition.ii) Pall, D.B., Kirnbauer, E.A,, andAllen, B.T., “Particulate retention bybacteria retentive membrane filters,”Colloids and Surfaces, 1(3-4), 235(1980). iii) Sanz, J.M., Jardines, D., Bottino,A., Capanelli, G., Hernandez, A., andCalvo, J.I., “Liquid–liquid porometryfor an accurate membrane character-ization,” Desalination, 200(1-3), 195(2006).iv) Wyart, Y., Georges, G., Deumi, C.,Amra, C., and Moulin, P., “Membranecharacterization by microscopicmethods: Multiscale structure,” J.Membrane Sci., 315(1-2), 82 (2008).v) Kunze, J., Burgess, I., Nichols, R.,

Buess-Herman, C., and Lipkowski, J.,“Electrochemical evaluation of cit-rate adsorption on Au(111) and thestability of citrate-reduced gold col-loid,” J. Electroanalytical. Chem.,599(2), 147 (2007).vi) Schlenoff, J.B., Li, M., and Ly, H.,“Stability and self-exchange in alka-nethiol monolayers,” J. Am. Chem.Soc. 117(50), 12528 (1995).vii) Stoeva, S. I., Smetana, A.B.,Sorenson, C.M., and Klabunde, K.J.,“Gram-scale synthesis of aqueousgold colloids stabilized by variousligands,” J. Colloid. Interface Sci.,309(1), 94 (2007).viii) Chen, S., and Chimura, K.,“Synthesis and characterization ofcarboxylate-modified gold nanopar-ticle powders dispersed in water,”Langmuir, 15(4), 1075 (1999).ix) Yonezawa, T., Yasui, K., andKimizuka, N., “Controlled formationof smaller gold nanoparticles by theuse of four-chained disulfide stabi-lizer,” Langmuir, 17(2), 271 (2001).

FN


Membranes | Wastewater

New Membrane Bioreactor SystemEliminates Municipal Surcharges withOnsite Wastewater Treatment FacilityBy Jim McMahon

he membrane bioreactor(MBR) system, designed andbuilt by ADI Systems Inc.,

treats up to 400,000 gallons per day ofraw snack food wastewater using ad-vanced membrane bioreactor technol-ogy for liquid-solid separation,reducing suspended solids and bio-chemical oxygen demand to less than 2milligrams per liter, eliminating$100,000 per month in municipalwastewater surcharges, and releasing250 gallons per minute of treated, fil-tered, oxygenated water into the localwatercourse ecosystem

Golden Flake Snack Foods (Golden

Flake) located in Birmingham, Ala-bama, was faced with a tough decision;either come up with a solution to stemthe escalating municipal wastewatersurcharges it was being assessed, ormove its 300,000 square-foot snackfood processing plant out of the countyto stem the significantly rising costs. In1998, the plant was paying $800 to$1,000 per month to Jefferson Countyin surcharges for decanting its 100,000to 350,000 gallons of wastewater intothe county’s municipal sewer system.By 2008 that figure had escalated to$100,000 per month in surcharges forthe same daily discharged wastewater

flow rate, with county projections thatthe rate would most likely raise to$250,000 per month within the nextfive years.

Given the fact that 68 percent ofGolden Flake’s 250-plus work forcelives within a 13-mile radius of theplant, the company preferred to keepits 80-year-old headquarters and mainmanufacturing facility in Birmingham,and find a solution to reduce or elimi-nate the surcharges. This meant, inessence, getting off of the county sewersystem.

The Alabama Department of Envi-ronmental Management, which sets

Golden Flake Snack Food’s membrane bioreactor in Birmingham, Alabama.

T


standards for wastewater regulationswithin the state, made it clear that ifGolden Flake could reach prescribedTSS (total suspended solids), BOD(biochemical oxygen demand), NH3-N(ammonia-nitrogen) and DO (dis-solved oxygen) concentrations, it couldreceive a discharge permit to conveytreated effluent directly into a creekthat runs along the perimeter of itsproperty, and bypass the JeffersonCounty sewer system altogether.

GOLDEN FLAKE’S WASTEWATER The Golden Flake plant manufac-

tures and distributes a full line of snackfood items, including potato chips, tor-tilla chips, puffed corn, corn chips,cheese puffs, cheese curls, onion ringsand pork skins. Pork skins are its spe-cialty, producing over a dozen varietiessuch as Louisiana Hot Sauce PorkSkins®, Hog Hides Pork Skins®, andWash Pot Style Pork Cracklins®.Golden Flake sells more pork skins inthe southeastern United States than anyother company.

It is also well known for its exten-

sive line of potato chips, which is theproduct that Golden Flake wasfounded on in 1923. Dill Pickle Thin &Crispy Potato Chips®, and SouthernHeat Dip Style Potato Chips® are a fewof the 15 varieties it produces and dis-tributes. The company’s popular brandsof Maizetos Tortilla Chips®, and Tosta-dos Mini Rounds® are highly recog-nized brands in the southeast U.S.

In 2009, Golden Flake’s Birming-ham facility processed more than 20million pounds of snack foods totaling$120 million in sales, 95 percent ofwhich was distributed within 12southeastern states.

The plant’s production mix of potatochips, corn chips and pork skins canvary, causing the raw snack food waste-water to have varying strengths andconsistencies, with flow rates rangingfrom 100,000 to 350,000 gallons perday (gpd).

All of the plant’s wastewater handledthrough its on-site wastewater treat-ment facility comes from the produc-tion of snack foods (no sanitary sewageenters this system), mainly from the

processing of potatoes and corn. Fromtheir arrival on site, the potatoes arecarried in a water flume to be peeledand sliced. The slices are then washedand put through deep fryers beforebeing packaged. The flume and washwater is drained daily and dischargedfor onsite wastewater treatment.

Raw corn, for the production of cornand tortilla chips, is cooked in kettleswith water and lime to loosen and re-move the husks, then soaked in vats toincrease the moisture content of thekernels. The kernels are then washed toremove impurities, milled, sheeted torun through ovens, deep-fried andpackaged. The water from theseprocesses is discharged after use for on-site wastewater treatment.

Pork skins arrive at the plant in pel-let form and go straight into deep-fry-ing, then seasoning and packaging. Theplant has seven deep fryers that handleits various product types. The majorityof the spent cooking oil is trapped in anoil pit and removed before enteringwastewater treatment. But the fryers doneed to be boiled-out weekly con-



tributing to the wastewater stream.Raw snack food wastewater is

pumped through vibrating screens,which collect 15,000 to 20,000 poundsper week of large food particles. This or-ganic matter is collected and transportedupstate to be used as animal feed.

From the time the facility was origi-nally built in the 1950s, the pre-screened wastewater leaving the plantwas received at a primary clarifier (forprimary sludge settling) with super-natant discharged to the county sewersystem (Golden Flake is permitted torelease up to 400,000 gallons of waste-water per day). The stagnant waste-water in the primary clarifier was notaerated or covered and would produceoff-odors. The clarifier was locatedalong the edge of a street, where subse-quently a housing development hadbeen built, and the odor was becomingan issue with residents.

“The wastewater being decanted tothe county sewer system had BOD andTSS concentration levels in the thou-sands, exceeding maximum surchargelevels” said David Jones, executive vicepresident of operations for GoldenFlake. “As our surcharges continued toescalate, we began looking for a treat-

ment technology that could not onlyhandle our high-volume peak flows of350,000 gpd, but also produce an efflu-ent that was below the Alabama De-partment of EnvironmentalManagement’s maximum allowable dis-charge concentration limits for BOD,TSS, NH3-N and DO.”

ENGINEERING A SOLUTION Golden Flake brought in ADI Sys-

tems to engineer a solution. The prob-lem was somewhat complicated by thefact that the plant is landlocked in itsposition, being in the Birminghaminner city. There was no room for siteexpansion, and little available room fora conventional activated-sludge facilitywith the footprint requirements forspray fields that would be required toprocess the plant’s wastewater flow.

ADI Systems recommended the im-plementation of a membrane bioreactor(MBR) system to treat the raw waste-water following the vibrating screens.The ADI-MBR process, based on tech-nology developed by ADI Systems andKubota Corporation, is a form of acti-vated sludge technology that uses asubmerged membrane barrier to per-form the liquids/solids separation and

Filtration

Mergers, Acquisitions

and Divestures

GL Capital, LLC

We understand the nuances ofthe domestic and internationalfiltration industry and bringover 70 years of combinedbusiness, technical and finan-cial expertise. The current eco-nomic climate is an ideal timefor sellers to locate buyersseeking to diversify and forbuyers to identify growth op-portunities through acquisition.

For a confidential conversation contact:

Edward C. Gregor704-442-1940

[email protected]

P. John Lovell719-375-1564

[email protected]

ADI-MBR system at Golden Flake, showing the pre-aeration tank.


reactor biomass retention functions, in-stead of gravity clarification, whicheliminated problems associated withsludge settling and separation.

The MBR process also fits on com-pact sites while providing consistent,high quality effluent that can be reusedin certain applications.

Golden Flake representatives likedthe MBR approach as the treated waste-water (effluent) from the MBR systemcould then be discharged into theUpper Valley Creek, adjacent to theproperty, no longer requiring the needand expense of discharging wastewaterto the county sewer system.

ADI Systems commissioned a 350-gallon MBR pilot plant onsite at GoldenFlake using a small stream of their pre-screened wastewater. The MBR pilotplant operated for three months todemonstrate and evaluate ADI-MBRtechnology for treating Golden Flake’swastewater.

The MBR pilot study was a successand demonstrated that ADI-MBR tech-nology was easy to operate, could con-sistently meet the effluent limits, andproduce a direct discharge quality ef-fluent while being situated on a sitewith a compact footprint.

“The technology is really what soldus,” explained Mr. Jones. “We toureda couple MBR facilities in Georgia thatwere using the Kubota submerged-membrane technology, and we werevery impressed by what we saw. Thequality of the effluent leaving theMBR for discharge into the streamwould meet the requirements of theAlabama Department of Environmen-tal Management.”

“The system also fits in to a verycompact and small footprint,” contin-ued Mr. Jones. “This is what we neededfor our site.”

MEMBRANE BIOREACTOR SYSTEM The ADI-MBR system provides a

near-absolute barrier to suspendedsolids and allows for operation athigher mixed liquor suspended solids(MLSS) concentrations (typically10,000 to 18,000 mg/L versus 2,000-5,000 mg/L as in conventional acti-vated sludge systems) resulting inlonger solids retention times, less

waste sludge production and a muchsmaller footprint.

The ADI-MBR system at GoldenFlake consists of a pre-aeration tankand two membrane basins, eachequipped with double-decker sub-merged membrane units (SMU).

The MBR system is also equippedwith aeration blowers, a re-aerationchamber, pumps, instrumentation andcontrols. The total package includes acontrol building with a dewateringpress/conveyor system, automatic com-

posite samples, laboratory, office andPLC systems.

During operation of the ADI-MBRsystem, treated effluent is passedthrough the membranes via a slightsuction, and then aerated to meet theDO limit prior to discharge to the ad-jacent stream. Waste activated sludgeis dewatered onsite with a screw pressand the sludge cake is removed fordisposal.

“Membrane treatment technologiesare often employed when higher qual-



ity effluents are required,” said MikeMcDermaid, project manager for ADISystems. “Additionally, the ADI-MBR

system is ideal when available plantfootprint is very limited, and when thewastewater characteristics make con-

ventional gravity settling technologiesdifficult or ineffective.”

“The ADI-MBR process results in arobust, ultra-compact treatment sys-tem, occupying significantly less foot-print compared to a conventionalactivated sludge treatment system,”continued Mr. McDermaid. “We feltthis would be a very suitable applica-tion for Golden Flake.”

The ADI-MBR system at GoldenFlake provides a design hydraulic re-tention time of approximately 1 day,and is designed for a daily influent flowrate of up to 400,000 gpd. The systemtreats pre-screened wastewater withBOD and TSS concentrations that rangefrom 1,000 to 10,000 mg/L and 200 to12,000 mg/L, respectively.

SYSTEM IMPLEMENTATION The new ADI-MBR system began

construction in February 2009, becameoperational in August 2009, and con-

Golden Flake pre-aeration tank and MBR partially open.


sistently produces effluent that is lowerthan effluent discharge limits set by theAlabama Department of EnvironmentalManagement: <2ppm TSS, (<30 ppmTSS limit); <5 ppm BOD, (<10ppmBOD limit); <1 ppm NH3-N (<1.5 ppmNH3-N limit); and >6 ppm DO (>6ppmDO limit).

Up to 250 gallons per minute of clean,high-quality effluent is released intoUpper Valley Creek, and serves to en-hance the downstream riparian environ-ment by improving the oxygenation of thewater flow within the small watercourse.

The final effluent produced by theADI-MBR system is clean enough toreuse for certain applications, such as siteirrigation. The waste activated sludgefrom the ADI-MBR system is pumpedthrough an on-site dewatering press toreduce the overall sludge volume to20,000 pounds per week, which is thentrucked upstate for farm fertilization.

“The entire ADI-MBR treatment sys-tem is automated,” explained Mr.Jones. “Our maintenance supervisorcan completely control the whole sys-tem from one location in the plant orfrom his home on a laptop. Everypump and motor can be controlledfrom the computer screen. This pro-vides a control flexibility we did nothave before.”

One of the biggest benefits of theADI-MBR system is that Golden Flakeis no longer discharging primarytreated wastewater into the countysewer system, and is no longer payingescalating surcharges for its wastewaterdischarge. “The ADI-MBR technologyhas given us excellent results. The ef-fluent quality we are discharging – theeffluent is almost crystal clear – has al-lowed us to completely eliminate ourdependence on the county sewer sys-tem and the escalating water surchargeswe were having to pay each month.”

ABOUT ADI SYSTEMSADI Systems Inc. is a technology

and design-build company that pro-vides a wide range of wastewater treat-ment systems to industrial companiesworldwide. In addition to generic tech-nologies, ADI Systems provides propri-etary and patented anaerobic andaerobic biological waste treatment tech-

nologies. ADI Systems Inc. is an oper-ating company within ADI Group Inc.ADI Group is an employee-ownedcompany established in 1945 and hasgrown steadily over the past 65 years.Its engineers, scientists, techniciansand support staff have experienceworking on more than 200 projects in30 countries around the globe.

For the past six consecutive years,ADI has been recognized with

“Canada’s 50 Best Managed Companies”award and is now a Platinum Memberin the program.

For more information please contact:

Graham Brown, President, ADI Systems Inc.

1133 Regent Street, Suite 300

Fredericton, NB E3B 3Z2

Tel: 1-506-452-7307 Fax: 1-506-452-7308


Website: www.adisystemsinc.com

FN


Filter | Testing

hen the process engineerfaces the question ofchoosing a filter medium,

he also considers the device for holdingthe medium in the process stream. Thatis, he may employ a flat-sheet medium ora tubular cartridge-type filter.

The flat-sheet design is straightfor-ward. Consider the fluid-approach veloc-ity while measuring filtration efficiency, aswell as measuring the volume of liquidpassing per area of the filter medium, be-fore the medium either plugs with smallsolids, or a cake of permeable solidsforms. In the case of a tubular cartridge,the liquid does not evenly feed the sur-faces of the medium. After all, both thefeed and the exit ports are at the same endof the cartridge, and some cartridges arevery long. Thus, a filter-performance testhas to be tied to the configuration of thefilter medium.

Many cartridge-type filters are on themarket and an industry has been builtaround testing just cartridges. In those

tests, a specific test dust, with a specificparticle-size distribution, is mixed with aspecific liquid then fed the cartridge at aspecific flow rate.

Then arises the question: How do testresults translate to the use of other fluids,particles, and flow rates?

HISTORY OF “STANDARD” TESTSDuring the years 1975-1990 a group of

people met twice a year to review andwrite filtration tests, calling themselvesCommittee F-21 of the ASTM (AmericanSociety of Testing and Materials). Progresswas very slow because some attendeesdidn’t want any new test methods appliedto their filter media. Yet the committeemanaged to turn out about fifteen stan-dard test methods, all of which were ad-vertised for comments before beingdeclared standard.

Further, the National Fluid Power As-sociation (NFPA) and the Society of Au-tomotive Engineers (SAE), wrote testprocedures for measuring the perform-

ance of cartridgefilters. Thosegroups employ asilica test dust inwhich their teach-ing of the particle-size distributiondiffers from thatfound in ASTMRound-Robin stud-ies [8].

Around 1990,the American Fil-tration Society(AFS) asked mem-bers to send incopies of test pro-cedures they founduseful. In 1995,those procedureswere gathered in abook [1], whichsoon went out ofprint. (Used copiesare for sale on theInternet.) A 1990book [2] reviewedknowledge, whileadding guidelinesfor reporting test

results, along with a plea to follow anEnglish-language style guide [3]. A 2004book [4] discussed using filters to sterilizeliquids.

MEASURING FILTRATION EFFICIENCY What follows comes from two ASTM

Methods [5,6]. In comparing the particle-size distri-

bution in the feed stream to that in the fil-trate, via use of a particle counter, employthe term filtration ratio, R. That ratio, foreach particle diameter, d, is the numberconcentrations of particles in the feedstream to that in the filtrate.

Avoid the beta ratio, the numbers of d-diameter-and-larger particles in the feedstream to that in the filtrate [7]. The betaratio is, obviously, a function of the parti-cle-size distribution in the feed stream.

Moreover, such a ratio provides an in-flated measure of filtration efficiency fordecreasing particle diameters.

One paper, some years ago, even sug-gested use of the mass, or volume, ratiosof d-diameter-and-larger particles in thefeed stream to that in the filtrate. Thatprocedure provides an even greater infla-tion of filtration efficiency for decreasingparticle sizes, more so than the betaratio—while also being tied to the parti-cle-size distribution in the feed stream.

Many writers refer to particle size as alinear measurement without saying if theymean diameter or radius. Radius has beenemployed in studies of gas filtration.

After gathering data of filtration ratiosR, vs. particle diameters d, the next ques-tion is: How does one plot such data? Stu-dents of physical chemistry learn to plotdata so that straight lines appear, provid-ing a clear relationship. It so happens thatplots, on log/log paper, of d vs. log R showstraight lines, illustrated in Figure 1.Then, add, across from log R, the corre-sponding, filtration efficiency, E, of indi-vidual d-diameter particles.

For a given filter medium, K and n arefunctions of many variables, such as tem-perature, fluid flow-rate, the nature of thefluid, along with the natures of the parti-cles and the filter medium.

Filter media are not sieves, as somewriters teach.

During the course of a run, as solids fill

W

Measuring the Performance of a Filter MediumBy Peter R Johnston, Consultant


the surface voids of the filter medium, fil-tration efficiency may increase.

One feature of the Figure-1 kind ofplot is: On employing two layers of a fil-ter medium, in place of one layer, all logR values increase by a factor of 2.0. Forexample, when log R, for a certain d, in-creases from 1.0 to 2.0, E increases from0.90 to 0.99.

Investigators who maintain that a fil-tration test measures the size of the“largest” pores, by capturing a certain par-ticle diameter with an efficiency of 0.99,or greater, would then wrongly say thatthe double-thick medium has smallerpores. Instead, it contains more internalsurface area, more pore walls.

The NFPA, rather than saying a certainparticle diameter is captured (or stopped)with great efficiency, prefers to say it isseparated from the fluid stream, with aspecific removal efficiency. As mentionedabove, that group specifies use of the bi-ased beta ratio.

Figure 1 thus provides, via ASTMMethods [5, 6] a standard way of display-ing results. Recall, from the literature, thevery wide variety of different E scales, andd scales, and plotted curves readers areasked to digest.

Of course, a less complicated measureof filtration efficiency lies in simply com-paring the turbidities of the two streams,or the mass concentrations of particles.

MEASURING LIFE OR CAPACITY Case 1. When the liquid-driving pressure is

constant (constant head of liquid) makea plot, on log/log paper, of increasing vol-ume filtered, V, vs time, t. Compare thatplot to those in Figure 2, derived frommathematical rate constants [9].

Notice, in Figure 2, all curves beginwith a straight line of slope 1.0, the symp-tom of laminar, viscose flow. If the slope is

less, getting into inertia flow, the operatoris asking too much of the medium.

It gets no better than Curve A, espe-cially when solids are to be recovered.

Writers who plot V vs. t on linear/lin-ear coordinates cannot tell what kind ofblocking rates occurred or that desirablecake filtration was achieved, or that liquidflow was viscose.

Case 2. When the liquid flow-rate is constant

(using a positive displacement pump),and when the initial flow is viscose, makea plot, on log/log paper, of the increasing

driving pressure, P, vs. time, t, and com-pare that curve to the curves in Figure 3.

When Curve D does appear, in eitherFigure 2 or 3, the addition of a filter aidto the feed stream, while also pre-coatingthe filter medium with filter aid, often en-ables an almost Curve A.

Sometimes a filter medium withsmaller pores may change a Curve D intoCurve C or B, or even A.

Make sure “driving pressure” is thepressure drop across the faces of the filtermedium, and does not include addedpressure drops across the device holdingthe medium.


Filter | Testing

In a test of cartridges filters [10] wherethe feed and exit ports are at the same endof the cartridge, a Figure 3 kind of plotshowed curves similar to Curves B, andC. Again, plots on linear/linear coordi-nates fail to tell what plugging rates occur.

Case 3. When a centrifugal pump is employed

to feed the filter medium, and the system“rides the pump curve,” plot data as inFigure 4, to see which theoretical curvematches the test results. These curves de-rive from data in Figures 2 and 3.

MICRON RATING Some writers have adopted a practice

of assigning a micron rating to a filtermedium, meaning that micron-diameterparticle the medium stops with an effi-ciency, E, of 0.98 (R = 50) or higher, in a

certain (and sometimes arbitrary) filtra-tion test.

But, of course, as mentioned above, therating has to be tied to many variables, i.e.,the nature of the medium, the thickness,the specific fluid, the fluid velocity, tem-perature, and the specific test particles.

A more realist rating, for a flat-sheetmedium, involves the structure, that is,the material(s) of construction, thickness,permeability in liquid viscose flow, andporosity, from which deduce the viscoseliquid-flow-averaged pore diameter. Thesesubjects belong in a separate discussionthat also involves the meanings of pore-size distributions, and the size of the“largest pores.”

A WAR STORYMany years ago the present writer ac-

companied a salesman calling on a po-tential customer who was using Brand Xfilter cartridges. We learned that if wecould demonstrate that our cartridge is asefficient as Brand X, he would considerus. He wanted to see test results of filter-ing hot water contaminated with particlesof black iron oxide.

Accordingly, we tested in our lab bothBrand X and our cartridge, and saw iden-tical results. Returning to the potentialcustomer, we showed him our plots of fil-tration efficiency vs. particle diameter. Heresponded that Brand X is more efficientthan we had found.

Later we learned that the Brand Xpeople had showed him results wherethe liquid was not hot water. It was alow-viscosity oil.


Peter R Johnston, Consultant

Tel: 1-919-942-9092


References [1] Johnston, P.R, 1995, A Survey of Test Methods in Fluid Filtra-tion. Gulf Publishing Co.[2] Johnston, P.R. 1990, Fundamentals of Fluid Filtration, a Techni-cal Primer, Tall Oaks Publishing Co, 2nd edition.[3] Strunk, William Jr, and White E.B, The Elements of Style,MacMilliam[4] Johnston, P.R., 2004, Fluid Sterilization by Filtration, 3rd edi-tion, Interpharm./CRC Press[5] ASTM F797-88, Standard Practice for Determining the Perform-ance of a Liquid Filter Medium Employing a Single-Pass, Constant-Rate, Liquid Test.[6] ASTM F796-88, ...Constant Pressure...[7] Dickenson, Christopher, 1992, Filters and Filtration Handbook,Elsevier Publishers[8] Johnston, Peter R., and Roy Swanson. 1982. “A Correlation Be-tween the Results of Different Instruments used to Determine theParticle-Size Distribution in AC Fine Test Dust,” Powder Technol-ogy, 32: 119-124.[9] Grace, H.P. 1956, “Structure and Performance of Filter Media,”AIChE Journal, 2: 307-336[10] Johnston, Peter R., James E. Schmitz, 1974, “A New and Rec-ommended Way to View the Performance of Cartridge Filters,” Fil-tration & Separation, 11, Dec.

FN


Show Report | Filtech 2011

Filtech 11 – Largest Event Since BeginningBy Adrian Wilson, European Correspondent

his year’s Filtech show, whichtook place in Wiesbaden, Ger-many, March 22-24, was bigger

and better than ever, with exhibitors upby 46% and visitors up by 38%.

As the founder of Filtech, Mike Taylorexplained that this highly successful showstarted in the 1960s at the Olympia inLondon, later moving to Holland, beforesettling in Germany.

“This reflects how the country hascome to dominate in Europe in the auto-motive field and many other industrialareas,” he said. “Wiesbaden is a short dis-tance from Frankfurt and its Rhein-Maincenter is an excellent choice for an exhi-bition of this size.”

At the same time, 56% of visitorstravelled to the show this year from out-

side Germany, reflecting the globalstructure of the filtration industry, and avery comprehensive conference featuredover 180 papers.

CENTER STAGE FOR H&VTaking center stage in Hall 1 at Filtech

11 was Hollingsworth and Vose, one ofthe key players in nonwoven-based filtermedia, with manufacturing sites in theAmericas, Europe and Asia.

The company’s NanoWave range ofnanofibrous membranes have a range ofuses, and at Filtech, the company out-lined how, for example, they are achiev-ing massive savings for a manufacturer ofbusiness and civilian jets.

At its U.S. dry-paint spray booth facil-ities, this company collects overspray

T

Founder of the Filtech show, Mike Taylor,with members of his team, Ariana Chittka(left) and Yvonne Klose, in Wiesbaden.


Show Report | Filtech 2011

paint in bag filters that periodically needto be replaced to ensure a consistent flowacross the paint bay. Obligated by law tocomply with proper procedures for thedisposal of hazardous waste, the companywas making eight filter set changes annu-ally at a cost of $11,000 each.

Annual savings as a result of replace-ment with H&V’s NanoWave-based bagshave been put at $45,000, as a result ofthe media’s dust-holding capacity, whichis said to be double that of both syntheticand glass fiber alternatives.

SURFACE AREANanofiber layers are the latest general

progression for nonwoven-based filtermedia, allowing greatly expanded surfacearea which allows for maximum effi-ciency with low resistance, while furtherincreasing particle-loading area.

As a consequence, most leading com-panies supplying nonwoven-based mediaare employing them, but Germany’s Iremahas gone a stage further, in introducing apatented single-step process for produc-ing meltblown nonwoven webs with fullyintegrated nanofibers.

The company’s 100% polypropyleneminipleat filter has recently been tested

and certified to a number of standards,which prove its performance to be on parwith glass fiber.

“The demand for our patented new fil-ter media, manufactured on the latestgeneration of our proprietary lines, isgrowing continuously, particularly in theventilation and air conditioning markets,”said the company’s Anja-Michen Muellerat Filtech.

Such new developments are only likelyto intensify in the coming years – the fil-ter media market now has an overall an-nual value of over $20 billion.

TECHNOWEB PROWith production facilities currently in

Asia, South Korea’s Finetex says it has ex-pansion plans for both North Americaand Europe. The company’s patentedTechnoweb Pro nanofiber technologyproduces webs, which are both glass andfluoro free.

“Our nanofibers are mechanicallystructured, as compared to other materi-als which rely heavily on an electrostaticcharge, pre-treated media or a combina-tion of very expensive nonwoven materi-als which can lose efficiency over arelatively short period or time,” said sales

manager David Seung. “Due to the liter-ally millions of channels in Technoweb,we can provide greater life expectancy forevery filter made, with less pressure dropand inexpensive nonwoven substrates, foreither surface or depth filtration.

Typical applications are in HVAC,HEPA and ULP clean-room grades andtransportation, and the company is cur-rently developing products for both themedical industry and battery separators.

Of particular significance as far asmedical applications are concerned, thelayered structure of Technoweb has mil-lions of pores, just like human tissue. Itexceeds 99.99% filtration at 01. micronswith good absorption and diffusion. Po-tential applications here are anti-bacterialmasks, surgical drapes, caps and gowns,sterile barrier systems and even cell cul-ture filtration systems.

Techoweb separators can also be usedin lithium-ion batteries for consumerelectronic devices, in addition to reservepower and grid management systems andelectric vehicles.

Techoweb advantages here includeoutstanding electrolyte affinity and im-pregnation, lower electrode and elec-trolyte interface resistance and high ion

The Eurocarb team

Reto Vogt of Textest shows their newMobilair FX 3320 portable air permeability tester.

Irema’s Anja-Michen Mueller at thecompany’s Filtech booth.

Fabio Bruschi of Tenax

Thomas Maahsen and MichaelCasp of Jentschmann AG showstheir ultrasonic cutting system.

Karl-Keinz Knotz and Roger Tischauser of Lanz-Ankler

FN


conductivity. In addition, the quality ofthe membrane can be easily controlledand the streamlined production processresults in lower cost.

NANOFICS A group of nano-scaled functional

coatings called Nanofics has been devel-oped by Europlasma, based in Oude-naarde, Belgium. The coatings are appliedby low pressure plasma polymerisationand are typically thinner than 100nm.

Europlasma’s Nanofics technologyguarantees a uniform coverage of com-plex, three-dimensional structures andapplications include:

• Super hydrophobic nanocoatings –to protect electronic devices such as hear-ing aids or smartphones against liquiddamage, to protect PCBs against corro-sion, to make ultra-light liquid aircraftfoams water repellent, for engine air in-take conducts and for improving the per-formance of diesel engine filter media.

• Oleophobic nanocoating to improvethe efficiency of electret filter media, tomake super oleophobic filter membranesto level 8, to prevent cell growth on med-ical implants and to improve personalprotective equipment.

• Super hydrophilic coatings to im-prove the wettability of culture growthproducts, blood filter media, battery sep-arators, etc.

• Barrier coating to prevent the oxida-tion of metal surfaces and for food pack-aging materials.

Specifically for gas filter media,Nanofics can be employed for:

• The oleophobic nanocoating of electrets• Respirator masks• HVAC filter media• Hydrophobic nanocoating of air conducts

• Super oleophobic nanocoating of fil-

tration membranes• Hydrophobic nanocoating of diesel engine filters

For liquid filter media, Nanofics canapply hydrophilisation to porous plasticsand ceramics and hydrophilic coatings toblood filter media and battery separators.

ACTIVATED CARBONEurocarb is the European center of op-

erations for Sri Lanka-headquartered Hay-carb, the world’s leading manufacturer ofcoconut shell activated carbon with anannual capacity in excess of 22,500 tons.

Haycarb recently received attention forthe completion of its Recogen project –the world’s first industrial electricity gen-erating charcoaling plant. Recogen is rec-ognized as a carbon credit generatingfacility by the Kyoto protocol.

Eurocarb provides effective solutionsfor the removal of gas and vapor contam-inants from air, with its high purity mate-rials – whether derived from coconutshell, coal or wood carbons – providingan optimum balance of surface area, den-sity and hardness.

The highly micro-porous structure ofcoconut shell carbons in particular, is em-inently suited to the removal of smallmolecules such as volatile organic com-pounds. Eurocarb carbons are also useddaily in critical water filtration applica-tions, where material homogeneity en-sures consistent water flow and silverimpregnation adds protection and longlife to filter units.

“In many cases we have supportedcustomers in determining an activatedcarbon particle size specification that bal-ances adsorption capacity against pressuredrop within desired parameters,” saidMarket Development Manager KC Perera.

METAL REPLACEMENTItalian-headquartered Tenax intro-

duced a new family of plastic nets madefrom PBT (polybutylene terephthalate).

“They can very successfully replacemetallic parts in filters cartridges,” ex-plained Fabio Bruschi, market managerfor the company’s Industrial and Packag-ing Division,“ as spacers for filter media,pleating supports, rigid tubes for innercores or external cages. They can be usedto assemble completely metal free filtercartridges which can be incinerated atend of life and they possess a good de-gree of shape memory and can be veryeasily pleated.”

In respect of mechanical properties,the PBT meshes have a high resistance todeformation at high temperatures and/orin contact with organic solvents, whilemaintaining a high toughness even whenused at low temperatures.

Key characteristics include:• Yield strength of 52mpa• Maximum operating temperature of 180-200ºC

• Minimum operating temperature of –40ºC

• Melting point of 220-230ºC• Good resistance to organic solvents• Good creep resistance• Flame retardancy

REGULATIONSWilhelm Höflinger of the Vienna

University of Technology explainedhow increasingly stringent Europeanregulations are currently driving thedust filtration market alone.

“Fine dust, especially particlesbelow one micron, can cause seriousheart and respiratory disease andmore efficient pollution standardshave recently been introduced to im-prove the ambient air quality in Eu-rope,” he said. “This is the drivingforce for speedily improving existingdust separators in respect of their fineparticle separation ability.”

Add to this the need for cleanerwater, a demand for finer degrees ofseparation in industry, the drive forbetter hot exhaust gas filtration andfor higher energy efficiencies in allseparation operations, and it becomesclear why Europe’s filtration industryis currently so buoyant, and why Fil-tech remains a vital platform for theexchange of ideas.

Birte Mahn and Elom Westi of Pintashowcased reticulated foam and nonwoven media with active carbon.

David Seung and Donald Cho ofFinetex


Mini M

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