6.0 Application Examples
6.1 Catalyst Recovery
Objective: To transfer from batch to continuous processing.
Existing batch process:
Proposed continuous process:
As the only reason for cooling the oil was 80°C to facilitate the filtration stage you can see a significant improvement in energy efficiency as well as a reduction in the capital cost and size of equipment required for the duty.
6.2 Corn Wet-Milling Experience
Applications in the corn wet-milling process include:
- 95 DE corn syrup
- low DE malto-dextrin
- fructose polishing.
Related applications also include:
- starch recovery and concentration
- chicory and wheat starch clarification
- cane and beet sugar juice/syrup clarification
- fermentation and broth clarification
Corn refinery flow diagram
6.2.1 95DE Glucose Clarifier System
- 2 parallel 4-stage systems
- Feed-and-bleed arrangement of stages
- Design Feed Flow: 291 m3/hour
- Feed Fluid: Glucose Syrup from corn starch at
- 32% dry solids
- 0.4% suspended solids
- 95 to 98 dextrose equivalent
- Temperature: 60ºC to 65ºC
- Viscosity: 1.18 cP
- Total membrane area: 3420 m2
- Constant permeate flow control by TMP
- 90% Recovery; 10X concentration
- Retentate to Ethanol Plant
Each of Eight Stages
 |
Module Type: |
|
38C-750A-20P2 |
| Number of Tubes: |
1302 |
| Membrane Area: |
456m2 (4908 ft2) |
| Circulation Pump: |
18x18-22 |
| Circulation Motor: |
150kW (200hp) |
| Power: |
460V/3ph/60hz |
| Current: |
200A |
| Motor Speed: |
900 rpm |
| Feed Pressure: |
2 - 4 bar |
| Circulation DP: |
1.3 bar (20 psig) |
| Initial Permeate Flow: |
> 75m3/hr |
| Permeate Flow after 24hrs: |
~46m3/hr (200 gpm)/td>
|
|
Flux vs. Online Time
|
|
Total Permeate Flow Trend
 |
6.2.2 Fructose Polishing Filter using dead-end Microfiltration -Post Evaporation
|
Clarifier Modules
|
55 FX Final Filtration System
- Constant Flux
- Dead-end filter
- Removes micro-organisms:
- yeast, bacteria, mold spores, and mold mycelia
- Filter is downstream of the final evaporator so Fructose properties are: 77% DS, 68 cp, 60ºC.
55 FX Final Filtration System: Stages
| Module Type: |
|
12-750A-20P |
| Number of Tubes: |
130 |
| Number of Modules/Stage: |
4 |
| Membrane Area/Stage: |
182.1m2 |
- Two stages
- Generally, only one stage is on line at a time.
- Stages are run for about 48hours or to about 40 bar TMP.
- When feed pressure reaches maximum, operator places clean stage on line.
- CIP takes about 2 hours.
- Clean stage rests until needed.
|
Membrane Check Filter Advantage
- Removes yeast, bacteriological, and particulate contamination after final evaporation, eliminating product contamination from the evaporators.
- Eliminates purchase, handling, worker exposure, and disposal of filter cartridges and/or filter precoat materials.
- Provides an order of magnitude finer filtration level.
- Delivers an effectively "pasteurized" final product to the shipping container.
Biological Rejection - 0.1 micron nominal
| Sample |
Feed |
Permeate |
Log Reduction |
| 1 |
9.6 |
1.7 |
7.9 |
| 2 |
9.8 |
3.1 |
6.7 |
| 3 |
10.1 |
2.3 |
7.8 |
- Dead-end 0.1 micron membrane modules.
- Two stages of four parallel modules.
- Total area is 365 m2.
7.0 Scepter® Membrane Summary
- Strong; rugged, tough; durable.
- Large area modules minimize system capital and operating costs, void volume, and floor space.
- Simple system design and operation; few parts to break or maintain.
- Welded construction minimizes downtime, maintenance labour, and cost of spares, purchase and inventory.
- Chemically compatible; relatively inert.
- Cleans relatively quickly and completely.
- Easily automated; Simple controls.
- Minimum pre-filtration required.
- Steam sterilizable; Back-pulsable.
- Hundreds of module design options to customize the system for the application.
- Tolerant of process upsets.
- Easily expandable.
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