Membrane filtration

Product Centre Membranes

PC Membranes

Alfa Laval

Main Menu
Alfa Laval Nakskov A/S
What is membrane filtration?
Product range
Applications
References/case stories

Alfa Laval

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One of the pioneers

Late 1950s
Membrane filtration introduced
1965
DDS Filtration
1989
Dow Liquid Separation Systems
1997
Danish Separation Systems AS
2002
Alfa Laval
Alfa Laval

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Alfa Laval Nakskov A/S

In-house membrane production

Spiral membrane rolling

Customer test centre for application

development

Pilot equipment from few m to 200m

Plate-and-frame and spiral module

production

Copenhagen

Engineered membrane systems

R&D department
Complete separation solutions (synergy)

Alfa Laval

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Nakskov

www.alfalaval.com

What is membrane filtration?

Membrane filtration is a physical

separation process and the driving
force is the pressure difference across
the membrane. It is characterised by
the ability to separate molecules of
varying sizes and characteristics by
using different membrane types.

Alfa Laval

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Separation processes and mechanisms

Alfa Laval

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Membrane filtration
Physical separation process
Semi-permeable barrier
One feed stream split into two individual
streams

Driving force is pressure

Either stream may contain the desired product
Feed . .
Membrane

Alfa Laval

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Cross-flow filtration
Cross-flow filtration

No filter cake
No use of filter aids

Feed . .
Membrane

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. . . . .. ..... . . . Permeate
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Uniform, controllable product quality

Continuous, automated process

Long membrane lifetime
CIP cleaning

Filter cake

Alfa Laval

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Membrane structure
UF & MF membrane

Thin top layer (0.10.5 m)

Porous sub-layer (50150 m)
Support paper for mechanical
stability (100200 m)

Different polymers
Cellulose acetate/triacetate
Polysulphone/polyethersulphone
Fluoropolymers
Composite membranes

NF & RO - thin-film membrane

polymerization of barrier layer

Alfa Laval

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The membrane
GR60PE surface, mag
100,000 x

High mechanical strength

High porosity
Sharp cut-off value

Excellent temperature, pH, and

chemical resistance
GRM 0.2m surface,
20,000 x

Easy to clean

Alfa Laval

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Reverse osmosis

Only water will pass

NaCl rejection > 9596%
Typical operating pressure 1560 bar
Concentration of liquids with low molecular
compounds at low solid levels

Alfa Laval

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Nanofiltration

Slightly more open than RO

MgSO4 rejection > 97%
Typical operating pressure 535 bar
Allows monovalent ions to pass
Rejects divalent and larger ions and most organic components

Alfa Laval

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Ultrafiltration

MWCO: 1,000100,000
Typical operating pressure 110 bar
Allows salts, sugars, organic acids and smaller peptides
to pass

Rejects proteins, fats and polysaccharides

Alfa Laval

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Microfiltration

Pore size 0.11 m

Typical operating pressure < 2 bar
Only suspended solids, bacteria and fat globules are
rejected

Alfa Laval

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Operation

Batch
Continuous
Diafiltration

Batch

Pre-treatment
Automation and control
Cleaning

Alfa Laval

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Batch operation

Retentate recycled until final concentration is reached

Minimum membrane area
Minimum automation

Used when holding time is not critical

Alfa Laval

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Continuous operation

Multiple loops with own recirculation pumps

Module selected to fit actual viscosity
Low residence time

Can be fully automated

Permeate
Feed

Retentate
Alfa Laval

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Diafiltration
To increase the purity of a given
product
Addition of water (or permeate) to retentate
to wash away impurities
Batch or continuous
Additional membrane area required to remove added water
Permeate
Feed

Retentate
Diafiltration water

Alfa Laval

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Pre-treatment
To reduce fouling and ensure optimum plant
performance
Most common pre-treatment methods:
Centrifugation
Filtration
Heating/cooling
pH adjustment
Enzyme treatment

Alfa Laval

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Automation and control

To secure overall plant

performance

To protect sensitive membranes

(temperature, pressure, pH)
Different levels of automation
Manual

Semi-automatic
Automatic

Alfa Laval

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Cleaning
To promote the optimum membrane
performance
Cleaning In Place (CIP)

Typically once per day or batch

Chemical cleaning agents
Recycling through system

Given pH, temperature and pressure

Specific water quality requirements

Alfa Laval

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Why use membrane filtration?

Lower cost of
production

Lower installation and energy costs

Increased yields
Environmentally responsible solution
Fewer processing steps

High end
product quality

Clean technology
Higher degree of purity
Compliance with stringent requirements

Flexibility
Alfa Laval

Range of viscosities
Continuous or batch
Modular structure
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Major processes
Membrane filtration can sucessfully be used for the following
processes:
Concentration
Purification
Clarification
Recycling
Product upgrading
Extraction
Recovery
Effluent upgrading
Fractionation
Alfa Laval

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Wide range of products

Membranes
Modules
Pilot equipment and test facilities
Systems and process lines
Spare parts and service

Alfa Laval

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Membranes

For all filtration processes RO, NF, UF, MF

Different combinations of polymers and support paper
Resistant to high temperature and wide pH range
Compliance with EU and FDA

Flat sheet membranes

Available
by the metre
20 x 20 cm sheets
Rolls 500 750 metres
for all plate-and-frame configurations
Alfa Laval

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Membrane overview
Membrane
process

RO

NF

Membrane
Series

Characteristics

pH

Pressure, bar

Temperature, C

CA995PE

Cellulose triacetate/diacetate
blend

NaCl rejection
95%

5-6.5

1-50

0-30

RO98pHt

Thinfilm composite on
polypropylene

NaCl rejection
96%

2-11

1-60

0-60

NF99

Thinfilm composite on polyester

MgSO4 rejection
99%

2-10

1-55

0-50

UFX5

Polysulphone permanently
hydrophilic

MWCO = 5,000

1-13

1-15

0-75

UFX10

MWCO = 10,000

1-13

1-15

0-75

GR40PP

MWCO = 100,000

1-13

1-10

0-75

2-8

1-10

0-50

1-11

1-10

0-60

1-10

1-10

0-60

1-11

1-10

0-60

1-11

1-10

0-60

1-13

1-10

0-75

Name

RO

NF

UFXpHt

GR51PP
UF

UF-pHt

UF-RC

UF-ETNA

MF-FSM
MF

MWCO = 25,000
MWCO = 20,000

Alfa Laval

CA600PP
FS40PP
FS61PP
RC70PP
ETNA01PP
ETNA10PP
FSM0.15PP

Polyethersulphone
Cellulose acetate
Fluoro polymer

Regenerated cellulose acetate

Composite fluoro polymer

Fluoro polymer

FSM0.45PP
MF-GRM

MWCO = 50,000

GR61PP
GR95PP

UF-FS

Polysulphone

GR60PP
GR81PP

UF-PP

Recommended operation limits - production

Membrane material

GRM0.1PP
GRM0.2PP

MWCO = 10,000
MWCO = 2,000
MWCO = 20,000
MWCO = 100,000
MWCO = 20,000
MWCO = 10,000
MWCO = 1,000
MWCO = 10,000
Pore size 0.15 m
Pore size 0.45 m

Polysulphone

Pore size 0.1 m

Pore size 0.2 m

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Membranes
Feed spacer

Spiral membranes

Membrane
Permeate spacer

Cost-effective

Membrane
Permeate tube

Full-fit, sanitary design

Comprehensive range of elements

(membrane, diameter, length, spacer)

Alfa Laval

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Membranes

Alfa Laval

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Spiral membrane overview

Membrane
Series

RO

Membrane material

Pressure, bar

Temperature, C

NaCl rejection 95%

5-6.5

10-28

5-20

Thinfilm composite on
polypropylene support paper

NaCl rejection 97%

2-10

1-55

0-60

Thinfilm composite

NaCl rejection 98%

3-10

1-55

0-50

3-10

Max. 55

Max 50

2-10

1-10

0-75

2-10

1-10

0-75

1-13

1-15

0-75

3-9

1-10

0-50

Cellulose triaceate/diacetate
blend

RO98pHt

RO99

NF99

Polyamide type thinfilm

composite on polyester

NF99HF
UF

SSE20

Polyethersulphone

GR40PP
GR51PP
UF-pHt

UFX-pHt

UF-PE

MgSO4 rejection
97%
MgSO4 rejection
98%
MgSO4 rejection
98%
MWCO = 20,000. Inline sterilisable spiral
element
MWCO = 100,000

Polysulphone

MWCO = 50,000

GR60PP

MWCO = 25,000

GR61PP

MWCO = 20,000

GR81PP

MWCO = 10,000

GR95PP

UFX5 pHt

Polyethersulphone

Polysulphone permanently
hydrophilic

MWCO = 2,000

MWCO = 5,000

UFX10 pHt

MWCO = 10,000

GR60PE

MWCO = 25,000

GR61PE

Recommended operation limits - production

pH

CE4040C-30D
(based on CA995PE)

NF97
NF

Characteristics

Name

Polysulphone

GR70PE

MWCO = 20,000
MWCO = 20,000

GR81PE

Polyethersulphone

MWCO = 10,000

UF-FS

FS40PP

Fluoro polymer

MWCO = 100,000

2-10

1-10

0-60

UF-RC

RC70PP

Regenerated cellulose acetate

MWCO = 10,000

2-10

1-10

0-60

2-10

1-10

0-60

1-11

Max. 1.5

0-60

1-11

Max. 1.5

0-60

ETNA01PP
UF-ETNA

MF-FSM

ETNA10PP
FSM0.15PP
FSM0.45PP

MWCO = 1,000
Composite fluoro polymer

Fluoro polymer

GRM0.1PP
MF-GRM

Alfa Laval

GRM0.2PP

MWCO = 10,000
Pore size 0.15 m
Pore size 0.45 m
Pore size 0.1 m

Polysulphone

Pore size 0.2 m

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Modules
Spiral modules

Compact

Inexpensive
Easy to use
Housing

ATD

Spiral element

Retentate

Permeate

Alfa Feed
Laval

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Modules
Plate-and-frame modules

Wide viscosity range

Channel height to match

varying product characteristics

High tolerance to suspended

material, therefore less pretreatment required

Easy re-establishment of
membrane performance

Alfa Laval

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Module range
Plateandframe

Spiral

- high viscosity and solids capability for max. concentration

- open channel sanitary design
- low running cost
- compliant with FDA and EEC regulations

- large membrane area per module for compact design

- resistant to high temperature and full pH scale
- low investment cost
- compliant with FDA and EEC regulations
Reverse Osmosis

Alfa Laval

Nanofiltration

Ultrafiltration
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Microfiltration
www.alfalaval.com

Pilot laboratory equipment

To establish process feasibility
To determine design data for scale-up
final product composition
required operation parameters
necessary cleaning procedure
To demonstrate process solutions
To optimize existing production lines
For small-scale processing

Alfa Laval

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From lab to pilot

Rental
equipment

Pilot plant
Nakskov

Capacity

Lab
tests
R&D

&

&

pilot

lab
tests

0
Alfa Laval

Scale
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Pilot laboratory equipment

Rental equipment

For on-site testing

Close technical support

Wide range of equipment

Alfa Laval

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Pilot laboratory equipment

Pilot plant Nakskov

State-of-the-art customer test

facilities

Production size modules

Large volumes
Expert technical staff
Joint tests with customers

Alfa Laval

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Membrane filtration systems

Tailor-made solutions

Developed in close cooperation with

customers

application
process requirements
choice of membranes
Spiral, plate-and-frame or combined
systems

Batch and continuous operation

Sanitary and industrial design
Installation support and commissioning
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More than 2,000 membrane filtration systems

Alfa Laval

www.alfalaval.com

Plate-and-frame systems

Alfa Laval

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Plate-and-frame systems

Alfa Laval

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Spiral membrane systems

Alfa Laval

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Spiral membrane systems

Alfa Laval

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Process lines
One system one supplier

Heat Transfer

Separation

Membrane
Filtration

Fluid
Handling
Alfa Laval

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Process lines
Synergies - Evaporator

Alfa Laval

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Process lines
Synergies High speed separator

Alfa Laval

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Process lines
Synergies Decanter

Alfa Laval

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Spare parts and service

Membranes

Genuine spare
parts

Plates
System spares

Guarantee of
performance quality

Re-membraning

Day-to-day
support

Tailor-made
service
agreements
Alfa Laval

Emergency service
Troubleshooting
Training

Performance analysis
Upgrading
Preventive maintenance
Re-membraning
Training
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Reduction of
downtime

Long-term cost
savings

www.alfalaval.com

Major applications

We help customers to
separate products such as
water, chemicals, beverages,
foodstuff, starch and
pharmaceuticals.

Alfa Laval

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Major applications

Alfa Laval

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Pharma and biotech

Antibiotics
UF and MF recovery and purification
NF and RO concentration and
desalting
For increased efficiency and higher
product quality

Enzymes
UF for concentration, purification, and
desalting
NF for recycling of water

For higher concentration and purity

with minimum loss of activity
Alfa Laval

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Pharma and biotech

Polysaccharides
UF and NF concentration and purification
in one process at low cost

Amino acids
UF recovery and purification and RO
concentration

For high product quality and low costs

Yeast extract
UF for recovery and purification

RO for concentration
For high purity and reduced water
Alfa Laval consumption
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Major applications

Alfa Laval

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Food and beverages

Beer
RO for beer dealcoholization
Quality in line with standard beer
at low cost

Food gums
UF for concentration and purification
RO for recycling of permeate
High purity at minimum operating costs

Gelatine
UF for fractionation, concentration
and purification
For gentle processing to avoid
denaturation

Alfa Laval

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Food and beverages

Juice
UF for clarification
RO for concentration

For greater profitability

and better quality

Eggs
UF for concentration of egg white and whole egg
RO for dewatering of egg white prior to drying

For gentle treatment and high-quality product

Alfa Laval

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Food and beverages

Wine
RO for the concentration of grape juice

RO for colour concentration from red wine

NF for aciditiy reducation in wine
NF/RO for dealcoholisation of wine

Animal blood plasma

UF for concentration and purification

Vinegar
UF for clarification

Alfa Laval

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Sugar and starch

Sugar industry
UF for removal of haze and colour from
sugar syrup
RO for concentration of sugarwater

Starch industry
MF/UF for mud removal after
saccarification
UF for polishing/pyrogen removal from
dextrose and HFCS

Sugar and starch industry

RO for evaporator concentrate polishing
RO for sweet water purification and
polishing
Alfa Laval
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Pulp and paper industry

Paper industry
UF for colour recovery

UF & NF/RO for white water purification

Pulp industry
UF for the purification and concentration of
lignin from KBL and SSL

Pulp and paper industry

UF/NF/RO for evaporator condensate
polishing

Alfa Laval

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References
Novo Nordisk
Glaxo SmithKline
Antibioticos
Milei GmbH
Arla Foods
Unilever

Citrosuco
Danisco Cultor
Lonza Biotec s.r.o

Biotech Paskov

Alfa Laval

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Lonza Biotec s.r.o., Czech Republic

Reliable performance

Through 16 years of collaboration, Alfa Laval has installed, restored

and replaced a number of membrane filtration systems.
For us, the important things are an informal yet close collaboration,
mutual trust, willingness to cope with problems, and a
high degree of professionalism. It is a pleasure to work with a
company that acts like a real partner, rather than a mere supplier.
Its exactly what were trying to provide for our own customers.

Tomasz Cieslewski, site manager, Lonza Biotec, s.r.o., Czech Republic

Alfa Laval

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Serum-Werk Bernburg, Germany

Easy expansion

Serum-Werk Bernburg installed its first membranes from Alfa Laval

in 1996. Advanced membranes ensure that only molecules of a
specific size are retained. It is also important that the processed
products are sterile, and ultrafiltration at high temperatures is how
we stop the growth of germs.
Due to the modular design of the membrane filtration system it was
easy to double the companys production capacity in 2002 and we
want to achieve another doubling of capacity next year
Werner Zimmermann, head of technology, Serum-Werk Bernburg,
Germany
www.alfalaval.com

Alfa Laval

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Citrosuco, Brazil
Fruitful cooperation

Citrosuco installed an ultrafiltration plate-and-frame plant for orange

juice processing in 1996. However, peel oil is very aggressive, and
the oil was basically destroying part of our equipment. Alfa Lavals
engineers worked with us on a series of tests and experiments and
support plates were developed that could withstand the oil-rich juice.
The success of this innovation led to upgrading of all 16 modules in
2002, and the signing of a five-year service agreement.

Srgio Moretti, production manager, Citrosuco, Brazil

Alfa Laval

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Edidan/Danish Crown, Denmark

Boosting capacity
When we reached our capacity limits, Alfa Laval gave us an
alternative to extending the dryer unit by installing a spiral
booster unit prior to the existing Plate & Frame unit.
This spiral unit undertakes preliminary concentration of blood
plasma. We can now boost production capacity by 50% with no
changes to the drying unit. Obviously, its much cheaper to remove
water by simply filtering it out.

Aage Christensen, plant manager, Edidan/Danish Crown, Denmark

Alfa Laval

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BIOTECH Paskov,Czech Republic

Experience makes the difference

As it is fully automated, the ultrafiltration plant requires very little

attention from operators. They occasionally check the relevant
parameters, but do not generally have to take specific action.
Jan Jon, production manager, BIOTECH Paskov, Czech Republic

Alfa Laval

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