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Particle Removal with Membranes in Water Treatment in Germany
State of the Art and Further Developments
Innovation of Membrane Technology for
Water and Wastewater Treatment
Yokohama (22.11.2006)
Rolf Gimbel, Stefan Panglisch, Andreas Loi-Brügger
2
Institute of Energy and Environmental EngineeringWater Technology
Campus Duisburg
Mülheim an der Ruhr
Campus Essen34,000 students in Duisburg and Essen
5,500 students in the Faculty of Engineering
3
IWW - Facts and Figures
Location
Muelheim an der Ruhr
Northrhine-Westphalia, Germany
IWW in Figures
about 50 scientists, engineers and technicians
IWW is an institute associated with the
University Duisburg-Essen as a limited
non-profit-making company:
Applied Research
Consulting
Service
Campus Essen
Muelheim an der Ruhr
Campus Duisburg
4
IWW-Organisation Chart
Water
Resources
Management
Dr. A. Bergmann
Water
Technology
Dr.-Ing. S. Panglisch
Water Quality
Dr. U. Borchers
Applied
Microbiology
Dr. G. Schaule
Management
Consulting
Dipl.-Volksw. A. Hein
Resources
Protection
Water Catchment
Simulation of
Transport and
Treatment Processes
Water Technology
Membrane Technology
Corrosion Prevention
Swimming Pool Techn.
Inorganic
Analysis Lab
Organic
Analysis Lab
Microbiological
Analysis Lab
Efficiency Consulting
Software
Development
Professional
Education
Hygiene
Biofilms
Biofilm Monitoring
Executive Board Dr.-Ing. Wolf Merkel - Klaus-Dieter Neumann
Scientific Board
Water Chemistry
Prof. Dr. H.-M. Kuss
Water Technology
Prof. Dr.-Ing. R. Gimbel
Microbiology
Prof. Dr. H.-C. FlemmingManagement Consulting
Prof. H. Schulte
Consulting Applied Research Fundamental Research
5
1. State of the Art in Germany
2. Developments in the German Market
3. Largest Membrane Plants in Germany
4. Current Research
Overview
6
Application of Membranes for Drinking Water Production in Germany
7
Origin of Raw Water for Ultrafiltration (relating to number of plants)
18,6%
81,4%
Surface Water Carstic, Well, and/or Springwater
8
Overview Germany: MF and UF plants > 8 m³/h for Drinking Water Production Number
-
10
20
30
40
50
60
70
80
Year of construction
Nu
mb
er
of
pla
nts
Zenon - - - 1 1 3 5 10 12
X-Flow - 1 1 5 9 17 17 19 19
Pall - - - - - 2 4 12 20
inge - - - - 4 7 9 13 18
Aquasource 1 1 1 1 1 1 1 1 1
1998 1999 2000 2001 2002 2003 2004 2005 2006
9
Overview Germany: MF and UF plants > 8 m³/h for Drinking Water Production Capacity
0
2.000
4.000
6.000
8.000
10.000
12.000
14.000
16.000
Year of construction
Ca
pa
cit
y in
m³/
h
Zenon - - - 39 39 157 577 1.461 1.675
X-Flow - 140 140 1.075 1.330 2.006 2.006 8.025 8.025
Pall - - - - - 210 265 526 987
inge - - - - 377 540 573 1.766 2.649
Aquasource 60 60 60 60 60 60 60 60 60
1998 1999 2000 2001 2002 2003 2004 2005 2006
10
Summary: State of the Art in Germany
Due to the water resources no need of reverse osmosis
or nanofiltration in general (up to some few special
applications)
Due to best removal of viruses mainly ultrafiltration,
just some microfiltration plants
Applications in germany:
Surface (reservoir) water
water affected by surface water (carstic water, spring water...)
backwash water (from conventional filtration, from membrane
filtration)
Currently, the largest UF in Germany for drinking water
treatment has a capacity of 7,630 m³/h (reservoir water)
incl. 630 m³/h backwash water treatment
11
1. State of the Art in Germany
2. Developments in the German Market
3. Largest Membrane Plants in Germany
4. Current Research
Overview
12
Process Development: Hybrid process Flocculation/ UF
UFFlocculation
+ UFNF
0%
20%
40%
60%
80%
100%DO
C-re
tent
ion
Range of results
Minimum retention
13
Process Development: Hybrid process Flocculation/ UF
150
170
190
210
230
250
270
290
310
12:00 20:00 4:00 12:00
Pe
rme
ab
ilit
y 2
0 °
C [
L/m
2/h
/ba
r]
0
Chemical enhanced
backwash
Failure of Al- Dosage
14
The Market in Germany:New Membrane Developments
Inge, Multibore
Higher mechanical stability
Membrana, Liqui-Flux
Higher packing density
(61 m²/module)
Nadir, Bio-Cell
Self-supporting Membrane Bags
Submerged Membranes
15
The Market in Germany:New Membrane Process Combinations
16
Nominal pore size 0.1 µm
Membrane surface area 25 m²
Size of channel 2.5 mm
Number of channel 2,000
Material Ceramic
Dimension 180 x 1,500 mm
The Market in Germany:New Competitors: Ceramic MF by NGK, Japan
economically comparable
flux performance higher
higher recovery
higher lifetime
no broken fibers to be expected
but:
less virus removal
references just starting in
Europe
17
Summary: Market Developments
Hybrid process Flocculation/ UF is on the
advance
Development of high stability capillaries and
self-supporting flat sheet membranes
Development of membrane modules with high
packing density
Development of new membrane combinations
New competitors from abroad with ceramic
membranes
18
1. State of the Art in Germany
2. Developments in the German Market
3. Largest Membrane Plants in Germany
4. Current Research
Overview
19
Roetgen: Commencements
In the middle of the nineties coliforms and E.coli were detected in the drinking water of the water works Roetgen (6,000 m³/h, using reservoir water) after heavy rainfalls
It was decided to investigate the suitability of membrane filtration
At this time there was no membrane filtration plant in Germany operated and no experience with technical membrane plants
Membrane pilot experiments were started
20
Treatment scheme of WW Roetgen and pilot phases
1. Stage
UF-pilot plants
X-Flow,
Zenon,
inge,
Puron
NaOH
Al2(SO4)3 or
Polyaluminium
ChloridFiltrate
Backwashwatertank
Reaction-Basin
Al2(SO4)3
Ca(OH)2
Ca(OH)2 Cl2 ClO2
Flocculation
agents (optional)Disinfection
1. Filtrationstep
2. Filtrationstep
Drinking watertank
Distributionsystem
reservoir
Discharge
Filtrate
2. Stage
UF-pilot plants
X-Flow,
Zenon,
inge,
Puron
KMnO4
21
Use of Chemicals to Clean the Membranes of the Pilot Plants in Roetgen
Start in 1995 with NaOCland H2O2
Later also with ClO2
Since November 2001 only with H2SO4
and NaOH
22
Applications I: Drinking Water TreatmentRejection of microorganisms (B.Subtilis, 300 nm)
09:3
5
09:4
5
10:1
5
10:4
5
11:0
5
11:3
0
11:4
0
12:1
0
12:4
0
13:1
0
13:3
0
permeate Aquasource (UF)
permeate X-Flow (UF)
permeate Memtec (MF)
feed
1,00E+00
1,00E+01
1,00E+02
1,00E+03
1,00E+04
1,00E+05
1,00E+06
1,00E+07
B.S
ub
tili
s/5
00
ml
back flush
23
08:45 09:45 10:30 11:0011:27 12:00
12:30
permeate UF1
permeate UF2
permeate MF
feed
1,00E+00
1,00E+01
1,00E+02
1,00E+03
1,00E+04
1,00E+05
MS
2-P
hag
en
/ml
back flush
Applications II: Drinking Water TreatmentRejection of MS2-Phagen (20 nm)
24
Intake Tank
Pre-filtration
Ultrafiltration
1. stage
Limestone filtration
Desinfection
Storage
Flocculation (in-line)
Powdered activated carbon (optional)
NaOH / CO2
CO2 (optional)
NaOH (optional)
New components
are underlined
Al2(SO4)3 or Polyaluminium chloride (optional)
reservoir
Re-feedUltrafiltration
2. stage
Discharge
Backwash-water
Optimal Process Combination (Roetgen)
25
Xiga Concept
70,000 m²
12 blocs, 36 pressure
tubes each
7,000 m³/h maximum
capacity
Largest membrane plant
in Germany
UF Membrane Plant in Roetgen:Start of operation in November 2005
26
UF Membrane Plant in Roetgen:Start of operation in November 2005
27
UF Membrane Plant in Roetgen:Start of operation in November 2005
28
UF Membrane Plant in Roetgen:Start of operation in November 2005
29
UF Membrane Plant in Roetgen:Start of operation in November 2005
30
Scheme of the backwash water treatment in Roetgen
Buffering of
chemical-free
backwash water
UF-plant for
backwash water
(2. Stage, (BW-UF)
Sedimentation tank 1
Refeed into the
feed of the 1. stageThickener
CentrifugeDischarge into
the receiving water
Buffering,
neutralisation,
and if necessary
reduction
Chemical-free
backwash water
Chemical-containing
backwash water
(Acid, base or, if
necessary oxidizing
agent)
Membrane plant for drinking water production (1. stage)
Sewer
Earth basin/
Soilfilter
Powdered activated carbon
(if necessary)
Reducing agent
(if necessary)
Sedimentation tank 2
31
Backwash Water Treatment: inge System
7,000 m²
3 blocs, 78
elements each
630 m³/h maximum
capacity
Largest backwash
water treatment
plant with
membranes (at
least) in Germany
32
Summary: Roetgen
Start of operation of the largest UF plants of Germany for drinking water production (7,000 m³/h) as well as for backwash water treatment (630 m³/h) in November 2005
Drinking water line is carried out as advanced hybride process with in-line coagulation
Permeability of drinking water line approx. 400 l/m²bar h
CEB just with acidic or alkaline solution and without dosing oxidizing agents
Overall recovery by additional backwash water treatment is higher than 99.5 %
Specific costs of the process (investment including building and operational costs) are below 10 €Cent per m³ produced drinking water
33
1. State of the Art in Germany
2. Developments in the German Market
3. Largest Membrane Plants in Germany
4. Current Research
Overview
34
Current Research in our group
Artificial Neural Networks (ANN) for
Monitoring, controlling and automation
Optimizing of operation and costs
Improvement of basic knowledge about membrane
processes
Computational Fluid Dynamics (CFD)
Optimizing of geometry and hydraulics of
membranes, modules and reactors
UF as pretreatment for RO-Desalination
Retention of Xenobiotics (nature extrinsic
organic substances) by PAC/UF, NF, RO
35
Optimization of UF/MF-plants by Artificial Neural Networks (ANN)
Input
Parameters
Output
ParametersANN
Temperature
Turbidity
------------------------------------------
Flocculation pH
Feed pressure
Backwashing conditions
Flux
Filtration time
Al-concentration
Water Quality
Process
Adjustable
36
Modelling of UF/MF by ANN
Further development in a research project
funded by the German Federal Ministry for
Education and Research- mechanism of membrane blocking
- evaluation of main effects responsible for blocking
- development of strategies to minimize blocking
- influence of coagulation pre-treatment
37
Computational Fluid Dynamics (CFD)
38
Computational Fluid Dynamics (CFD)
39
UF as Pretreatment for Seawater RO (SWRO); Background
Today, RO has a market share of 20 % of the
worldwide installed capacity for seawater
desalination
It is assumed, that the market share with new
plants will grow to 50 % in the next years
40
UF as Pretreatment for Seawater RO (SWRO); Background
Advantages RO:
Investment costs approx. 30 % lower than for
thermal plants
Much lower energy demand
Lower required space
Disadvantages RO:
Possibly operational problems by membrane fouling
Varying quality of rawwater has big influence on
plant performance, chemical consumption,
membrane lifetime, ... and operational costs
41
UF as Pretreatment for Seawater RO (SWRO)
Pilot experiments of the companies Taprogge and inge
at Arabic Gulf with scientific consultancy of IWW
42
Many Thanks
for Your
Interest
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