Ultrafiltration on degreasing bath application - Surface Treatment - Automotive Market By Frederic Rob, Marc Antoni Marti and Jose Manuel Martin

1. ULTRAFILTRATION ON
DEGREASING BATH APPLICATION
- SURFACE TREATMENT -
Automotive Market
INDUSTRIAL MANUFACTURING
Frederic Rob – France
November 16th 2011
Marc Antoni Marti - Spain
Jose Manuel Martin - Spain Pall Corporation

2. Pall Presentation
• Headquarter :
Port Washington, NY, USA • 10,400 employees
• Sales figures : • 2 activities: Life Sciences
$2.7 billion Industrial
• More than 80 plants in 30 • 69th at Newsweek Green
countries Ranking
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3. Pall Presentation
Argentina Mexico
Australia Netherlands
Austria New Zealand
Belgium Norway
Brazil Poland
Canada Puerto Rico
China Russia
France Singapore
Germany South Africa
India Spain
Indonesia Sweden
Ireland Switzerland
Italy Taiwan
Japan Thailand
Korea United Kingdom
Malaysia United States
Venezuela
3

4. Pall Presentation
Quick open Nylon/Polypropylene/PTFE
Multibags Housings Bags
Metallic Basket
Magnetic candles
Housings
Bags Housing
4

5. Pall Presentation
Many Absolute filtration element made of polypropylene/Nylon,
Glassfiber… manufactured all around the world with low volume
dishes because high dirt capacity
thanks to a gradient deep structure
ncy
e ff ic ie
98%
99.
Melt Blown Element with Profile Star Element Ultipleat Profile
Sivler Filter Housings
5

6. Pall Presentation
PROCESS APPLICATION SYSTEMES
Process fluids Micro-Ultrafiltration – from 0.8µm to 5nm
Water quality Improvement Microfiltration - 0.1µm, Reverse Osmosis
Effluents Ultrafiltration, M.B.R, Reverse Osmosis
Bacteria Organic Microfiltration
Liquid / Liquid Coalescence Industrial water production device Demineralized water production
System 0.1µm membrane complete system (MF + R.O.)
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7. Pall Presentation
A wide range filtration element for fluids, blowing, and air device
filtration with Micro and Ultrafiltration.
Main Applications
• Degreasing bath
• Effluent treatment
• Water conditionning
Ceramic membrane Shapes Ceramic Membranes One small ultrafiltration unit
Capacity : 1,8 m3/hour
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8. Pall Presentation
Microfiltration Containers
til 360m3/hr
PVDF Organic membranes and
Ceramic membranes
Reverse Osmosis water production
installation
8

9. Degreasing Bath Application
ULTRAFILTRATION ON
DEGREASING BATH APPLICATION
Automotive Market
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10. Degreasing Bath Application
Technical data :
120 body cars per hour
24h/day
5 days/week
Surface of each body car : 100 m²
Oil quantity on body car : 1.4 g/m²
16.80 Kg of oil/hour bring by cars in degreasing bathes
Process objective : Maximum Oil concentration to maintain : 3g/l
Cleaning system frequency : maximum 14 days
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11. Degreasing Bath Application
Environmental objectives :
Volume of waste water 3000 m³/year reduction
COD 4500 Kg/month reduction
Financial objectives :
Degreasing Labour cost
(bath drains, bags replacement) 300 h/year
Bags filters consumption
(alcalin bath) 3000 €/year
Industrial water consumption 3000 m³/y.
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12. Degreasing Bath Application
Technical Process Information Before UF
Step 1 Step 2 Step 3
30m³ 85m³ 85m³
E E E
Bags Filter
Hydrocyclone
Paper band
Effluent : Constant filter
E
Drain
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13. Solution:
Ceramic Membrane
EP1940
• Full pH range compatibility : 0 – 14
EP3730
• Withstands high pressure and temperature : 10 bars
at 95°C (more with special housings)
• Long membrane service life : up to 15 years
(according to application, pore size and feed quality)
• Stringent QC policy (100% bubble point tested)
EP3740
Selected membrane
EP1960 Length 1020 mm
Channel diameter 4 mm
EP4840 IC Intermingled channel
Number of channels 37 or 48
Channel diameter (4mm) Filtration area 0.47 or 0.69 m2
Number of channels (48) Geometry Hexagonal and IC
ceramic membrane
Pore size 50 or 100 nm Z
13

14. Solution:
Ceramic Membrane
Filtrate flow
Feed
flow
MEMBRALOX CERAMIC MEMBRANE
Filtration layers
=
Support (Al2O3)
+ Membralox support :
Intermediate layer(s) (Al2O3) 12 µm
+
Filtration Layers (Al2O3, ZrO2, TiO2) SEM Picture
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15. Solution:
Ceramic Membrane
Water/Solvent
Flow direction
Ions Particles Macro
Molecules
Filtrate or
G
permeate
Ions Water/ Small particles
Solvent
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16. Solution:
Ceramic Membrane
Module type HCB :
Use of a single global gasket in PTFE instead of
individual gaskets in EPDM or FPM
No chemicals limitation
Proved reliable sealing which does not require any
more gaskets replacement
Perfectly suited for the high robustness and long
lifetime of Membralox membranes
High packing density of the membranes inside the
housing
Cost-effective system design with smaller foot print
Large success since 1999 with more than 700 of
HCB modules already sold worldwide
16

17. Solution:
Ceramic Membrane
PURCHASED SYSTEM
PALL CERAMIC UF SYSTEM
• Membranes : Membralox 60P37-30HCB
• Set : 4 modules (2x2 in parallel)
• Cut off : 50 nanometer
• Channel diameter : 3 mm
• Filtration surface : 4x21m² 84m²
• Permeate Flowrate calculated : 5600 l/hour
(Target: 3 g/l of oil) with 58m²
• Flowrate requested: 8000 l/hour
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18. Solution:
Ceramic Membrane
Technical Process After UF
Step 1 Step 2 Step 3
30m3 85m3 85m3
E E E
Bags Bags Bags
1000µm 1000µm 800µm
Hydrocyclone
Paper band Concentrate
filter Permeate
Paper band filter
MEMBRALOX
with magnetic UF loop
Still in place device
New instalaltion for UF FP CP
Working Tank
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19. Solution:
Ceramic Membrane
Magnetic paper band
filter
Metallic Basket
Protection
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20. Environment &
Economical Savings
Savings per year Exploitation costs
Unit Cost/unit Savings Unit Cost/unit Spendings
Effluents Effluents
Waste Water Treatment m3 3685 0.4 1 474 € Oil to evacuate 30 300 9 000 €
Hydrocarbon Tonnes to treat 20 300 6 000 €
EDI
Tap water Savings Demin water consumption m3 300 5 1 350 €
Tap water Savings 3685 0.39 1 437 €
Power
Power UF power consumption Kw/h Kw per day
Step 1 : Heating savings 106894 0.0227 2 426 € 500m3/H @ 3 bars 43 1040 0.0227 7 555 €
Step 2 : Heating savings 60573 0.0227 1 375 € Feed UF Loop 80m3/h @ 3 bars 9 213 0.0227 1 550 €
Working Tank Feed 12m3/h @ 2 bars 1 21 0.0227 155 €
Degreasing Chemical Product
Before UF (gr./véhicule) 522 Cleaning Product
After UF (gr./véhicule) 250 P3 ultraperm 20kg 20 408 165 3 366 €
Total saving per vehicule (g) 272 P3 acid 20kg 61 1224 286 17 503 €
Number of Vehicules Manufact 450000
Total saving (kg) 122400 1.32 161 568 € Degreasing Chemical Product
Working Tank charge 8000 1 8 000 €
FIP (Filtration In Place) Manpower
Bags Filtration 375 6 2 250 € Cleaning UF (Metallic basket + chemical p 22 20 440 €
Manpower Membranes
Draining time 100 20 2 000 € 240 Membranes splitted on 7 years 240 7 320 10 971 €
Bags Filtration Maintenance 80 20 1 600 € Manpower Membranes 4 modules 4 7 2000 1 143 €
Total Saving per year 180 131 € Total Spending per year 61 033 €
Investment 450 000 €
Saving per year 119 098 €
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21. Environment &
Economical Savings
Environmental objectives :
Waste Water Treatment plant
Waste water 3680 m³/year reduction to treat
COD ~4800 Kg/month diminution (54000 Kg/year)
Hydrocarbon Drains ~26000 kg/year decreasing
Environmental Savings
Water consumption
120000 6000
3380 m³/year saved
100000 5000
What we were not able to
calculate: 80000 4000
Volume (m3)
- Quality Improvement
Kg
60000 3000
- Reduction Maintenance cost
on rinsing bath 40000 2000
2E+
K
V
g
o
u
Environmental Savingsfrom TTS
l
050 Hydrocarbon drain
Bef
20000 1000
COD
Waste Water qty
0 0
Water Consumption Before UF With UF Reduction
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22. Environment &
Economical Savings
Financial objectives :
Labour cost (bath drains, bags replacement) 168 h. per year
Bags filters consumption (alcalin bath) 2250 € per year
Water consumption 3380 m³per year
Global Saving
Effluents
200 000 € 180 131 €
180 000 € 161 568 € Tap water
160 000 € 132 699 €
140 000 € 119 078 € Power
120 000 €
100 000 € Mineral Base and Degreasing
Amount € 61 053 €
80 000 € Product
60 000 € FIP
40 000 € 28 869 €
20 000 €
0€ Manpower
-20 000 €
Direct Savings Spendings Savings per Total Real Savings
Department
Saving and Spending
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23. en tion
r att
r you
yo u fo
Th ank
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