TITLE: MICROPOROUS MEMBRANE FILTRATION AND BACKWASHING
PROCESS
FIELD OF THE INVENTION
The present invention relates to filtration processes of the kind using a
microporous membrane, wherein feed containing contaminate matter is applied under
pressure to a feed receiving surface of the membrane for passage therethrough and
filtrate is withdrawn from the permeate side of the membrane. More particularly, the
invention relates to systems that include means for backwashing the filter membranes.
BACKGROUND OF THE INVENTION
In all membrane filtration processes of the kind referred to above, contaminant
matter filtered from the feed continuously builds up on the feed receiving surface of the
membrane. This leads to a decrease in filtration efficiency and a corresponding decrease
in achievable permeate flux or an increase in operating pressure. Accordingly, it is
necessary to periodically clean the feed receiving surface of the membranes.
This is most commonly achieved with a frequent and generally regular
backwashing process, wherein a source of fluid under pressure is applied to the permeate
side of the microporous filter membrane so as to dislodge at least a portion of the
contaminant matter lodged within and/or on the feed receiving surface of the membrane.
The dislodged contaminant matter is then flushed out of the system by passing a
sweeping fluid over the feed receiving surface of the microporous membrane, the
resulting waste then being separately diverted from the system for subsequent disposal or
further treatment.
In small filtration units, this backwash comprising the sweeping fluid and
contaminate matter is often disposed of by use directly for irrigation purposes or the like.
However, in large scale membrane filtration plant, the problem of disposing of the
significant volumes of backwash fluid is a major concern.
The preferred solution to date has been to provide backwash settling lagoons.
The levels of the lagoons are controlled to some extent by natural evaporation and
currently by feeding the supernatant from the lagoons back into the main feed on a
continuous basis at a predetermined inclusion proportion of the feed flow.
However, recent tests have shown that this reprocessing of the backwash
supernatant has a surprisingly adverse affect on the overall efficiency of the filtration
system, resulting in significant increases in the rate at which the trans-membrane
pressure (TMP) increases, which ultimately affects achievable permeate flow rates.
Furthermore, simply ceasing to reuse any of the backwash is not desirable, as some
means external to the filtration process will then be required to handle the increasing
volumes of backwash which would then add to the cost and complexity of the process.
It is an object of the present invention to provide a filtration and/or backwashing
method and apparatus of the kind referenced above which overcomes or substantially
ameliorates one or more of the above discussed disadvantages of the prior art or at least
offers a useful alternative thereto.
DISCLOSURE OF THE INVENTION
According to a first aspect of the invention there is provided a method of
backwashing microporous membranes which have been subjected to a filtration
operation wherein feed containing contaminant matter is applied under pressure to a feed
receiving surface of the membrane for passage therethrough and filtrate is withdrawn
from a permeate side of the membrane remote the feed receiving surface, said method
comprising the steps of:
(a) terminating the filtration operation by ceasing supply of feed under
pressure to said feed receiving surface of said membrane,
(b) applying a source of fluid under pressure to said permeate side of the
membrane such that said fluid under pressure passes in a reverse direction through said
membrane so as to dislodge at least a portion of contaminant matter lodged within and/or
on said membrane,
(c) passing a sweeping fluid past said feed receiving surface of said
membrane to flush out the dislodged contaminant matter and form a backwash liquid,
and
(d) delivering the backwash liquid to a reservoir,
wherein at least a part of said sweeping fluid of step (c) comprises previously
accumulated backwash liquid from step (d).
Preferably, the backwash liquid used as sweeping fluid in step (c) comprises
supernatant from a backwash settling lagoon.
This method is particularly suited to backwashing systems of the kind comprising
a plurality of hollow elongate fibres having microporous walls which have been
subjected to a filtration operation wherein feed containing contaminant matter is applied
under pressure to the exterior surface of said hollow fibres and filtrate is withdrawn from
the ends of the lumens of the fibres, the fibres being contained within a shell or housing,
said method then comprising the steps of:
(a) terminating the filtration operation by ceasing supply of feed under
pressure to said exterior surface of said membrane,
(b) sealing the shell,
(c) applying a source of fluid under pressure to said lumens such that said
fluid under pressure passes through said walls so as to dislodge at least a portion of
contaminant matter lodged within and/or on said fibre walls,
(d) passing a sweeping fluid past said exterior surface of said membrane to
flush out the dislodged contaminant matter to form a backwash liquid, and
(e) delivering the backwash liquid to a reservoir,
wherein at least a part of said sweeping fluid of step (d) comprises previously
accumulated backwash liquid from step (c).
Desirably, the backwash liquid used as sweeping fluid comprises supernatant
from a backwash settling lagoon.
Preferably, the supernatant from the settling lagoon is delivered to the feed
receiving surface of the membranes by direct injection into the feed line. It is presently
believed that some form of plug flow will be achieved, albeit with a certain degree of
mixing at the interfaces. In this manner the switching of the process to backwash
sweeping mode can be triggered on a time or volume flow basis calculated from the
point at which the supernatant is injected. Alternatively, presence of the backwash
supernatant at the membrane can be detected by monitoring the change in the trans-
membrane pressure (TMP). In most cases the TMP will show a shaφ increase when the
supernatant reaches the membrane, as despite the settling process, there is still likely to
be a substantial quantity of fine particles that have remained in suspension in the
supernatant.
According to a second aspect of the invention there is provided an apparatus for
backwashing microporous membranes which have been subjected to a filtration
operation wherein feed containing contaminant matter is applied under pressure to a feed
receiving surface of the membrane for passage therethrough and filtrate is withdrawn
from a permeate side of the membrane remote the feed receiving surface, said apparatus
comprising:
(a) means to terminate the filtration operation by cutting off supply of feed
under pressure to said feed receiving surface of said membrane;
(b) means to apply a source of fluid under pressure to said permeate side of
the membrane such that said fluid under pressure passes in a reverse direction through
said membrane so as to dislodge at least a portion of contaminant matter lodged within
and/or on said membrane;
(c) means to deliver a sweeping fluid past said feed receiving surface of said
membrane to flush out the dislodged contaminant matter and thereby form a backwash
liquid;
(d) means to deliver the backwash liquid to a reservoir, and
(e) means to extract previously accumulated backwash liquid from said
reservoir for use as, or at least inclusion with, said sweeping fluid.
Preferably, the backwash liquid used as sweeping fluid comprises supernatant
from a backwash settling lagoon.
The method and apparatus of the first and second aspects of the invention
provides a convenient means of at least partially reusing and thereby controlling the
volume of accumulated backwash waste, in a manner that also increases the overall
efficiency of the filtration process when compared to the prior art method of
reprocessing the backwash by incoφoration with the main feed.
According to a third aspect of the invention there is provided a method of
operating a filtration system of the kind having a micro-porous membrane wherein feed
containing contaminant matter is applied under pressure to a feed receiving surface of
the membrane for passage therethrough and filtrate is withdrawn from a permeate side of
the membrane, the system further including means to backwash said membranes by
applying a source of fluid under pressure to the permeate side of the micro-porous filter
membrane so as to dislodge at least a portion of the contaminant matter lodged within
and/or on said feed receiving surface, the dislodged contaminant matter then being
flushed out of the system by passing a sweeping fluid over said feed receiving surface so
as to form a backwash liquid, said method of operation including the step of
accumulating and recycling some or all of said backwash liquid as feed prior to storing
the liquid in a settling lagoon or sending it to waste.
According to a fourth aspect of the invention there is provided a filtration system
of the kind having a micro-porous membrane wherein feed containing contaminant
matter supplied under pressure to a feed receiving surface of the membrane the passage
therethrough and filtrate is withdrawn from a permeate side of the membrane, the system
further including means to backwash said membranes by applying a source of fluid
under pressure to the permeate side of the micro-porous filter membrane so as to
dislodge at least a portion of the contaminant matter lodged within and/or on said feed
receiving surface, said system further comprising means to pass a sweeping fluid over
said feed receiving surface to flush the dislodged contaminant matter out of the system in
the form of a backwash liquid, said system including means to accumulate and recycle as
feed some or all of said backwash liquid prior to storing the liquid in a settling lagoon or
sending it to waste.
Preferably, the method and apparatus includes a step of, or means of,
accumulating the backwash in a backwash reservoir and, prior to the scheduled
backwashing step, switching from feed to recycling the backwash liquid from said
reservoir through the system until it has all been filtered.
More preferably, the backwash liquid is recycled a pre-determined number of
times prior to finally being directed in its then more concentrated form to storage or
waste.
Even more preferably, the method of operation includes the step of intermittently
backwashing with feed after a pre-determined number of steps of recycling the backwash
liquid.
The method and apparatus of the third and fourth aspects of the invention
similarly provide a convenient means of at least partially re-using and thereby
controlling the volume of accumulated backwash waste. This not only increases the
overall yield but suφrisingly has little, if any, detrimental effect on the overall efficiency
of the filtration process.
In a further embodiment there is provided a system that incoφorates both the
modified backwash process of the first and second aspects of the invention, in
combination with the backwash recycling features of the third and fourth aspects of the
invention.
All aspects of the invention are applicable to both dead end and cross-flow
filtration operations.
BRIEF DESCRIPTION OF THE DRAWINGS
A preferred embodiment of both the first and second as well as the third and
fourth aspects of the invention will now be described, by way of example only, with
reference to the accompanying drawings in which:
Figure 1 is a schematic view of a filtration process in accordance with the first
and second aspects of the invention;
Figure 2 is a graph illustrating the variation in TMP with time for a prior art
process that uses supernatant recycle into the main feed;
Figure 3 is a graph illustrating variation of TMP with time for a process
according to the first and second aspects of the invention that does not use supernatant
recycle into the main feed;
Figure 4 is a graph illustrating variation of TMP with time for processing normal
feed followed by supernatant.
Figure 5 is a schematic view of a prior art filtration process;
Figure 6 is a schematic view of a filtration process in accordance with the third and
fourth aspects of the invention; and
Figure 7 is a graph illustrating the variation in resistance with cumulative volume
treated per unit membrane area.
PREFERRED EMBODIMENTS OF THE INVENTION
Referring to Figure 1 , there is shown a schematic representation of a preferred
form of the filtration process according to the first and second aspects of the invention.
The apparatus 1 comprises one or more filtration modules 2 which each include
filtration membranes in the form of a plurality of a hollow elongate fibres 3 having
microporous walls 4 which define central passages or lumens 5. The fibres are housed
within a shell 6 and sealed by means of two end plugs 7. These plugs serve to hold the
hollow fibres in place and provide a barrier between the feed that is delivered to the
exterior surfaces 8 of the fibres and the filtrate which flows out of the lumens.
An inlet port 9 and outlet port 10 are provided intermediate the plugs 7 for
admission of feed from the feed line 11 to and through the module 2. Similarly, two
ports 12 are also provided on the remote side of the plugs 7 for both extraction of the
permeate or admission of pressurised backwashing fluid to the lumens.
The filtration system also includes a backwash liquid reservoir in the form of a
settling lagoon 13 to which backwash from the outlet port 10 is diverted. In the
embodiment illustrated, a recycle circuit 14 is also included for recirculating the feed
during normal cross-flow operation of the filtration module 2. However, the invention in
all aspects is equally applicable to dead end filtration systems.
The system further comprises means shown generally at 15 to extract supernatant
from the reservoir, which in the preferred form is the settling lagoon 13 and direct it via
piping 16 into the main feed line 11 for use in the backwash sweeping operation. A
secondary delivery line 17 connects with the piping 16 for optional addition of some
other form of suitable sweeping fluid.
In use, feed is directed under pressure to the inlet port 9 of module 2 via the main
feed line 1 1 , in a manner whereby at least a portion of the feed permeates through the
walls 4 of the fibres 3, the resulting filtrate being extracted from ports 12. The excess
cross-flow feed is diverted from outlet port 10 for recirculation through circuit 14.
Whilst the cross-flow through module 2 helps to limit the build-up of
contaminant matter on the membrane walls 4, the gradual accumulation will nonetheless
result in an increase in trans-membrane pressure (TMP). This results in a decrease in
filtration efficiency and accordingly, a periodic backwashing process is required to
remove the accumulated sludge to keep the process operating effectively.
During the backwashing process, the filtration operation is terminated by ceasing
supply of feed under pressure to the shell 6. In one preferred process, gas is applied
under high pressure to the lumens, in a manner whereby it is caused to pass through the
fibre walls 4 in a reverse to normal direction to dislodge at least a portion of the
contaminant matter lodged within and/or on the membrane. Flushing fluid is then
directed into the shell 6 via inlet 9 to flow past the external surface 8 of the membrane
walls 4 to flush out the dislodged contaminant matter. The sweeping fluid and dislodged
sludge is then diverted from outlet 10 to the settling lagoon 13.
The sweeping fluid in the process according to a preferred form of the first and
second aspects of the invention comprises, at least in part, supernatant extracted from the
settling lagoon 13. The flushing fluid, comprising either supernatant alone or in
combination with another liquid delivered at 17, is preferably injected directly into the
main feed line 11 , where it is believed that a certain degree of plug flow will occur. In
this regard plug flow is not critical, the fluid just needs to be circulated long enough to
sweep out the solids.
In order to maximise the usage of supernatant and minimise the use of feed
during this sweeping operation, the supernatant is directed into the main feed line in
5 advance of commencement of the backwashing process. The presence of the supernatant
in the module can be established either on a time and flow rate basis where plug flow is
assumed, or alternatively can be directly detected by monitoring the trans-membrane
pressure (TMP) during the normal filtration process. In this regard it is expected that the
presence of the supernatant will result in a rapid increase in the rate of change of TMP as
o illustrated in Figure 4.
Referring next to Figure 2, there is shown a graph illustrating variation in TMP
with time for prior art systems that incoφorate backwash supernatant into the main feed.
Each step of the graph represents a normal filtration period where the TMP gradually
increases with time, each stage having a backwash operation therebetween. Figure 3
5 illustrates the variation of TMP with time for the same system in which the backwash
supernatant is not added back to the main feed.
Figure 4 illustrates the effect of introducing backwash supernatant into the feed
stream. TMP rise is very slow with no supernatant, but as soon as supernatant is added
there is a sudden increase in TMP. This increase then triggers an automatic backwash.
0 As it can been seen by comparing the graphs, the add back of the backwash
supernatant dramatically reduces the overall filtration efficiency of the process which is
shown by the rate of TMP increase during filtration. It presently appears that use of the
supernatant as the backwashing fluid only, will result in an operation efficiency that is
closer to that illustrated in Figure 3 than in the prior art process of Figure 2.
Turning next to the remaining figures 5 to 7, a preferred embodiment in
accordance with the third and fourth aspects of the invention will now be described.
In this regard, figure 5 illustrates a standard filtration system with backwash
facility. The system comprises, in its preferred form, a continuous micro-filtration
(CMF) module 20 having a feed inlet port 21 , a permeate outlet 22 and a backwash
outlet 23.
Connected with the feed inlet port 21 is a feed pump 24 which draws feed from a
break tank 25 via a control valve 26. The backwash outlet port 23 connects to a
backwash tank 27 which itself has an outlet 28 that leads to waste.
In use, feed is directed into the CMF module 20 and the permeate is recovered
from the outlet 22. As the contaminant matter gradually accumulates on the feed
receiving surface of the membrane walls, a periodic backwashing process is required to
remove the accumulated sludge so as to keep the process operating effectively.
As discussed previously, during the backwashing process, the filtration operation
is terminated by ceasing supply of feed under pressure to the module. In one preferred
process, gas is applied under high pressure to the permeate side of the membrane in a
manner whereby it is caused to pass through the membrane walls in reverse to normal
direction to dislodge at least a portion of the contaminant matter lodged within and/or on
the membrane. Flushing fluid, normally in the form of extra feed, is then directed into
the module to flow, not through the membrane, but past the feed receiving surface to
flush out the dislodged contaminant matter and thereby form the backwash fluid. The
backwash fluid is then directed from outlet 23 to the backwash tank 27. From the tank
the backwash fluid is then subsequently diverted to waste which in some installations,
may comprise a settling lagoon which may also include supernatant recycle in
accordance with the prior art.
Turning next to figure 6, there is shown the system of figure 5 modified in
accordance with the third and fourth aspects of the present invention. Where
appropriate, like reference numerals have been used to denote corresponding features.
The modified system includes means 30 to divert the backwash fluid from the
backwash tank 25 to the feed inlet port 21 of the CMF module 20. In the embodiment
illustrated, this includes a booster pump 31. The system also includes a waste outlet 32
down stream of the booster pump 31.
In use, the system is operated to process feed, such as river water, in the manner
described above. However, just prior to operating the periodic backwashing process, the
feed is switched to backwash fluid feed until all the backwash fluid in the backwash tank
25 has been filtered. After this step the backwash operation is continued as for the
standard system described above. In the embodiment tested to date, once the backwash
has been filtered about 10 times it is sent to waste and the next backwash conducted
entirely with feed and the process repeated from here on.
Preliminary trials have been conducted to compare systems using recycled
backwash (unit 2) with those using a standard backwash arrangement (unit 1), the results
of which are set out below:
Average Feed Water Conditions
As can be seen from reference to figure 7, the method and apparatus of the third
and fourth aspects of the invention provide a means of increasing the overall yield by
partially re-using the backwash fluid, thereby simultaneously controlling the volume of
accumulated backwash waste, with suφrisingly little affect on the overall efficiency of
the filtration process. More specifically, figure 7 shows that even with 10 recycles, the
performance of the unit is virtually no different (in fact slightly better in this example)
than the unit operated with no recycle (conventional method). This is thought to arise in
part from the fact that the backwash fluid will contain a particle distribution that will be
the same as the particles within the cake of accumulated contaminants on the feed
receiving surface of the membranes. It is considered that this distribution of particles to
include large particles (which would not be present in, say, supernatant from a settling
lagoon) helps to prevent the filters clogging. Also the particles are filtered onto an
already existing filter cake and are thus more readily backwashed off the surface than if
applied directly to a clean membrane.
Finally, it will be appreciated that the backwash liquid from the backwash tank 25
identified in respect of the third and fourth aspects of the invention can readily be used
as part of the sweeping fluid referred to in respect of the first and second aspects of the
invention, alone or in combination with the step of recycling part of this backwash fluid
as feed.
Although the invention has been described with reference to specific
embodiments, it will be appreciated by those skilled in the art that the invention may be
embodied in many other forms.