Manual For CERAFILTEC Membrane Module: (General Information, Assembling & Installation, O & M)
Manual For CERAFILTEC Membrane Module: (General Information, Assembling & Installation, O & M)
Manual For CERAFILTEC Membrane Module: (General Information, Assembling & Installation, O & M)
III
List of pictures and tables
IV
1 Introduction
Congratulations on choosing CERAFILTEC’s ceramic membrane module.
The CERAFILTEC system is a highly sophisticated product. We strongly recommend using only trained
and experienced technicians for assembly, installation and troubleshooting. To locate the closest
authorized service technician or to request an assembly training please contact your CERAFILTEC
representative or visit our website at http://www.cerafiltec.com/team/.
If you decide to install the equipment yourself, please follow this assembling manual. For installation
assistance, contact your CERAFILTEC representative. You will ensure a successful installation as well as
reliable operation by carefully reading this manual and following the operational guidelines. Convince
yourself about the easy assembling. Under the following links we show you demonstration videos of
assembling and operation references:
http://www.cerafiltec.com/how-to-assemble/
http://www.cerafiltec.com/videos-processes-references/
This document contains general guidelines. Depending on the application and project specific
installation requirements, e.g. how many modules per tower to be assembled, construction of
accessories inside the filtration tank, like position holders, aeration and sprinkler sets, hose
connections of tower, main filtered water header, and other need to be considered. Please follow
these additional instructions, listed in the project design and execution documents. If you do not have
the project design or execution documents, please contact your CERAFILTEC representative.
Please contact your CERAFILTEC representative or check on our website http://www.cerafiltec.com for
any further manual updates to insure correct and safe assembly and installation.
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2 Technology and Product Introduction
With an average filter pore size of 0.1 micron the UF membrane acts as a physical barrier to removal
any suspended solids from the water, like:
Ultra-filtration technologies with a pore size of 0.1 µm are commonly understood as filtration solution
to remove suspended solids such as clay and silt, pollen, algae, precipitated metal oxides as well as
fractions of colloids. They are also a physical barrier for germs and bacteria and are classified as
disinfection solution with typical log removal value (LRV) above 5.
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Figure 1: Classification of filtration technologies
CERAFILTEC’s ceramic flat sheet membrane solution is more than just a common ultra-filtration. In
conjunction with developed pre-treatment processes, e.g. active cake layer filtration for a selective
removal of dissolved ions, CERAFILTEC provides a superior filtration solution. Therewith, only
CERAFILTEC achieves unprecedented filtered water quality, and consequently being the best pre-
filtration solution for all NF and RO applications. The technology is typically used as pre-filtration for
desalting technologies, like Nano-Filtration and Reverse Osmosis. CERAFILTEC’s filtration module is
highly seawater resistant and corrosive free.
http://www.cerafiltec.com/classification/
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3 Ceramic Flat Sheet Materials
The CERAFILTEC module housing can be used with a wide variety of ceramic flat membranes. The
module housing of CERAFILTEC is the standard and the different ceramic membranes can be used
specifically according to the application. The ceramic plates marketed by CERAFILTEC have different
properties depending on their choice. Please refer to the manufacturer's instructions for the
membranes.
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4 CERAFILTEC´s Ceramic Membrane Module
One module is a single, modular and expandable filtration unit consisting of a glass fiber reinforced
plastic housing and the flat sheet ceramic plates. The module housing was developed to tightly
transport the liquid medium in internal channels, while at the same time withstanding high mechanical
forces. Our 3rd generation module is flow optimized to achieve the maximum performance of the
ceramic membranes. The four large internal filtered water channels allow for flux rates up to 1,500
LMH (equal to 9 m³/hr) with one single module at minimal pressure losses. The entire housing, as well
as all accessories are free of any metals and therefore usable in the harshest applications and at the
same time achieving a very long lifespan. Additionally, no surrounding frames or hose connections
between the modules are required.
Benefits:
▪ Less filter area needed due to high flux operation – high CAPEX savings
▪ Suitable for seawater and other challenging applications without any risks of corrosion
problems
▪ Operation at hot temperature up to boiling water
▪ Fully modular due to no surrounding frame – option to change number of modules per tower
at any time either to optimize project costs or to increase the plant capacity in future
▪ Most compact design – towers can be installed in close distance to each other as no hoses are
needed
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4.1 Module 6.0 S
The Module 6.0 S is our standard for most applications.
Specifications
Table 1: Specifications for Module 6.0 S
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4.2 Module 6.0 H
The Module 6.0 H is our specialist for hot water applications above 60°C.
Specifications
Table 2: Specifications for Module 6.0 H
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4.3 Module ST Series
The Modules ST Series is the allrounder for sludge thickening applications.
▪ Filtration module with ceramic flat sheet membranes suitable for sludge thickening process and other
applications with very high TSS concentrations
▪ Multi ceramic plate configuration with exchangeable single ceramic plates
▪ Extra large distance between single plates available in 3 standard configurations
▪ Internal filtered water piping
▪ Module hosing fully made of glass fiber reinforced resin – free of any steel parts exchanger systems
STANDARD CONFIGURATIONS
Without
formed cake layer
With
SPECIFICATIONS
Table 3: Specifications for Module ST Series
Module configuration ST 20 ST 33 ST 46
Distance between ceramic plates 20 mm 33 mm 46 mm
Max. recommended cake layer thickness 7 mm 12 mm 18 mm
Max. sludge volume per module 21 L 27 L 36 L
No. of single ceramic plates 16 11 8
Filter active area 2.8 m² 2.0 m² 1.4 m²
Dry weight 21.0 kg 16.9 kg 14.5 kg
Max. flow [m³/hr] 4.2 m³/hr 3.0 m³/hr 2.1 m³/hr
Dimension LxWxH [mm] 700x576x160 mm
Module material NORYL™ resin 30% glass fiber reinforced blend of PPE/PS
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4.4 Accessories and tools
The accessories can be divided into essential accessories and optional accessories. The essential
accessories must be supplied by CERAFILTEC, the optional accessories can also be manufactured
according to CERAFILTEC´s specifications. It is recommended to use optional accessories and is
depending on the process specification in the technical projection.
http://www.cerafiltec.com/accessories/
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Figure 7: Essential Accessories – Base Set for Module Towers
At lower flow rates, the sprinkler can also be used for an efficient chemical cleaning by spraying
concentrated chemicals over the ceramic flat sheet membrane surface (on-air cleaning). Due to the
capillary force of the membrane pores, the chemicals are sucked into the membrane (CapClean mode).
http://www.cerafiltec.com/double-line-sprinkler/
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up to 46.0 mm which allows a maximum cake layer formation of up to 18 mm. Single plate slots can
be closed with a plug on the front sides of the module housing.
Benefits:
▪ Safe operation in applications with extremely high sludge and TSS concentrations up to 5 %
▪ Change of plate distance at any time even during operation
▪ Change at a later time is possible with minimum efforts – plates to be removed and plugs to
be fixed
▪ No additional changes of module housing or accessories are required
http://www.cerafiltec.com/variable-plate-distance/
Figure 12: Differences between submerged (out-to-in) and pressurized (in-to-out) Filtration
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Benefits:
▪ Cake layer can be used as additional filter bed for enhanced removal of very small particles
and colloidal fractions
▪ Sorption processes inside the cake layer enable the selective removal of dissolved contents,
like radium, uranium, arsenic or organics
▪ Formed cake layer can function as protective coating to minimize biofouling or scaling
▪ Improvement of filtered water quality can reduce design and process efforts of subsequent
treatment steps
http://www.cerafiltec.com/active-cake-layer-filtration/
Benefits:
▪ Ceramic membranes with very high hydrophilicities – superior for removal of hydrophobic
water contents, like oil
▪ High flux operation of ceramic flat sheet membrane at very low pressure leads to low power
consumption
http://www.cerafiltec.com/hydrophilic-membrane/
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4.5.5 Low Fouling potential on ceramic membrane surface
The higher the negative charge of the membrane the lower the susceptibility to fouling and clogging.
Benefits:
▪ Ceramic flat sheet membrane material based on SiC with very high negative charge and
isoelectric point at around pH 3 leads to stable high flux and low-pressure operation even at
very low operating pH
▪ Lowest cleaning and maintenance requirements using SiC membranes
▪ Negatively charged ceramic flat sheet membranes are ideal for active cake layer filtration
process using negatively charged HMO for the removal of heavy metals and radioactive
isotopes
▪ SiC membrane achieves highest removal rates of negatively charged contents, like germs &
bacteria, TEP and oil
http://www.cerafiltec.com/low-fouling-potential/
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4.6 CERAFILTEC´s Design Concept
A module is equipped with up to 34 exchangeable ceramic plates and a total membrane surface area
up to 6 m². A single module or up to 15 modules can be stacked up to a tower. In addition to the
modules a tower consists of a base set and a header set with a distribution channel for internal
channels and are connection to common piping systems.
A module tower can be configured as a multi-tower. Several single towers can be simply connected
through a common header pipe at the top. A fully modular configuration, no limitation in tower design
as there is no surrounding steel frame.
http://www.cerafiltec.com/design-concept/
Filtered water from each single plate is collected inside the module housing and transported to the
header set through 4 filtered water channels integrated in both module housing sides.
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Figure 18: Module principle of filtration process
The filtration towers are fully submerged in a tank (filtration train) which contains the feed (raw) water.
All towers are connected at the top with a common header pipe. The filtered water is transported
through the header set of each tower to the top and from there through the common header pipe to
the tank outside where a filtration pump is connected to transfer the clean water to the filtered water
tank.
Reversed flow direction to filtration. A very small amount of filtered water is used to backwash the
membrane. Within seconds, the formed cake layer comes off in flakes. Air-scouring can enhance the
cake layer removal.
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Figure 20: Membrane principle of backwash process – from in-to-out
Filtered water from all 4 filtered water channels is transported to both module fronts and enters from
there into each single plate. Filtered water from all 4 filtered water channels is transported to both
module fronts and enters from there into each single plate.
A small portion of the produced filtered water is taken from the filtered water tank and is transferred
by a backwash pump through the common header pipe into each filtration tower.
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Figure 22: Filtration train principle of backwash process
http://www.cerafiltec.com/how-it-works/
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5 How to assemble a Module Tower
A filtration tower consists mainly from ceramic filtration modules. The ceramic is a very robust material
and withstand for long time in harsh conditions inside of the filtration tank. But if a mechanical impulse
comes on the ceramic it can break and must be repaired or changed. Also dust and oily aerosols will
be not helpful if the equipment should later be installed in drinking water application.
If a new delivery comes to installation site, please open only the top of the wooden box to control if it
is all ok with the modules and to check with the bill of delivery if all components are there. Afterward
close the box and keep it closed until the assembling of the towers will start.
The ready assembled modules normally come stacked in a wooden box on a euro pallet. Even if the
stacked modules are looking as a ready tower it is necessary to dis- and reassemble the tower to put
the permeate gaskets between each module. To fix the tower during transport the key locks are
installed and must be removed first.
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5.3 Tools for Tower assembling
The filtration tower can be assembled only with a few tools and with at least two persons. The
following things should be on site:
▪ Sliding agent for all profile gasket at the permeate connections. As a standard the gasket is
made from EPDM. Because of this, the sliding agent must not contain mineral oils or other
ingrediencies which degrades EPDM. Depending on the application the agent must meet the
local regulations for the application (e. g. drink water approval).
▪ Clean brush for putting the slide agent.
▪ A flat stable floor of the size of at least 1x1 m (3x3 ft).
▪ One or two ring spanner size 17 or similar (e. g. which works very well is a spark plug spanner).
This tool is used for the key lock. Do not use a screwdriver, the key lock can be damaged.
Figure 23: Sliding agent to be put with brush (e.g. Molykote compound 111)
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5.4 Assembling of module Tower
Did you like to play with LEGO™? Then you will love to work with our system!
Two persons must do the assembling of a filtration tower at least. Please follow the steps in the correct
succession:
(1) Put one base module on the floor. Put it on the front frame and lift one side. Put 2 corner feet
in and fix it with 2 key locks. Lift the module in the same way on the other side and assemble
the other both feet inclusive key lock.
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(2) For one tower two ropes are necessary. The ropes must have all the same and right length. Both
ends must be cut with a special hot rope cutter not with a knife or a scissors. The diameter of
the rope ends should not much wider than the rope itself otherwise it comes to problems during
threading.
(3) Thread one rope left and right into the holes on the lower side of the corner feet until it comes
out on the top of the first module. If it stops, try to drill the rope with the fingers under light
pressure. Do the same with the second rope on the other side. Finally, all 4 ends of the two ropes
are on the top of the first module.
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(4) Put 4 asymmetric profile gaskets on the first module. Put the thicker side down. When all 4
gaskets are in the right position coat only the outer side of the gasket with slide agent. Use a
clean brush for this work.
Thin side
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(5) Put the second module on the top press it light and put the key lock into the holes and close it
with the ring spanner.
(6) Thread the rope on every corner inside of the top module.
(7) Repeat the instruction (4) to (6) until the right size of the tower is reached.
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(8) The completion of a tower is the header collector. Installation is the same as for a module (step
(4) to (6)).
(9) Prepare the lifting knots at every end of the ropes (see special chapter and video).
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(10) Install the pipe clips for sprinkler system. Put the sprinkler pipes and turn until the top holes are
horizontal.
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(11) Assemble the header adapter to the header collector
(12) Insert the thimble and the shackles for lifting the tower
For more details “How to assemble a tower” see the CERAFILTEC website.
http://www.cerafiltec.com/how-to-assemble/
For disassembling a tower, first must be opened all 4 knots of the ropes. Next step is to open all 4 keys
of the top module with a ring spanner. Lift the top module with 2 people. Repeat this procedure for
the next modules.
Take care by handling with the modules. Put them on a flat floor. Don’t put tools on the modules. If
the modules should store for longer time, cover the module, or put them into a box.
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6 How to Install
We provide all details of the tank design and surrounding filtration equipment. Due to the modular
design concept of the towers it is very easy to install our equipment. During the project execution, we
provide all requirements and guidelines for a fast installation and start-up.
Most important for every process is a good working sludge removal during a backwash with emptying
the tank. For this, under every tower or tower row a ditch with a defined slope of at least 5° and a
width of the total inner width of the membrane tower is necessary (in general 520 mm).
The train should be prepared for installation which means the civil works construction is completed;
piping, valves and instrumentation are installed (scope of project partner).
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(1) Installation of filtered water header pipe holders on left and right side of concrete walls.
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(3) Connection of installed air-scouring sets to common blower pipe.
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(5) Position of first module tower.
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(7) Repetition of tower positioning for all remaining tower lines.
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(9) Connection of installed sprinkler sets to common sprinkler pipe.
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(11) Installation of first filtered water header pipe, connection to each tower, fixing on wall holders
and coupling.
(12) Repetition of filtered water header pipe installation for all remaining tower lines.
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(13) Test and process start-up
(14) Ready for operation. Train can be put into operation as per projection
http://www.cerafiltec.com/how-to-install/
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7 Transportation and Lifting of a Module Tower
A filtration tower with already installed profile gaskets at the permeate channels should be not
transported over long distances to protect the gasket for damaging. This also depends on the size of
the tower, the packaging, and the expected shocks during the transport.
For the lifting of a tower it is necessary to follow the local set of regulation and safety instruction for
lifting heavy goods by crane.
It is also recommended to use the original traverse from CERAFILTEC for lifting a filtration tower.
Otherwise the danger of destroying the filter tower or the rupture of the rope can be the consequence.
▪ Original CERAFILTEC lifting traverse inclusive shackle, grommet, and coil loop.
▪ A crane which can handle the given weight at the necessary cantilever.
Take care that all 4 ends of the rope are at the same height. If not, it is necessary to open one knot and
put it on the right position to achieve the same height. Put a grommet inside of every knot.
The lifting tool should be hanged-up in the middle of the tool onto a crane hook by a suitable belt.
Figure 25: Fixing the tool onto a crane hook (left). Connect coil-loop with rope by shackle.
Connect 4 coil-loop with 4 shackles (best to use triangle shackles) with the lower holes of the lifting
tool. The length of the coil-loop depends on the individual requirements of the location. The coil-loop
should relate to the rope by shackle or with carabiner.
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During connecting the lifting tool with the filtration tower, take care on the right position. Because the
module has a rectangular cross-section it is necessary to have the right position of the lifting tool. The
coil-loops must be exact vertical. If this is not the case, the shackles must be opened, and the lifting
tool must be turned by 90°.
Figure 26: Lifting a tower with the Lifting Tool. The coil-loops must be exact vertical
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8 Operation
The membrane filtration process includes several process steps that are described below:
▪ Filtration: The filtration step is a physical barrier that removes oxidized metals, suspended
solids, and bacteria.
▪ Backwash: A periodical backwash is needed to remove the cake layer from the membrane
surface.
▪ Sprinkler: Water is sprayed directly onto the top of the filtration tower to increase the
backwash and cleaning efficiency.
▪ Aeration: Air is supplied from the bottom of the filtration towers. The upstreaming coarse
bubbles improve the backwash and cleaning process.
▪ Chemical circulation: Removal of fouling or scaling from inside of the membrane body.
▪ CapClean: Removal of fouling or scaling from outside of the membrane body.
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The key objective of this backflushing is to remove the outside layer and flush out the pores by
reversing the filtrate flow for a short period. Membrane backflushing is usually carried out by stopping
the filtration pump and changing the flow direction of filtration pump or starting the backwash pumps.
The picture below shows a typical flow diagram of a filtration process with periodical backwash and
without backwash.
If the decreased flow and/or increased transmembrane pressure reach a certain defined value a
chemical cleaning is required. The typical maximum transmembrane pressure for filtration is 0.5 – 0.7
bar, depending on the water source and process steps. The calculated maximum filtration pressure
can be find in the specific technical projection document.
The chemical cleaning frequency depends on the characteristic of the inflow water (concentration of
inorganic, organic, and non-oxidized compounds). In general, an intense chemical cleaning mode is
required after 1 – 3 months of operation but depends on local effects.
Biological / colloidal fouling is the term used to describe the accumulation of colloidal dissolved
substances on the membrane surface whereby a slimy film is formed. This is generated by a bacterial
growth caused by the nutrients available in the feed. This type of fouling occurs in all places where
moistened surfaces are prevalent and they are present in almost every technical system that does not
operate on a sterile basis. This type of deposit on the surface can reduce pore diameter, which result
in a decrease in membrane flux. Membrane blocking caused by fouling can be removed by cleaning
with an oxidant. To make a rough estimate p(permeate) ~ p(backflush) can be apply.
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Scaling is the term used to describe salts that have formed on the membrane and in the pore structure
caused by inorganic precipitation. These generated by exceeding the solubility product on the
membrane surface in the form of sulphates, carbonates and phosphates. Since inorganic salts cannot
degrade biologically and solubility cannot be increased by raising the pH value for example, the only
possible way to prevent this is to avoid wastewater with high salt concentrations. In any case, salt
concentration should be measured to detect possible scaling. If scaling occurs, the deposits can
generally be removed with acids. To make a rough estimate p(permeate) < p(backflush) can be apply.
In addition, due to the pre-oxidation before the filtration process all potential organic fouling effects
are minimized.
Therewith, the main effect of the membranes will be an inorganic micro-scaling. Typically used
cleaning chemicals are acids (pH reduction down to 2.5 for re-dissolving), e.g. citric acid or HCl or a
mixture from both.
The inorganic micro-scaling is a typically long-term effect. The chemical cleaning frequency depends
on the characteristic of the inflow water (concentration of inorganic and non-oxidized compounds). In
general, a chemical cleaning mode is required after 1 – 3 months of operation but depends on local
effects.
The following table introduces the possible chemical dosing volume of citric acid and sodium
hypochlorite in the cleaning solution.
Table 5: Chemical dosing of Citric Acid and Sodium Hypochlorite (NaOCl)
If available concentrates of sodium hypochlorite or citric acid features different concentrations than
specified above, dosing volumes must be recalculated by the user. The temperature of the cleaning
solution shall be in the range of 10 - 45°C.
Leakages can be detected with a bubble-point test. For this, the filtered water header pipe is connected
to an air pipe with a suitable adapter/connector. The complete tower including header pipe must be
submerged in clear water (filtration tank or separate tank).
While filling the tank larger leakages can already be identified. In case of using the filtration tank, hand
valves or all automatic valves related to the filtration line (filtration, degassing, circulation,…) have to
be closed before the tank is smoothly filled with clear water (e.g. tap water). If there are any larger
leakages, the air inside of the filtration tower will exhaust and coarse bubbles will occur in the water.
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If no leakages are detected during filling, the filtered water pipe is afterwards charged with an over
pressure. The applied pressure depends on the actual submersion depth respective hydrostatic head
above the filtration tower. We recommend a submersion depth of about 3,0 m and thus a total over
pressure of 550 mbar. Actual over pressure is calculated as follows:
Before charging full over pressure to the filtration tower, pressure is increased step by step as
described in the following:
▪ Charging 50-100 mbar in order to detect leakages on the filtered water header and connected
piping. Holding time: 5 minutes.
▪ Increasing pressure up to 100-150 mbar in order to detect leakages on the upper filtration
modules and piping. Holding time: 5 minutes.
▪ Increasing pressure up to 200-250 mbar in order to detect leakages on the median filtration
modules and piping. Holding time: 5 minutes.
▪ Increasing pressure to 550 mbar (depending on actual submersion depth, see above) in order
to detect leakages on the lower filtration modules and piping. Holding time: 10 minutes.
Intact filtration towers show an evenly distributed forming of fine bubbles only above the ceramic
membranes.
If a filtration tower shows uneven distributed coarse bubbles, one or several membranes, sealings or
frame parts are possibly damaged. In that case, a detailed leak verification and fault correction has to
be operated.
We recommend checking for leakages periodically, e.g. after every chemical cleaning.
Only filtration towers which are faultlessly assembled and installed may be started. A successful
leakage test of the filtration towers is mandatory before start-up. All pipes and tanks should be rinsed
and free from any deposits (e.g. production residues, sludge). If tank filling was combined with leakage
test the degassing valve needs to be opened until all air is evacuated.
Once the preparation procedure is completed, sequence part can be put into operation:
▪ After filling of the filtration tank, the filtration should be started first with a reduced flow of 25
% and after trouble-free operation it can be increased in 25 % steps every hour. Recommended
operation time: 3 hours
▪ Aeration system is started and functionality of blower and air pipes is checked. An even
distribution of air bubbles must be ensured. Recommended operation time: 5 minutes
▪ Sprinkler system is started and functionality is checked. Recommended operation time: 5
minutes
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▪ Backwash (including aeration and sprinkler) is started as specified in the description of
operation after finishing 1 normal filtration step. Backwash pressure and flow as well as time
for emptying and filling the filtration tank should be recorded.
During the start-up time, the following parameters should be checked periodically, at least every hour:
After three hours of operation the values of these parameters should be in accordance with the design
parameters. During the first 3 days of operation, permeate quality and all operation parameter
(pressure, flow) should be checked and recorded every two hours.
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9 Maintenance
In order to ensure a safe operation of the membrane filtration system and to prevent damages to the
environment, people or system components, regular maintenance and service activities have to be
conducted. The user has to carry out all maintenance work that essentially consists of status and
function checks as well as checking of the most important operating parameters. Additionally, all
status, function and operating parameter checks shall be documented in a log book. Deviations from
target values and malfunctions shall be noted in a log book and eliminated immediately with the help
of responsible maintenance personnel. Malfunctions that could adversely affect safety must be
reported to the responsible expert personnel immediately. All described intervals and duties only
relate to parts and components delivered by CERAFILTEC, but e.g. unusual noises of pumps,
compressors and any other component should be recorded as well. The operating instructions
described in this document must be observed for all arising tasks!
▪ Sliding agent for all O-Ring connections. As a standard all O-Rings are made from EPDM.
Because of this, the sliding agent must not contain mineral oils or other ingrediencies which
degrades EPDM. Depending on the application the agent must meet the local regulations for
the application (e. g. drink water approval).
▪ Clean brush for putting on the slide agent.
▪ A flat stable table of the size of at least 1x1 m (3x3 ft). It is helpful if on the table 3 sides wooden
strips forms an open rectangle with the size of one module.
▪ Membrane mounting rake which can be ordered at CERAFILTEC.
▪ 3 collets with a free length of at least 800 mm.
▪ Allen key (hexagon socket screw key) size 17 mm.
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Figure 29: Sliding agent to be put with brush (e.g. Molykote compound 111 or vegetable glycerine)
For perfect easy installing CERAFILTEC have an assembling tool contains the rake and the collets. This
tool can be ordered at CERAFILTEC.
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9.3.2 Disassembling of Modules
The disassembling of a ceramic membrane module can be done by one person only, but a third hand
will be helpful. Please follow the steps in the correct succession:
(1) Put the collets between the two front frames and increase slowly the forces on the collets.
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(3) Remove the membranes on the opened side.
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(5) Remove both side frames by using a tool between indentation of front and side frame.
(6) Remove the single plates successively. For this, hold the membrane plate only on the plastic shoes.
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(7) Remove the loose membrane plates.
(8) Remove the non-loose plates with aid of plastic tool or with hose protected screwdriver.
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(9) Remove the last membrane plates.
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9.3.3 Assembling of Module
The assembling of a membrane module can be done by one person only, but a third hand will be
helpful. Please follow the steps in the correct succession:
(1) Take one front frame and mount the 4 O-Rings (36,2mm x 2,6mm) on the left and right permeate
channel.
(2) Put sliding agent on the O-Rings and stick the front frame into both side frames.
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(3) Put the module frame on the table inside of the open rectangle with the open side in front of
you.
(4) Put slide agent into all small permeate channels in the front frame with a clean brush. Before
installing the membranes check if the 2 O-Rings (8,1mm x 1,6mm) on each plastic shoe are
existing, if not install the O-Rings.
2 x O-Ring
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(5) Put the first membrane plat and slide it with its nipple into the right hole (left handed people
start left). For this, hold the membrane plate only on the plastic shoes. Hold with the left hand
the distant shoe in the middle of the shoe with the right hand same on the opposite side. Hold
the plate exact vertical and slide it parallel to the side frame into the permeate channel. Control
the right vertical position.
(6) Put the rake under the front shoe of the first membrane plate.
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(7) Repeat point (5) for all remaining membrane plates until the module is fully loaded. If the space
for the left hand is too small hold the membrane on the top of the shoe. Avoid touching the
membrane surface.
(8) If all membranes are ready insert align the rake, so all shoes are standing on it. Take care that
the front and side frames are forming a rectangular.
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(9) Take the second front frame, mount the other 4 O-Rings and put slide agent on the O-Rings and
on the small permeate holes for the membrane shoes.
(10) Put the front frame in front of you and hold it in the right position without pressure.
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(11) The second person puts now the 2 collets on the left and middle position with low force. Please
note: No pressure should be exerted on glued/ welded corners!
(12) Increase the force on the left and middle collets until the big permeate channels of the front
frame starts to slide into the side frame.
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(13) Install the third collet on the right or move the middle collet to the right of the front frame.
Please note: No pressure should be exerted on the glued corners!
(14) Wobble on the top of the membrane shoes during increasing the force evenly on all collets until
the front frame and the side frame are together without a gap.
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(15) Put on all 4 corners the plastic bolt and nut and fix them without strong force (hand strength of
max. 10 Nm). A new set of bolts and nuts is mandatory. Do not use previously used bolts and
nuts. No tool for the nut is necessary. Press the nut into the hexagon shape during turning the
bolt with an Allen key (hexagon socket screw key) size 5mm. Stop turning when the first “clack”
can be heard.
(16) Remove the module from the table with two persons. Hold the module on the front frame. The
fingers must be beside the long nut.
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10 Safety instructions
The instructions in this chapter are to be followed to prevent damage to the person or the system.
The re-filling of the chemical storage tanks needs to be done if the tanks are empty. Following
procedure must be applied:
Wear adequate protection clothes for handling with chemicals (e.g. gloves
& safety glasses) and follow the instruction in the MSDS.
It should be carefully attended to fill the chemicals in the correct storage
tanks (compare with the safety labels on the storage tanks).
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WARNING OF HEAVY
COMPONENTS!
Some components may be heavy.
Always ensure that adequate
workforce is available. We
recommend for the handling of the
Filtration Modules at least 2
persons!
CORROSIVE MATERIAL
In the event of cleaning (ACEC)
avoid any contact with irritant
and/or corrosive chemicals. We
recommend wearing protective
goggles and gloves during the
whole cleaning process! Please
follow the safety instructions in this
document and the material safety
data sheet (MSDS) of the
chemicals!
RISK OF BREAKAGE!
Some components are fragile
(inparticular the ceramic
membranes). Always handle all
components with care. We
recommend wearing gloves in case
of any damage! Please follow the
safety instructions in this
document.
EXCESS PRESSURE
In the event of backwashing
(periodically during the normal
operation) and cleaning (CCC, iCC)
the permeate channels and the
Filtration Modules are charged with
an excess pressure up to 2 bar.
Keep clear of these components
during the described processes. We
recommend wearing protective
goggles at any time!
BIOHAZARD
In the event of using CERAFILTEC®
for the treatment of e.g. waste
water or other water with possible
biological contaminations ensure
that all local regulations are
observed. We recommend wearing
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protective goggles and gloves at
any time!
GENERAL WARNING
Please note that not all local
regulations, hazard warning notices
and safety instructions are covered
by this document using CERAFILTEC
modules. Please acquaint yourself
with the local regulations in order
to avoid any health risk! We
recommend wearing protective
clothing at any time!
11 Contact information
For more information visit our website www.cerafiltec.com, contact your sales representative
http://www.cerafiltec.com/team/ or for technical questions contact the German engineering team.
CERAFILTEC Germany
Science Park 2
66123 Saarbrücken
E-Mail: engineering@cerafiltec.com
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