Mechanical Separation Division

Westfalia SeparatorMembraflow

Westfalia SeparatorMembraflowDynamic Filtration

Westfalia Separator and Membraflow –

increased efficiency through a complete process chain

Centrifugal Separation Technologyand Dynamic Filtration from a Single Source

Westfalia Separator, with more than 50 salesand service companies worldwide, is holding a top position in the mechanical separation sector. Supported by 100 years of innovation,first-class engineering and extensive process-technological know-how, the company pro-duces centrifugal separators and decanters.

They are used for clarifying suspensions, separatingliquid mixtures with simultaneous removal of thesolids, but also for extracting active substances andfor concentrating and dewatering solid material. Inall, Westfalia Separator gathered experience with more than 2500 different applications. This enables the company to provide perfectly

customized solutions in terms of machine and process technology. Westfalia Separator recentlyextended its product portfolio by another future-oriented high-end technology: filtration with ceramic membranes.

As a specialist in dynamic filtration, Westfalia Separator Membraflow offers equipment tailoredprecisely to individual customer requirements. Westfalia Separator Membraflow develops, manufactures and installs ceramic membranes andcomplete membrane filtration systems. Thanks tomembrane filtration with ceramic elements, a solution is now available from a single source for many application areas requiring the parallelemployment of separators, decanters and membranefiltration.

Benefits to the user: intelligent technologies usingcentrifugation and membrane filtration, matched toeach other, provide a significant improvement inprocess line efficiency – for example, in the foodindustry, biotechnology, the chemical industry or inwater and waste water treatment.

Since 1988, the company installed more than 1000 systems in a variety of sizes and for various applications, operating worldwide anddemonstrating the outstanding competence ofWestfalia Separator Membraflow.

High-tech manufacturing facility: the Westfalia Separator

Membraflow manufacturing facility brings together development,

production and logistics under one roof.

Individual solution Manufacturing Test stand operation Customer installationAnalysis of

the problem

Westfalia Separator

now offers complete

product clarification within

the process chain.

... “centrifugation

with decanters and

separators and ...

Optimisation of

efficiency by

matching the

technologies...

... dynamic filtration with

ceramic membranes”.

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Filter Systems for Extreme Chemicaland Physical ConditionsTechnology and function of the ceramic membrane elements

The schematic drawing combined with an REM image show a cross-section through the support and membrane.

The multi-layer construction is clearly visible. The size of the particles determines the size of the spaces, the pores.

Where other filtration systems meet their limits,dynamic filtration with ceramic membrane elements opens new horizons.

The demands for maximum mechanical and chemicalstability, coupled with the lowest possible flow resistance are met by using a support made of pure�-Al2O3 with a macroporous structure.

The membrane is applied to this support materialand consists of at least one, but usually several, layers of highly porous ceramic, with a precisely defined texture. The layer with the finest porositydetermines the filtration characteristics.

Westfalia Separator Membraflow offers a wideapplication-specific spectrum of membranes and element geometries, unmatched by the competition.Membranes with nominal pore diameters from 1 to 1400 nanometers are available.

Ceramic membranes are therefore almost predestinedfor use in the areas of ultra and microfiltration.

The outstanding properties offered by these typesof membrane elements are being successfully usedthroughout the world in Westfalia Separator Membraflow filter systems.

The Basis: the Ceramic Multi-Channel Element

The body made of highly porous ceramic contains numerous round channels runningparallel to its longitudinal axis. The membraneis mounted on the surface of these channels.

The suspension being clarified flows along the membrane in the channels with a portion of theflow passing through the membrane as the filtrate:this is then carried off by the support material.Thanks to the extremely high permeability, pressureloss during passage through the support is so low as to be negligible when compared to the pressure loss resulting from the passage through the extremely thin membrane.

A powerful filter element

Inert materialAcid and base resistantSolvent resistantCan be regeneratedNo problems with backflushingWear resistantLong service lifeOperationally safeHeat resistant – can be sterilised with steam

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Pore diameters of the ceramic membranes

Pore diameter Pore diameter Molecular weight

µm nm kD

1.4 1400 –

1.0 1000 –

0.8 800 –

0.5 500 –

0.2 200 400

0.1 100 200

0.05 50 100

0.02 20 50

0.005 5 10

Round channels: Westfalia Separator Membraflow utilises a

channel form which provides optimum flow characteristics.

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Matching the ceramic elements, modules and systems to

the individual requirements of the filtration task

High-performance materials manufactured in-house

Production of the filter elements, the modules, andthe individual membrane layers all takes place in-house. It is based on decades of know-how in thedevelopment and manufacture of high-performanceceramic materials made of aluminium oxide, zirconium oxide, titanium oxide and non-oxidizing,mechanically resistant materials.

Multi-channel filtration elements

During dynamic filtration, membrane elements areoperated with process-optimised flows across themembrane surface. A portion of this flow passesthrough the membrane and is carried off as the filtrate.

The optimal conditions for flow are achieved in acircular tube which is standard in all ceramic membrane filter elements. In practice, a number ofthese tubes are embedded in the coarsely poroussupport ceramic. This creates a multi-channel filterelement. The diameters of the channels are matchedto the requirements of the filtration process and liein the range of between 2 and 8 mm.

Application-specific module housings

Module housings serve to hold one or more membrane filter elements. The membrane is onlytechnically usable once it has been installed in sucha housing. The module’s primary functions include:

Holding the working pressureEnsuring flow channelling of the raw solution, the permeate and the retentateChannelling the filtrateAllowing a controlled flow across the membrane

Geometry selection is always application-specific,based on the requirements. Module housings aremanufactured from stainless steel or other corrosionresistant materials.

Essential design features of the module housing

Elastic and secure sealing of the filter elementsFiltrate guidanceComplete evacuation of the filtrate side

Modules with variable membrane

surfaces, manufactured using

housings made of stainless steel,

titanium or other materials

Multifunctional Filter Technology –Modules with Variable MembraneSurfaces

Analysis of the problem Individual solution Manu

Westfalia Separator Membraflow –System Partner for Dynamic Filtration with Ceramic MembranesHigh-end technology and qualified employees

guarantee maximum customer satisfaction and the

highest level of product reliability

ufacturing Test stand operation Customer installation

Experienced specialists, innovative technology and process competence

From the analysis of the problem right up to finalinstallation – Westfalia Separator Membraflow isable to offer integrated solutions from a single source.

Using innovative technologies combined with a unique level of process competence, Westfalia’s process engineers work with the customer to develop the most profitable separation process.Westfalia Separator Membraflow manufacturescompact and powerful filter equipment to cover awide spectrum of applications.

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Customer-specific

requirements profile

Analysis of the Problem

The process begins with the analysis of the problem. Working with the customer, the requirements are first defined and specified.Only a precise knowledge of the individualcomponents will produce a complete picture ofthe whole and lead to the initial solution, frequently this is combined with testing.

The detailed analytical data concerning the individualsubstances, such as their concentration, structure,size, chemical and physical behaviour during theprocess are all of fundamental significance. Anunderstanding of the molecular relationships permits the selection of the membrane offering theproper cut-off for the specific application inquestion. The results of orienting tests in the lab areconfirmed by additional field tests carried out on alarger scale which enables the secure scale-up toproduction equipment.

The equipment begins to take shape

Details come together and a system begins to takeshape. 3D visualisation on the computer helps makethe details apparent.

As early as in the problem

analysis stage, 3-D

visualisations

help to illuminate the details.

The precise analytical

data of the individual

substances are of

fundamental importance.

Special solutions – ’tailor made’ developments

based on specific requirements

Individual Solution

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Since the beginning of 2000, all subsidiaries at home and

abroad have been certified to the highest quality standard.

In 2001 DIN EN ISO 9001:2000 was introduced.

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Experienced specialists ensure

highest quality standards

All ceramic membrane filter elements, the modulesand the entire system are subjected to rigorous quality conformance tests to satisfy the stringentdemands of the pharmaceutical or chemical industry. Before the system undergoes a test bedrun, thorough tests ensure that the system meetsthe quality requirements.

Total quality management means for WestfaliaSeparator Membraflow not only to be satisfied withwhat we have achieved in the past, not only to havein place a quality control system, but also to specifically improve all processes. Potential problemsare identified and eliminated early.

For the customers of Westfalia Separator Membraflow,total quality management means: higher standardsof safety and reliability, long service lives of the filter systems, minimised maintenance and sparepart costs and greater reliability and efficiency in thelong run.

Quality-ControlledProduction

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The elements and modules are individually subjected to an acceptance test. Filter systems areassembled prior to delivery, tested in accordancewith the order requirements and – after plant acceptance by the customer – are made ready fordelivery.

The advantages of this procedure are immediatelyapparent and help safeguard the investment. At thetime of transfer, customers can rest secure in theknowledge that quality-assured components orseparation systems offering maximum performanceare being integrated into their production operation.

Functional testing under

near operational conditions

The essential functional

tests are performed

prior to delivery on the

company´s own test stand.

Test Stand Operation

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Customer Installation – Completeand Competent from a Single Source

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Highly qualified in-house specialists monitor

commissioning and ensure efficient production

operation

The fully tested system is

installed by experienced

process engineers.

At the time of delivery and installation, the customerreceives a quality-assured product, which has been subject to detailed tests. This thorough testingmeans that on-site installation can proceed rapidlyand smoothly.

Westfalia Separator Membraflow provides highlyqualified in-house specialists who assume totalresponsibility for all aspects of the installation, commissioning, and final customer acceptance.

Timely and comprehensive training of the customer’semployees is vital for smooth production and forefficient maintenance. This task is also performedby the commissioning engineers.

Finally, comprehensive documentation ensures optimal performance.

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A Broad Spectrum of Applications for Ceramic Membrane Filters

Economical advantages in many branches of industry

compared to conventional filtration systems

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Ceramic membranes have outstanding propertiesthat make them valuable in numerous processes.Over 1000 filter installations are currently in operation world-wide – to the satisfaction of ourcustomers.

Each solution has been individually developed fora specific task. By way of example, the productionof foodstuffs is subject to different requirementscompared with the treatment of waste water or processes in the chemical industry.

Different regulations, market conditions or naturallaws all represent new challenges.

No matter how diverse the fields of application for our membrane filtration installations are, we develop the optimum solution jointly with our customers for the specific duty and in this way open up the economical advantages of ceramicmembranes.

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Due to the mechanical barrier, a ceramic membraneinstallation continually delivers a clear filtrate with the clarification efficiency and capacity forwhich it has been rated. These special propertiesoffer economical advantages in many branches of industry compared to existing filtration systems, forexample in the:

Food industryProduction and processing of dairy productsClarification of fruit juices, wine and beerWater treatment

BiotechnologyContinuous contamination-free separation ofbiotechnologically recovered products fromfermenters

Chemical industryCatalyst recoveryPurification and recovery of raw materialsRecycling of solvents

Recycling technologyWater treatmentRecycling of cleaning bathsOil-water-emulsion separation

Convincing Solutions for Industries World-Wide

A ceramic membrane

installation delivers

a constantly clear filtrate.

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Whoever supplies capital goods in cost-intensiveindustries will only win and keep the customer if hesucceeds in helping him avoid the “fixed cost trap”. The ”Total Cost of Ownership (TCO)” is theessential indicator for economy.

Westfalia Separator Membraflow performs im-pressively in terms of TCO with an extremely longservice life of the systems and with extremely lowcosts for replacement elements. Damaged elements,for instance, can be re-coated – a further examplefor low replacement costs.

Likewise a significant factor for the economy: theceramic elements are robust in operation, relativelyinsensitive to faulty operation and are capable ofachieving high dry substance contents, in otherwords high yields.

Westfalia Separator Membraflow provides maximumeconomy through its leading technology. More efficient filtration installations with higher performance that cause low fixed costs, consumefewer resources. All this, in conjunction with services ranging from analysis of the problem rightthrough to installation at the customer, createsadded value in the value creation chain of the customer.

Profitable solutions – from

problem analysis right up to

installation at the customer

Creating Value

Efficient filtration systems

ensure low fixed costs

and provide high yields.

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Ceramic membranes are attractive due to theiroutstanding characteristics which make themvaluable in many processes.

Westfalia Separator has had a worldwide presencefor decades. Whether in Europe, America, Asia, Africa or Australia – Westfalia Separator customerseverywhere receive optimal support,individually tailored to their specific requirements. This is ensured by a global presence of around 50 subsidiary and service organisations as well as additional sales organisations in more than 60 countries.

Uniform quality throughout the world

Westfalia Separator customers may be in everyregion of the world, but the Westfalia Separatorquality they receive is always the same. One external symbol of this claim is the world certification bestowed by the TÜV Rhineland, ofwhich Westfalia Separator is currently one of only a handful of companies. This certificate indicatesthat the high quality standard is not merely limitedto the parent company, it is also maintained in all subsidiary companies. Our customers can rely on this wherever they are located at all times.

Westfalia Separator Membraflow –Worldwide Presence Thanks to a Strong OrganisationThink globally – act locally

Oelde, headquarters of the international

operations of Westfalia Separator and

production plant for separators

Niederahr plant,

decanter production plant

Château-Thierry, France,

specialised in the production

of separators

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Beverage Technology

Dairy Technology

Oils and Fats Processing

Chemicals, Pharmaceuticalsand Biotechnology

Oils and Fats Recovery

Starch Technology andIndustrial Biotechnology

Environmental Technology

Marine

Energy

Oilfield

Industry

Engineering

Second Hand Machinery

Service

The information contained in this brochure merely

serves as a non-binding description of our products

and is without guarantee.

Binding information, in particular relating to capacity

data and suitability for specific applications, can

only be provided within the framework of concrete

inquiries.

Printed on chlorine-free bleached paper

www.kabutz.de

9997-1239-000/0606 EN

Printed in Germany

Subject to modification

Westfalia SeparatorMembraflow GmbHRobert-Bosch-Straße 9973457 Essingen (Germany)

Phone +49 7365 9614-0Fax +49 7365 9614-40membraflow@gea-westfalia.dewww.westfalia-separator.com

Take the Best – Separate the Rest

A company of GEA Group

Westfalia SeparatorMembraflow