Professional Documents
Culture Documents
02 Filtration Training Rev1
02 Filtration Training Rev1
Clarity requirement
Protect downstream equipment
What is Refinery “Mud”?
– Combination of fats and protein released
from starch in the conversion process
Suspended Solids - Sediment
Coagulated enzyme protein
Solid-Liquid Separation
Settle-float (gravity)
Centrifuge (1000 X gravity)
Filter (size exclusion)
– Filter media selection
Size rejected
Renewable surface
High loading
Disposal
Filtration Options
Filter Presses - Pressure Leaf Filters
– Use Mud Centrifuge on Liquefact (CSU)
Ultrafiltration – Microfiltration (UF/MF)
– Very clean filtrate
– Limit on % recovery
– Huge viscosity effect
– not good for low to medium DE syrups
Rotary Vacuum Precoat Filters
Rotary Vacuum
Precoat Filter
Typical Equipment Schematic
Process Feed
air
Vacuum Filter
Vacuum
Receiver
Vacuum Pump
To Process Filtrate Pump
seal water
Rotary Vacuum Precoat Filter
Operating Cycle (A Single Drum Revolution)
Dry Zone
Cake
Discharge
Zone
Form Zone
Filter Aid Selection
What’s important?
Syrup Clarity
Filtration Flux rate (permeability)
– Darcies
– (m3/m2-hr) or (gal/sqft-hr)
Filter aid usage.
– Penetration
– Fouling layer
– Area available
Rotary Vacuum Precoat Filter
Filter Aid Grade Selection
Penetrated Solids
Filtered Solids
Requirements of the
Precoat
Maintain required process filtrate
Filter clarity
Cloth
Maintain desired & achievable flow
rates
Knife Blade
Precoat
Clean Precoat
Minimize process solids’
penetration
cake cross section view
Flow Flow
Filtered Cake Solids
Solids Penetration
minimal
high
excessive
Precoat Cake
Types of Filter Aid
Cellulose Fiber
Perlite
Rotary Vacuum Precoat Filter
Knife Cut Analysis
Excessive Knife Advance Rate Per Drum
Revolution
Excess
low filter aid efficiency
Precoat
i.e. more filter aid used per
Filter Cloth gallon of slurry than what is
normally required
10,000
FW - 80
FW - 70
FW - 60
FW - 50
FW - 40
Flow Index
1,000 FW - 20
FW - 18
FW - 14
FW - 12
FW - 10
FW - 6
FP - 4
FW - 2
100
1000 990 980 970 960 950 940 930 920
Clar ity Inde x
Filter Aid Grade Table
Questions?
Rotary Vacuum Precoat Filter
Operating Parameters
Drum Submergence
Impact of a “Vat Level”
Decrease…….
(operating vat level)
(typical trends)
~ Benefits ~
Maximum filter flow rate
Maximum filter aid usage efficiencies
Rotary Vacuum Precoat Filter
Drum Submergence Analysis
(High Vat Level Operation)
100 %
vs
% Drum
Submergence
100 %
~ Benefits ~
Improved filtered cake dryness
Improved filtrate recovery
Rotary Vacuum Precoat Filter
Operating Parameter Analysis
Filter thru-put………………………..
Thickness of filtered cake………….
Moisture content of filtered cake….
Flow rate per drum revolution……..
Filter aid efficiency………………….
All other operating parameters constant
Rotary Vacuum Precoat Filter
Knife Cut Analysis
0.000 0.001 0.002 0.003 0.004 0.005 0.006 0.007 0.008 0.009
Knife Advance Rate (inches per drum revolution)
Rotary Vacuum Precoat Filter
Knife Cut Analysis
Lost Production
Consistent
Relative Filter Flow Rate
Cut
Irregular
Cut
2 3 4 5 6 8 10 12 15
MPR
0.5 4.2 2.7 2.1 1.7 1.4 1.0 0.8 0.7 0.6
0.75 6.3 4.2 3.1 2.5 2.1 1.6 1.3 1.0 0.8
minutes per revolution
1.0 8.3 5.6 4.2 3.3 2.8 2.1 1.7 1.4 1.1
Drum Speed
1.5 12.5 8.3 6.3 5.0 4.2 3.1 2.5 2.1 1.7
2.0 16.7 11.1 8.3 6.7 5.6 4.2 3.3 2.8 2.2
2.5 20.8 13.9 10.4 8.3 6.9 5.2 4.2 3.5 2.8
3.0 25.0 16.7 12.5 10.0 8.3 6.3 5.0 4.2 3.3
3.5 29.2 19.4 14.6 11.7 9.7 7.3 5.8 4.9 3.9
4.0 33.3 22.2 16.7 13.3 11.1 8.3 6.7 5.6 4.4
Optimum Range
Rotary Vacuum Precoat Filter
DESIGN PARAMETERS
– Hydrolysate
13 – 15 gal/hr-ft2 (0.5 - 0.6 m3/hr-m2) (K-1000)
0.4 RPM
0.004 inch /rev (0.10 mm/rev) knife cut
4.5 inch (115 mm) cake
– Glucose
8 – 10 gal/hr-ft2 (0.3 – 0.4 m3/hr-m2) (K-2500)
– Maltodextrin
4 – 5 gal/hr-ft2 (0.15 – 0.21 m3/hr-m2) (K-5200)
Rotary Vacuum Precoat Filter
Filter Cloth Selection ~ General
Specifications
Common Filter Cloth Design Parameters
Applicable For All Rotary Vacuum Precoat Filters
……….. Mono or multifilament, depending upon solids
Yarn retention and cleaning requirements. DO NOT USE
SPUN-STAPLE.
……. Twill is the best ‘All Around’ weave, providing
Weave good flow characteristics and excellent durability. DO
NOT USE PLAIN WEAVE WITH PRECOAT.
Multifilament
Yarn
(for minimum ‘bleed-
thru’)
Rotary Vacuum Precoat Filter
Filter Cloth Selection ~ Weave
Preferred Weave
Selections
High
150
Permeability ~ CFM / ft2
FW-40 FW-80
Medium
100
Low
FW-20 FW-60
FW-12 FW-40
Very Low
50 FW-6 FW-10
Process Feed
Recirculated Filtrate
air
Vacuum Filter
Vacuum
Receiver
Vacuum Pump
Filtrate Pump
seal water
To Process
Rotary Vacuum Precoat Filter
Suggested Precoating Procedures
Filter Area
– High clarity – High DE
12 gal/sq ft-hr (0.49 m3/m2-hr)
– Glucose Syrups
7.5 gal/sq ft-hr (0.31 m3/m2-hr)
– Maltodextrin
5 gal/sq ft-hr (0.21 m3/m2-hr)
Design Conditions –
cont’d
Vacuum
– Operational
2 ACFM/sq ft & 23+ in Hg
0.32 m3/hr -m2
– Precoating
4 ACFM/sq ft
0.64 m3/hr-m2
– Cloth blinded
Troubleshooting
Low Filtration rate
– Wrong filter aid – (too many fines)
– Cake blinding – insufficient knife cut
– Insufficient Vacuum
– Low Temperature / high viscosity
– High Fine fiber in starch
– Syrup supply changed for the worst
Oil, protein, unconverted amylose & sediment
– Cake too tight
Troubleshooting
Foaming in receiver
– Insufficient vacuum
– Air leak
Troubleshooting
Knife Chatter
– Dull knife
– Wrong angle on blade holder or bevel
– Drum bearings worn
– Cake too hard