Filtration system with enhanced cleaning and dynamic fluid separation

• US 20050023219A1
• Filed: 07/30/2004
• Published: 02/03/2005
• Est. Priority Date: 07/30/2003
• Status: Active Grant

• Current Assignee: Phase Incorporated
• Original Assignee: Phase Incorporated
• Inventors: Fuller, Berkeley F., Kirker, Curtis
• Granted Patent: US 7,294,274 B2
• Time in Patent Office: Days
• US Class Current: 210/636
• CPC Class Codes: B01D 2313/2011 Pressure vessels
• CPC Class Codes: B01D 2313/36 Energy sources
• CPC Class Codes: B01D 2321/185 Aeration
• CPC Class Codes: B01D 2321/2058 by vibration of the membrane, e.g. with an actuator
• CPC Class Codes: B01D 2321/2075 Ultrasonic treatment
• CPC Class Codes: B01D 2321/35 with acoustic waves
• CPC Class Codes: B01D 63/0822 Plate-and-frame devices
• CPC Class Codes: B01D 63/10 Spiral-wound membrane modules
• CPC Class Codes: B01D 63/16 Rotary, reciprocated or vibrated modules
• CPC Class Codes: B01D 65/02 Membrane cleaning or sterilisation ; Membrane regeneration
• CPC Class Codes: B01D 65/08 Prevention of membrane fouling or of concentration polarisation

Abstract

A filtration system is provided with filter media operable to remove solids, particulate and colloidal matter from a process fluid. Acoustic, vibration and sonic energy may be used to clean associated filter media to allow substantially continuous filtration of process fluids. The filtration system may be satisfactorily used with process fluids having a relatively high concentrations of solids, particulate and colloidal matter.

Claims

1. A filtration system operable to separate a process fluid into selected components comprising:

a housing having at least one inlet operable to receive the process fluid;

the housing having at least a first outlet for a concentrated fluid and a second outlet for a clarified fluid;

at least one filter element disposed within the housing;

each filter element having a first membrane layer and a second membrane layer spaced from each other;

a central portion of each membrane open for contact with the process fluid and operable to separate the process fluid into the concentrated fluid and the clarified fluid;

a first flow path coupling the concentrated fluid with the first outlet;

a second flow path coupling the clarified fluid with the second outlet; and

an energy source operable to vibrate the central portion of each membrane without interruption of an association filtration process.

2. The filtration system of claim 1 further comprising a plurality of filter elements.

3. The filtration system of claim 1 further comprising the energy source selected from the group consisting of a linear reciprocating mechanical vibrator, an ultrasonic vibrator, a sonic energy vibrator and a plurality of piezo-electric transducers.

4. The filtration system of claim 1 further comprising vibration energy directed substantially perpendicular with each membrane layer.

5. The filtration system of claim 1 further comprising vibration energy directed at an acute angle less than ninety degrees and more than ten degrees relative to each membrane layer.

6. The filtration system of claim 1 further comprising energy absorbing material disposed within the housing opposite from the energy source.

7. The filtration system of claim 1 further comprising a plurality of conduits disposed within the housing and operable to inject gas bubbles into the process fluid contained within the housing.

8. The filtration system of claim 1 wherein the housing further comprises at least one flexible outer wall generally aligned with the central portion of each membrane to facilitate vibratory cleaning of each membrane.

9. The filtration system of claim 1 further comprising a second flexible outer wall disposed in the housing generally opposite from the first flexible outer wall.

10. The filtration system of claim 8 further comprising an energy source coupled with the flexible outer wall and operable to vibrate the central portion of each membrane.

11. A method for separating a process fluid stream into a clarified fluid stream and a concentrated fluid stream comprising:

communicating the process fluid to at least one inlet of a filtration system;

directing the process fluid to contact at least one filter element disposed within the housing;

separating the clarified fluid from the process fluid by the clarified fluid flowing through at least one surface of each filter element;

directing the clarified fluid to at least one respective outlet from the housing;

directing the remaining concentrated fluid to at least one respective outlet from the housing; and

applying energy to each filter element to remove or inhibit any accumulation of scale, solids cake or film on each filter element.

12. The method of claim 11 further comprising directing acoustic energy to clean the at least one surface.

13. The method of claim 11 further comprising directing sonic energy to clean the at least one surface.

14. The method of claim 11 further comprising vibrating the filter element to clean the at least one surface.

15. The method of claim 11 further comprising combining a first method for cleaning each filter element with a second method for cleaning each filter element.

16. The method of claim 11 further comprising alternatively tensioning and relaxing a membrane sheet disposed within filter element to remove or inhibit any buildup of scale, solids cake or film on the membrane.

17. The method of claim 11 further comprising alternately flexing a membrane sheet disposed within each filter element to remove or inhibit any buildup of scale, solids cake or film on the membrane.

18. The method of claim 11 further comprising alternately twisting a membrane sheet disposed within each filter element to remove or inhibit buildup of scale, solids cake or film on the membrane.

19. The method of claim 11 further comprising producing vibration energy using an air powered vibratory generator.

20. The method of claim 11 further comprising producing reciprocating linear mechanical vibration using a motor powered vibrator.

21. The method of claim 11 further comprising:

directing a reciprocating energy wave selected from the group consisting of vibration, acoustic and ultrasonic through at least one membrane sheet disposed within each filter element; and

bouncing each membrane sheet with the energy wave to displace any solids, particulate and colloidal matter from at least one surface of the membrane sheet to allow clarified fluid to flow through the associated membrane sheet.

22. The method of claim 21 further comprising directing the reciprocating energy wave through at least a second membrane sheet disposed within each filter element.

23. The method of claim 11 further comprising:

directing cleaning energy in a direction generally perpendicular with each filter element; and

directing gas bubbles in a direction generally parallel with each filter element whereby the vibration energy and the flow of bubbles cooperate with each other to enhance cleaning of the associated filter elements.

24. The method of claim 11 further comprising:

directing a substantially continuous roll of filter elements through a housing;

applying tension to portions of the filter elements disposed within the housing; and

varying the amount of tension applied to the filter elements during an associated filtration process.

25. The method of claim 24 further comprising directing gas bubbles into the housing to assist with removing scale, solids cake or film from the surface of the filter elements disposed within the housing.

26. The method of claim 11 further comprising applying reciprocating torsional energy to a plurality of filter elements stacked with respect to each other within the housing.

27. The method of claim 11 further comprising applying the energy to a plurality of filter elements with their respective central, working portions generally aligned with each other and an associated energy source.

28. A method for forming a filtration system operable to separate a process fluid into selected components comprising:

forming a housing having at least one inlet operable to receive a process fluid;

forming at least a first outlet from the housing for a retentenate fluid to exit from the housing;

forming at least one second outlet from the housing for a permeate fluid to exit the housing;

forming at least one spiral wound membrane envelope;

installing the at least one spiral wound membrane envelope in the housing;

connecting at least one conduit with a chamber formed within each membrane envelope to allow communication of permeate fluid from the chamber to the second outlet from the housing; and

applying vibration energy to the membrane envelope to clean any scale, solids cake and film from upstream surfaces of each membrane envelope.

29. The method of claim 28 further comprising:

attaching each spiral wound membrane envelope with a first end cap and a second end cap; and

inserting the first end cap and the second end cap into the housing.

30. The method of claim 28 further comprising slidably reciprocating the first end cap, the second end cap and each attached membrane envelope relative to the housing during an associated filtration process.

31. The method of claim 30 further comprising applying vibration energy to each membrane envelope while reciprocating the first end cap and the second end cap.

32. The method of claim 28 further comprising:

placing the housing within a second pressure vessel; and

controlling variations in fluid pressure within the second pressure vessel and the housing during a filtration process.