Tetra Pak Ultra Filtration (UF) and Reverse Osmosis (RO) line

Skid mounted Tetra Pak Allcross US Ultra Filtration (UF) combined with a Tetra Pak Allcross RS Reverse Osmosis (RO) line for continuous circulation / concentration / filtration of product. Previously running in a cheese plant in Switserland. The line exist out out of 2 different sections:

• Section 01: UF Unit, Tetra Pak project name: K166061

Tetra Tetra Alcross US. The feed liquid is pumped to the inlet valve by an external pump. The 2x centrifugal feed pumps arranged in series one after the other, pump the liquid into the low pressure side of the circulation loop. The circulation pump gives the feed liquid a high speed within the spiral membrane modules. The spiral membrane basically consists of a "sandwich", i.e. of successive layers of spacer fabric, membrane and holder, flexible, permeable holder (permeate channel) and membrane. This "sandwich" is wound around a perforated tube (permeate collection tube). The feed liquid flows through the spacer fabric, a part of the feed liquid - the permeate - passes through the membrane and flows spirally along the permeable permeate channel to the perforated tube in the middle and is collected there. From the perforated tube, the permeate flows through the permeate distribution tubes, leaves the recirculation loop through the permeate flow meter and is directed to the permeate valve. The remaining feed liquid - the retentate - is cooled and returned to the recirculation pump, mixed with new feed liquid and then passes through the spiral membrane modules again. The retentate leaves the last recirculation loop through the retentate control valve. The flow is measured as the ratio between feed liquid flow and retentate flow.

The UF unit exist out:

* Skid 1 with 2 balance tanks, 2x centrifugal feed pumps (Alfa Laval LKH-50/180 FSS, 15 kW, 1996, serialnr 000907 + Alfa Laval LKH-60/180 SSS, 18,5 kW, 1996, serialnr 000908), 1x CIP return pump (Alfa Laval LKH-20/150 FSS, 5,5 kW, 1996, serialnr 000836), double filter, pneumatic valves and interconnectinging piping. Floor area: length x width: ± 2,3 x 2,4 meter.

* Skid 2: circulation / concentration / filtration loop 01: 051-20-01, 6 Tubes of 3 meter length with 6'' Housing for UF Membrane with 3 filters per tube (total 18x filters), circulation pump (Alfa Laval LKH-60/210 FSS, 30 kW, 1996, serialnr 000911), inline tube cooler, pneumatic valves and interconnectinging piping. Extra pump for dialyse water UF/RO (058-02-01, Alfa Laval LKH-112 SSS, 5,5 kW, 1995, serialnr 001239). Floor area: length x width: ± 3,6 x 2,4 meter.

* Skid 3: circulation / concentration / filtration loop 01: 051-30-01, 6 Tubes of 3 meter length with 6'' Housing for UF Membrane with 3 filters per tube (total 18x filters), circulation pump (Alfa Laval LKH-60/210 FSS, 30 kW, 1996, serialnr 000912), inline tube cooler, pneumatic valves and interconnectinging piping. Floor area: length x width: ± 3,6 x 2,4 meter.

* Skid 4: circulation / concentration / filtration loop 01: 051-40-01, 6 Tubes of 3 meter length with 6'' Housing for UF Membrane with 3 filters per tube (total 18x filters), circulation pump (Alfa Laval LKH-60/210 FSS, 30 kW, 1996, serialnr 000909), inline tube cooler, pneumatic valves and interconnectinging piping. Floor area: length x width: ± 3,6 x 2,4 meter.

* Skid 5: circulation / concentration / filtration loop 01: 051-50-01, 7 Tubes of 3 meter length with 6'' Housing for UF Membrane with 3 filters per tube (total 21x filters), circulation pump (Alfa Laval LKH-60/210 FSS, 30 kW, 1996, serialnr 000910), inline tube cooler, pneumatic valves and interconnectinging piping. Floor area: length x width: ± 3,6 x 2,4 meter.

* Skid 6: circulation / concentration / filtration loop 01: 051-60-01, 4 Tubes of 3 meter length with 6'' Housing for UF Membrane with 3 filters per tube (total 12x filters), pump (Fristam FPE 3552/240A, 45 kW - 2.900 rpm, serialnr 45839144), inline tube cooler, pneumatic valves and interconnectinging piping. Floor area: length x width: ± 3,6 x 1,4 meter.

The feed capacity of the UF Unit is in total is 26.000 ltr/h and the retentate output is 2.150 - 5.000 ltr/h and the permeate output is ± 22.000 ltr/h.

Layout and loop connection point available.

Control panel with SattCon OP45 operation panel and productions hours counter: 55.466 hours.

• Section 02: RO Unit, Tetra Pak project name: K166062: TA RS, 4x7/6 - UF permeate 8l % TS / RO anlaeg til UF permeate fra K166061, flowchart no: 32574-4130-2.

Tetra Tetra Alcross RS, designed for UF permeate or whey. The feed liquid is pumped to the inlet valve by an external pump. The 3x centrifugal feed pumps arranged in series one after the other, pump the liquid into the low pressure side of the circulation loop. The circulation pump gives the feed liquid a high speed within the spiral membrane modules. The spiral membrane basically consists of a "sandwich", i.e. of successive layers of spacer fabric, membrane and holder, flexible, permeable holder (permeate channel) and membrane. This "sandwich" is wound around a perforated tube (permeate collection tube). The feed liquid flows through the spacer fabric, a part of the feed liquid - the permeate - passes through the membrane and flows spirally along the permeable permeate channel to the perforated tube in the middle and is collected there. From the perforated tube, the permeate flows through the permeate distribution tubes, leaves the recirculation loop through the permeate flow meter and is directed to the permeate valve. The remaining feed liquid - the retentate - is cooled and returned to the recirculation pump, mixed with new feed liquid and then passes through the spiral membrane modules again. The retentate leaves the last recirculation loop through the retentate control valve. The flow is measured as the ratio between feed liquid flow and retentate flow.

The RO unit exist out:

* Skid 1 with 2 balance tanks, 3x centrifugal feed pumps (3x Alfa Laval LKHP-40/235 FSS, 22 kW, 1996, serialnr 001131 / 001132 / 001133), 1x CIP return pump (Alfa Laval LKH-10/140 FSS, 3,0 kW, 1996, serialnr 000810), single filter, pneumatic valves, flowindicator PD340 and interconnectinging piping. Floor area: length x width: ± 2,3 x 2,4 meter.

* Skid 2: circulation / concentration / filtration loop 01: 061-50-01, 6 Tubes of 6 meter length with 4'' Housing for RO Membrane with 6 filters per tube (total 36x filters), inline tube cooler of 1,4 m2 - diameter 101 mm, pneumatic valves, flowindicator PD340 and interconnectinging piping. The circulation pump is excluded (should be a Alfa Laval LKHP-50/205 S 18,5 kW FSS). Floor area: length x width: ± 6,6 x 2,4 meter.

* Skid 3: circulation / concentration / filtration loop 02: 061-60-01, 7 Tubes of 6 meter length with of 4'' Housing for RO Membrane with 6 filters per tube (total 42x filters), inline tube cooler of 1,4 m2 - diameter 101 mm, pneumatic valves, flowindicator PD340 and interconnectinging piping. The circulation pump is excluded (should be a Alfa Laval LKHP-50/205 S 18,5 kW FSS). Floor area: length x width: ± 6,6 x 2,4 meter.

The feed capacity of the RO Unit in total is 22.300 ltr/h and the retentate output is 11.500 ltr/h and the permeate output is 11.800 ltr/h.

Manual in German, P&ID and components list available.

Total electrics RO: 113 kW - 380 V - 50 Hz

Cooling water: Temperature::  < 15 °C - Flow: 2.800 ltr/h - Feed pressure: 3 bar

Seal flush water: Temperature: min. 1 °C - max. 40 °C - Flow: 200 ltr/h - Feed pressure: min. 3 bar

Soft water for rinsing/cleaning: Temperature: 50 till 54 °C - Flow: ± 22.000 ltr for rinsing (capacity 20.000 ltr) - Feed pressure: 1 bar

Retention volume: Quantity: ± 1000 ltr, including 500 ltr in the expansion tank.

Additional features:

Following items are missing / excluded:

• UF Unit: 2x Flowindicators PD340.
• RO Unit: 2x circulation pumps (061-51-01 and 061-61-01, Alfa Laval LKHP-50/205 S 18,5 kW FSS).
• RO Unit: Control panel.
• UF/RO Unit: Some interconnecting piping / pneumatic valves in the UF and RO skids / between the skids.

The original filters and spacers from the last production run are still inside the filtration tubes (not conserved), needs to be replaced by new filters.