2011 volume 14 issue 2 know how is published by pentair
A clean solution for wastewater treatment
production and upgrading Pentair Foodservice helps Stirrings, LLC produce simply better cocktails Green innovations from Pentair Residential Filtration
29 Innovation, globalization, mergers and reorganizations… our markets and industries are evolving quickly and the world economic environment is constantly changing. In this turbulent world, Pentair is uniquely positioned to serve our global customers, in a broad variety of markets and with breakthrough innovation. I am excited to share the breadth and scope of Pentair’s portfolio of products and solutions and truly hope you benefit from the various case studies presented in this edition of KnowHow.
With the integration of Clean Process Technologies essentially complete, KnowHow will highlight our focus on providing innovative solutions and applications that improve customer efficiency, sustainability and profitability. Additionally, we remain committed to showcasing our capabilities at key industry tradeshows around the world, such as Amsterdam’s Aquatech or Nuremberg’s Brau Beviale, where we are highlighting products from across our broad range of water solutions, fluid processing technologies and technical products for infrastructure and the electronics industry. We hope to see you at one of the upcoming trade shows – in Amsterdam or Nuremberg or perhaps at WEFTEC in the U.S. or the Big 5 Show in Dubai. As a global company, it is critical to Pentair’s further development of applied solutions that we invest in regions of importance to many of our customers and business partners. Our new, world-class Research and Development Lab in Suzhou, China enables Pentair to design, develop and test advanced products to address local customer needs. In the lab, products undergo chemical, biological, electrical and structural testing to ensure customers receive the best and safest products in the marketplace. We also recently opened our first Customer Experience Center in the commercial district of Shanghai. The center is equipped with our latest water treatment technologies and products where customers may gain a deeper understanding of available water treatment technologies and experience, first hand, Pentair’s innovative product offerings.
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It remains an exciting time for Pentair and the industries we serve. Our commitment to continuous improvement will always be at the core of what we do. The advancements we are making with respect to innovation provide truly exciting technologies and solutions that our customers demand. Innovation, coupled with our internal commitment to the Pentair Integrated Management System (PIMS), ensures we will continue to drive Lean Enterprise to constantly focus on quality, delivery, cost, and of course, safety. By recently implementing the Net Promoter Score (NPS) initiative across our businesses, we can better gage customer satisfaction and loyalty through metric-based tools, which help our employees learn about our strengths and weaknesses from a customer perspective. In turn, these metrics assist us in identifying where we need to make changes to improve the customer experience. We thank you for your continued support and look forward to sharing some of the exciting developments at Pentair and our industries in future editions of KnowHow. Michael V. Schrock President & Chief Operating Officer Pentair, Inc.
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Clean water for Moscow As one of the oldest water systems in Europe, Moscow’s 100-year-old plus central water supply and the City of Moscow are faced with the challenge of meeting today’s enormous water demands. The majority of the water requirements come from the growing population, 11.5 million at present, and the industries in the Moscow area.
validate the performance of the membranes and to optimize operating conditions. The remaining 110 Aquaflex units containing another 3,300 membrane modules will be installed in eight phases with completion set for the second quarter of 2012.
To ensure a safe and reliable supply of drinking water, the City of Moscow added a large-scale drinking water plant almost a decade ago. With ultrafiltration (UF) technology at its core, the Drinking Water Plant SouthWest Moscow is one of world’s largest UF plants with a capacity of 6.6 million gallons per day (250,000 m3/d).
Pentair X-Flow’s UF membranes remove all fine silt and turbidity (suspended particles) and create a hygienic barrier for bacteria, viruses, and other micro-organisms. The Aquaflex units combine a vertical configuration with the advantages of an advanced UF module that uses low energy while providing maximum performance. This allows the system to be designed with higher flux rates, a reduced footprint, and the flexibility to treat a broad range of feed water qualities.
In 2010, WTE Wassertechnik GmbH, the German company that designed, constructed and operates the drinking water plant, was looking for a new UF membrane supplier. Based on a range of selection criteria Pentair X-Flow’s Aquaflex™ UF membrane modules were chosen to replace the original ones.
“Pentair X-Flow is delighted to be entrusted with this project,” said Jürgen von Hollen, Managing Director of Pentair X-Flow. “This project requires close cooperation with WTE Wassertechnik GmbH and it gives all involved great pleasure to see our solution succeed at this strategic drinking water plant that serves Moscow’s population.” The South-West Moscow project is divided into several phases as the retrofit takes place during production, which means that each new unit instantly goes on-line. In the last quarter of 2010, two Aquaflex units containing 60 Aquaflex membrane modules were installed to
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Pentair X-Flow extends the range of membrane filtration products strengthening its water reuse product portfolio written by frans knops, erik roesink
Current generation hollow fiber (HF) and spiral wound (SW) membrane modules leave a gap in the current filtration market that needs to be closed in order to make more water reusable. While existing low pressure HF membrane filtration technologies can filter a wide range of particles out of a wide range of feed water types, there is still room for improvement and an urgent need for membrane filters with different characteristics. Existing SW nanofiltration (NF) technology requires extensive pre-treatment and is not resistant to oxidative cleaning substances. Pentair X-Flowâ€™s new HF Nano membranes are specifically designed to fill this gap and extend the range of membrane filtration. This new type of capillary membranes with NF characteristics opens new horizons and makes substantial amounts of water reusable. 04
performance, but its true uniqueness shines through in the ability to adapt the membranes to specific applications. Advantages of the Pentair X-Flow’s HF Nano membrane include:
Smaller footprint Reduced energy consumption Reduced water loss due to higher product recovery Reduced chemical consumption since no coagulation and/or pH correction is required Capable of recycling high or low pH solutions currently being discharged No pre-treatment required Chlorine and chemical resistance
The HF membranes’ skin is on the inside, thereby applying Pentair X-Flow’s proven in-to-out filtration concept.
Application areas Due to its unique characteristics, the HF Nano membrane can be applied in many fields where current technology is insufficient. Different pore sizes and different fiber diameters make it possible to selectively remove colloidal matter (silica), organics (humics) and small organics (DOC/TOC), if necessary combined with direct coagulation.
Nanotechnology – A quick introduction Nanofiltration is a pressure-driven membrane process which, in terms of separation characteristics, lies between ultrafiltration (UF) and reverse osmosis (RO). The separation characteristics of NF are dictated both by size exclusion, like UF, as well as by charge or Donnan exclusion, like RO. Therefore, the ability to handle elevated solids levels is important as well as correct control of the concentration polarization layer. The pore size of the NF membrane is characterized by a cut-off value, expressed in Dalton, that is consistent with the molecular weight of the smallest molecule that can be 90 percent rejected by the membrane.
Properties of Pentair’s HF Nano With the new HF Nano capillary membrane, Pentair X-Flow is the first company that successfully combines the advantages of both NF and HF technologies. In one single process step Pentair X-Flow’s HF Nano membranes are capable of removing pollutants impossible to remove with currently available technologies. The HF Nano membranes thus offer a leading-edge separation
Removal of colloidal silica is of interest in power plants or for untreated surface water. Particulate silica (sand particles) can be removed by conventional pre-treatment and reactive silica (ionized) can be removed by ion exchange and/or RO. Colloidal or polymerized silica however can only be partly removed by conventional treatment methods. HF Nano is a robust membrane that can offer a true alternative here as it offers the most reliable protection for boilers and turbines. The silica removal rate is 10 times better, no coagulant is needed and the HF Nano membranes can be used early on in the process as pre-treatment instead of polishing.
are needed and there are no disinfection by-products. It also offers a low chemical and energy consumption. Moreover, the wastewater does not need to be neutralized prior to processing. This offers the opportunity for recycling high or low pH rinse water. Ultrapure water In areas where ultrapure water is required, for example the semiconductor, solar or pharmaceutical industries, HF Nano membranes can be used for the final polishing in the ultrapure water loop. The HF Nano membranes have unique properties, such as shipment without glycerin. This improves the TOC rinse up, thus decreasing rinsing times. The special construction inside the membrane and the use of customized pressure vessels allows for operation at elevated pressures, e.g. as final polishing step downstream of the circulation pumps.
HF Nano technology outlook During the last several months, Pentair X-Flow has shipped small scale demonstration HF Nano plants worldwide. These “quick scan units” are easy to set up and allow customers to witness performance and to quickly see results on specific feed water and applications. The first orders for Pentair X-Flow’s HF Nano have been received for silica removal in boiler feed reference plants. Currently, research is directed into fine-tuning the HF Nano membranes for distinct applications with different characteristics, such as pore size, retention properties, solids handling ability, and operating pressure. Targets for the near future include designing membranes for removal of micro-pollutants, such as endocrine disruptors and reduction of divalent salts. In the future, new applications such as one-step potable water production (elimination of micro-pollutants, turbidity and microbiology from surface water), sulfate removal and the complete elimination of biological fouling by removing all dissolved organics will be applied.
Organics removal HF Nano’s organics removal rates offer new perspectives to produce potable water from surface water and to treat wastewater. For the purification of surface water, HF Nano offers a one-step treatment to remove humic and fulvic acids without sludge production. No coagulants are needed, the treatment requires few cleaning chemicals, water recovery is high, and water produced can be approved for potable water use. As the HF Nano membrane allows for selective removal of color, it is especially fit for the treatment of wastewater, e.g. in the textile or food industries. During the filtration process, no sludge is produced, no coagulants knowhow 2011
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Pentair Filtrix introduces the sterile Medical ShowerFilter Targeting a new ‘infection control’ segment
written by frank van heusden
Water purification using membrane technology has been proven reliable over the years in applications such as large drinking water installations. For some time now, membrane technology has also been applied in point-of-use (POU) products and is a successful weapon in the fight against Legionnaires’ disease. While membrane technology can serve as a temporary solution to combat Legionella contamination, it is also ideally suited as a permanent answer to solve the challenge of water purification in hospitals. Photo: Astrid Paulisch
Pentair Filtrix products are applied in a variety of markets with the common factor of ‘health protection’. The applications that are developed within the area of ‘drinking water solutions’ are mainly targeting the OEM market. And for the other key area ‘infection control’, Pentair Filtrix develops complete ready-to-use systems for POU as well as for point-of-entry (POE) purposes.
Shower filters for the medium risk level
Regulations and risk management With the increasing attention for waterborne infections, governmental regulations are getting stricter. At the same time organizations or departments that are responsible for infection control are using more and more advanced risk management models. In order to prioritize their risk response activities, they usually quantify the probability and the severity of the consequences of identified risks.
Medical filters for the highest risk level The highest risk levels appear in the healthcare market. Examples of high-risk organizations are hospitals, home care organizations and nursing homes. Patient safety is of vital importance, especially in sterile areas such as hematology, oncology, burn units and intensive care units. One of the main concerns is the risk of bacterial infections, which can be caused by microbiologically contaminated shower and tap water. Waterborne pathogens can accumulate in biofilm located within the plumb-
Biofilm (red) retained by membrane (green)
ing system, even if the water is disinfected at the pointof-entry. The pathogens can be transmitted to patients when the water is used for their care.
A new product meeting specific needs For these extremely high-risk areas Pentair Filtrix developed a Medical ShowerFilter with a full CE 1S (sterile) validation. The gamma radiation treatment, the sterile blister packaging and the additional anti-microbial layer on the filter head assure the safety of extremely vulnerable patients. In situations where organizations are dealing with highlevel risk areas that do not require sterile spaces – home care organizations and elderly homes – the nonsterile version of the Medical ShowerFilter can provide permanent safety for patients.
For organizations such as hotels, sport facilities, wellness and spa centers that face a medium-risk level the most harmful water bacteria is Legionella. This waterborne pathogen can cause the dangerous Legionnaires’ disease. The most common route of infection is inhalation of airborne droplets containing the Legionella bacteria from outlet points of hot water installations, such as showers. For the safety of their guests or visitors, these medium risk level organizations check their water system on a regular basis for the presence of Legionella. If Legionella is found in the water it can be eliminated from the water system via different water treatment methods. But, until the water is tested again in order to see if the treatment was effective, the water is not 100 percent safe. During this period, temporarily remedy can be provided with the Pentair Filtrix ShowerFilter. This unique ShowerFilter looks and handles like any familiar handheld shower and will not make the guests unnecessarily anxious or suspicious. But at the same time it holds a replaceable filter cartridge that contains microfiltration membranes, which effectively retain any Legionella bacteria present in the water. With this clearly balanced product offering Pentair Filtrix covers the three main segments within the infection control market – health care/sterile areas, health care/non-sterile areas and hospitality.
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Green innovations from Pentair Residential Filtration written by francois imhof
Hybrid Deionization Technology Over the last few years, there has been an increasing tendency to consider the environment in its whole and to reduce the footprint. Because Pentair Residential Filtration focuses on sustainable solutions, this created an opportunity for innovation. It has taken years of market research and extensive testing before being able to validate a brand new concept for residential and light commercial applications that would treat water in a brand new way. This new process of treating water is called Hybrid Deionization technology, which uses 90 percent each of the capabilities of a standard water softening system and a reverse osmosis system. Using fuel cells and super capacitor capabilities, this unit will be the first device providing simultaneously an all-in-one water treatment process : softened water and “bottle-quality” drinking water throughout the home, without the use of salt and consumable membranes. This will not only provide a new level of convenience to the homeowner but will also contribute to a greener planet as the Hybrid Deionizer will also reduce the need for bottled water by providing “bottle quality” water to every tap in the house. Furthermore, unlike traditional softening units which often require frequent salt deliveries and filter changes, it will only need a single annual cleaning to restore peak performance. With a touch screen interface it will allow water professionals and home owners alike to easily monitor, diagnose and adjust the system. Consumers will have the ability to fine tune water to their particular taste while using the system’s intelligence. Less waste, softened and pure water, financial savings, are strong key selling points, which the Hybrid Deionizer can claim thanks to its technological leap forward.
9100TS – Twin Tank Sensor Pentair Residential Filtration has developed a new solution for those wishing to go one step further into sustainability by reducing the amount of water and salt used in each regeneration. This solution is the new 9100TS (Twin Sensor), which is able to save regenerant and less water (up to -15 percent) and deliver conditioning performance that is completely consistent. How does it practically work ? Twenty four hours a day, a microcomputer designed to respond to changes in system status detects fluctuating water conditions thanks to a pair of non-corrosive gold-plated electronic sensor probes and triggers an instant response to deliver two big benefits: firstly a consistent quality, thanks to those sensors which signal a drop below optimum condition, so water never passes through untreated. Secondly a 100 percent efficiency as it is able to use all of its treatment capacity before regenerating, saving both water and regenerant. Those sensors are always on guard against changes in the water conditions, responding only when the time is right to protect water quality and conserve valuable resources. Besides, thanks to its twin tanks the system switches to a fresh tank that is always standing by, changing from one tank to the other so quickly that the homeowners won’t even know a changeover is taking place. The tank conditioning capacity is therefore 100 percent used, meaning less regeneration, less water sent to the waste, less salt used, making the 9100TS one of the most efficient softeners from the market.
Pentair Fairbanks Morse engineering flood control solutions written by norm gassaway
In 2005, Hurricane Katrina, the costliest natural disaster in U.S. history as well as one of the strongest U.S. storms on record, caused widespread devastation along the central Gulf Coast states. Damage was estimated at $81 billion and sadly 1,836 people died during the hurricane and subsequent flooding. New Orleans was particularly hard hit after 53 levee breaks magnified the storm’s impact flooding 80 percent of the city with 20 feet (~ 6 m) of water. Today, 350 miles (~ 563 km) of levees, floodwalls, gates and Pentair Fairbanks Morse pumps now provide a first line of defense against the effects of future severe storms. This system, known as the Army Corps of Engineers’ (ACOE) Gulf Intracoastal Waterway West Closure Complex (GIWW WCC), markedly improves the patchwork of levees and walls that were breached during Hurricane Katrina.
The system will minimize the risk of storm surges across the west bank area near New Orleans and is a major component of the Hurricane and Storm Damage Reduction project. The WCC will reduce the storm surge risk to residences and businesses in the Orleans, Jefferson and Plaquemines parishes on the west bank of the Mississippi River.
1,740 cubic feet per second (5.5 m3/s) – approximately 800,000 gallons per minute (3,000 m3/m), per pump 10-foot propeller diameter (20,000 pound/~ 9,000 kg stainless steel cast) 12-foot diffuser diameter, 60,000-pound diffuser (~ 27,000 kg) 140-inch (356 cm) discharge diameter (flowerpot) 52 tons (~ 47,000 kg) per bowl assembly 70 tons (~ 63,500 kg) per pump assembly 5,444-horsepower diesel engine
The Challenge: Design, Develop, Deliver
How It Works
Pentair first started work on pump stations in New Orleans after the ACOE awarded the company the 17th Canal Street project. In just six months, Pentair Fairbanks Morse delivered 11 pumps weighing 85,000 pounds (~ 38,500 kg) each to the 17th Street Canal in 2007.
With construction of the WCC, located approximately one mile south of the confluence of the Harvey and Algiers canals on the Gulf Intracoastal Waterway, the ACOE hopes to prevent storm surges from backing up into those canals via the closure gate. Once the gate is closed, the surge is blocked; however, water is still collected, which makes it necessary to pump water past the gate. The WCC pumping station removes that excess water. Each pump moves 800,000 gallons (~ 3,000 m3) of water per minute pushing it past the gate and away from the surrounding parishes to protect homes, businesses and most importantly people.
The experience on the 17th Street Canal project allowed engineers at Pentair Fairbanks Morse to quickly run tests necessary to develop the 140-inch Vertical Propeller Pumps for the pumping station at the West Closure Complex. Pentair Fairbanks Morse designed, developed and delivered 11 20,000 cubic feet per second (566 m3/s) pumps for flood protection to the WCC in June 2011 – in time to protect New Orleans ahead of hurricane season.
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Pentair Haffmans CO2 system equips desalination plant in China written by roy spee
Pentair Haffmans is supplying its first carbon dioxide (CO2) injection system to a desalination plant in China. The 13 million gallons per day (50,000 m3/d) seawater reverse osmosis system (SWRO) is located in the Caofeidian Industrial Zone near the city of Tangshan and part of a large-scale governmental construction project. Seawater Reverse Osmosis is a leading process for desalination. While the characteristics of RO membranes are ideal for removing the salt, they also remove minerals from the water. As a result, after RO membrane treatment the water is not suitable for consumption. A post-treatment to re-mineralize the water is required. The Pentair Haffmans’ CO2 dosing and injection system installed at Caofeidian, 136 miles (~ 220 km) from Beijing, contributes the re-mineralization process as it adds CO2 to the permeate flow during post treatment. To make RO water drinkable, water leaving the RO membranes is carbonized so that minerals can be dissolved at the calcite filters. Pentair Haffmans’ Carbo Controller side stream carbonation system automatically and accurately doses the CO2 into the water to decrease the pH value. This allows the calcium ion to recreate some hardness and alkalinity in the water, as required by the World Health Organization standards. Carbon dioxide is an ideal solution as it is a non-toxic, non-hazardous drinking water additive that replaces toxic chemicals such as calcium chloride or sodium hypochlorite, which are becoming obsolete. Striving for safe, environmentally friendly and efficient solutions is an integral part of the Pentair philosophy. “This project is a great accomplishment for Pentair Haffmans,” said Olaf Müller, Pentair Haffmans Managing Director. “Our expertise in carbon
dioxide and oxygen management as well as gas treatment technologies gained from the beverage industry has helped us to move into new markets. The Chinese market for desalination is one of the fastest growing worldwide.” Aqualyng Norway, in conjunction with joint venture partner Tangshan Caofeidian Infrastructure Construction Investment Co. (IIC), developed and will operate the desalination plant. Hangzhou Development Center of Water Treatment Technology Company was chosen to build the plant. The Caofeidian Industrial Zone, owned by the Chinese government, is on China’s list of pilot areas for sustainable economy. According to the construction plans, the entire industrial zone will cover an area of 124 square miles (~ 310 km2) by 2020. Goals are high in terms of
ecological and economic sustainability, including the construction of a climate-neutral eco-city, offering space for a population of approximately one million people.
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Introducing CodeLine membrane housings Since 1977, Pentair’s CodeLine® has set the standard in the membrane housing industry. Every product of world leading CodeLine brand is conceptualized, designed and manufactured to maximize the efficiency and performance of water purification systems. Housings sizes, ranging from 2.5, 4.0, 8.0, 11 to 16 inch in diameter, are available to suit critical and demanding applications including desalination, reverse osmosis, nanofiltration and ultrafiltration. CodeLine housings fit any make of standard membranes. CodeLine has many firsts to its credit and technologies including Side-port or Multiports, which were introduced by CodeLine, revolutionized the membrane housing industry. CodeLine focuses on developing products that bring the most benefit to its customers including reducing energy cost in desalination and making membrane technology cost competitive. These are just a few of the reasons why most of the major global membrane-based projects use CodeLine. CodeLine has two manufacturing facilities in Goa, India and Suzhou, China, and its products carry the most quality accreditations in membrane housing industry, including ISO, ASME, CE, NSF, and DWI.
Brazilian bioethanol distillery equipped with CO2 recovery plant from Pentair Haffmans Usina Vale awarded a contract for a Pentair Haffmans carbon dioxide (CO2) recovery system to Pentair Water do Brasil. The bioethanol distillery, located in São Paulo State, produces sugar and alcohol and plans to sell the recovered CO2. The CO2 source is a sugar cane distillation process that produces bioethanol. The CO2 recovery system will enable Usina Vale to reduce CO2emissions while generating an additional source of income. The system was commissioned in August of this year with an initial capacity of two metric tonnes per hour. Usina Vale is able to sell recovered CO2 for beverage and food applications. Moreover, the inclusion of a highly efficient Pentair Haffmans gas washer allows them to recover more ethanol from the CO2 stream – thus reducing the product losses. “This is a great step for us,” said Brazilian based Sales Manager Marcelo Rampazzo. “This first Pentair Haffmans CO2 recovery plant in Brazil will open many doors, not only in the distillery market but also in the brewing industry.”
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written by arne zark, rob borgerink
The Dutch Water Board Regge and Dinkel and Pentair X-Flow have successfully started the first Pentair Airlift™ MBR Megablock at the wastewater treatment plant (WWTP) Glanerbrug. An upgrade of the existing conventional installation was necessary in order to meet new capacity requirements and comply with the European Water Framework Directive (WFD).
A six month test period was launched in May during which Pentair is operating the upgraded wastewater treatment plant. The objective is to demonstrate that this new concept is technically the most efficient and cost-effective solution for upgrading existing WWTP’s. In the next phase, planned to start in the fourth quarter of 2011, the capacity will be doubled allowing for more wastewater to be reused. The Pentair AirliftTM MBR Megablock system at Glanerbrug handles 75 percent of the sludge/water separation by treating 79,250 gallons per hour (300 m³/h) with membranes. This results in a significant improvement of the water quality, especially during dry weather conditions, an effluent without suspended solids, and
an absolute barrier for bacteria and viruses. This project is co-financed by the Water Framework Directive Innovation Program executed by AgentschapNL by order of the Dutch Ministry of Infrastructure and The Environment. The Megablock is an integrated solution showcasing cross business know-how and product innovations. These types of integrated solutions allow us to deliver competitive advantage and make it difficult for competitors to follow our lead. Furthermore our customers are receiving the best possible packaged solution knowing that all components work and will be serviced by one company – Pentair.
A clean solution for wastewater
Pump developed for Megablock
treatment Advantages of the Pentair AirliftTM MBR Megablock: 1. Lowest energy consumption The Megablock is able to follow daily wastewater flow fluctuations and switch off units that are not needed. This reduces the energy consumption by 25 to 50 percent compared to submerged systems. This cannot be done with submerged systems as the sludge will settle to the bottom of the tank if the aeration is switched off.
2. Clean solution As a dry solution (sidestream) all modules can be accessed individually. There is no need for manual operation as the cleaning of the membranes is entirely automatic without operator intervention.
During the development of the Megablock, Pentair Nijhuis was involved in optimizing the hydraulic aspects of the design. In the design phase, detailed CFD analyses were performed to minimize energy consumption and keeping the filter load as even as possible (mixing). CFD, an acronym for Computational Fluid Dynamics, is used for making calculations to analyze fluid flows and is routinely applied during the design of rotating machinery. Pentair Nijhuis has considerable expertise in this field. Pentair Nijhuis developed in-line pumps customized for the Megablock application. In addition to minimizing energy consumption, also minimizing floor space formed a main objective in this development process. Axial propeller pumps were the best choice for the capacities and pressure heads required. The pumps developed provide a unique and integrated solution for this specific application.
3. Minimized footprint The ultrafiltration (UF) unit is built in a new skid design, with the modules grouped together. This results in a minimized footprint.
4. Internal circulation/minimized feed flows The specially developed recirculation loop reduces the feed flow to and from the UF unit, which results in smaller pipe dimensions. The highly efficient internal recirculation pump, designed by Pentair Nijhuis, guarantees the right velocities in the individual membrane modules.
5. Modular system The Megablock unit is based on modular segments and is easy to expand. The Megablock can have one to six modular segments each with 36 membrane modules and a nominal capacity of 20,000 gallons per hour (75 m3/h).
6. Unique integrity detecting solution In case of an incident the integrity of the modules can be individually checked without dissembling the whole unit. This is unique for UF membrane units in wastewater treatment.
7. Quick and easy connections The newly developed connections result in a faster total construction time and significantly reduce the time required for unit built-up and membrane loading. knowhow 2011
Transport saline water safely Jung Pumpen “U 3 K(S) special” submersible pump now available for softening plants. written by andreas kämpf
Overhaul Biesbosch pumps for Evides Waterbedrijf written by inge sluijter
Recently, Pentair Nijhuis overhauled the exchangeable pump set of Evides Waterbedrijf, a water company in the Netherlands. These pumps are used by Evides to move untreated surface water from the Meuse River to reservoirs in the Biesbosch. Evides supplies citizens of southwestern Netherlands with drinking water and large industrial companies with industrial water. In addition, Evides is active in wastewater treatment. The pumps are in constant operation and thus need to be overhauled every five to six years. Since it is crucial to maintain the buffer store level in the reservoirs to ensure uninterrupted drinking water production, the pumps cannot be shut down for extended periods. Therefore, Evides Waterbedrijf has an exchangeable pump set that acts as a back-up to the active pumps. The Services department of Pentair Nijhuis overhauled the exchangeable pump set, removed the active pumps from the cellar in situ, and installed the overhauled pumps. It concerned two large pumps, 18.7 feet (5.7 meters) long and 6 feet (1.85 meters) in diameter with a capacity of 1056 gallons per second (4 m3/s) each. The pumps were serviced at Nijhuis Services in Beverwijk, the Netherlands. In addition, several technical improvements were made to the pumps. The project was completed with minimal pump downtime, ensuring Evides could maintain a continuous water supply to its customers. 14
The Biesbosch has developed into a wetland where large groups of water birds find food, shelter and nesting places. Three reservoirs in the Biesbosch, ‘De Gijster’, ‘Honderd en Dertig’ and the ‘Petrusplaat’, store surface water from the Meuse River. The water in these reservoirs undergoes a “natural” flushing process for several months, before it is pumped to various water treatment areas.
Submersible pumps from Pentair’s Jung Pumpen U 3 series have been recognized for decades for their reliability to transport a variety of wastewater. In 2009, Pentair Jung Pumpen launched the “U 3 special”, which provided additional resistance to aggressive substances such as silage juice, liquid fertilizer, and slightly acidic condensate, as well as more abrasive substances, such as drainage water. By using especially high-quality materials, the manufacturer has extended the pump’s range of applications again. The new “U 3 K(S) special” can now safely transport saline water from, for example, softening plants.
* Watch the YouTube-movie of this foam flammability test. Go to YouTube.com and search for “Schuimtest Versteijnen Logistics”.
Fig. 1: The motor casing’s high-quality alloy enables the “U 3 K(S) special” to transport more aggressive substances, for example, from condensate- or softening plants.
Softening plants have become more popular in recent years as they prevent washing machines, faucets, and other household appliances from calcifying. During the water softening process, the plants accumulate salt brine, which – depending on the softening plant’s installation site – must be removed with pumps. The high levels of salt in the water, however, may cause pitting corrosion on the pump components. Chloride ions, contained in salt water, trigger this pitting corrosion. The new “U 3 K(S) special” from Jung Pumpen offers an optimal solution for softening plants. Alloying their motor casing with high-quality stainless steel ensures the safe transport of salt water solutions. The new “U 3 K(S) special” is also portable and can be used as a bilge pump in seawater or brackish water - on boats, for example.
Fig. 2: The new “U 3 K(S) special” can now safely transport saline water from, for example, softening plants. The water is collected in a sturdy container and subsequently discharged over the flood level into the sewers.
Pentair Nijhuis pump units used in expansion foam system New hazardous substance warehouse well protected against fire. written by inge sluijter
An impressive foam flammability test was performed at Versteijnen Logistics’ new hazardous substances warehouse in Tilburg, the Netherlands. The test of the sprinkler and high expansion foam protection system proved that the warehouse is well equipped to fight potential fires. Nijhuis Pompen BV, part of Pentair, supplied and installed the firefighting pump unit to feed the sprinkler system with extinguishing water. “We are a service provider that focuses on thoughtout solutions for transporting and warehousing,” said Jorn Versteijnen, manager of Versteijnen Logistics. “Transporting hazardous substances (ADR goods) requires special attention, which is why we have specialized in this field. We handle these hazardous substances with the utmost care for safety and expertise. This also includes safe storage.” On July 8, 2011, Versteijnen Logistics introduced its new ADR warehouse with an impressive foam flammability test. Niels van den Hurk, Area Sales Manager at Pentair Nijhuis witnessed this test. “For this foam flammability test, the pump unit we installed was used.” he said. “A foam concentrate was added to the water, which enhances the extinguishing capacity for flammable substances. The test showed how the warehouse, with a volume of almost 813,000 cubic feet (23,000 m3), was filled with foam to the
roof in just a few minutes.* We can confidently say that Versteijnen Logistics is well-prepared for fire emergencies at this warehouse, and that environmental and other damages will be kept to a minimum in the event of a fire.”
Membranes maximize waste-to-energy production Get more out of your waste with Anaerobic MBR written by janna dirks
Handling and disposing of waste streams is a basic part of the manufacturing processes, but can be a unique challenge for many dairy, food and beverage plants. Often these production processes yield high-strength waste streams that are costly to treat and dispose of using traditional treatment methods. Pentair X-Flow’s technologies including the Crossflow Membrane BioReactor (MBR) and expertise in wastewater applications are applied to the anaerobic treatment process resulting in a system that produces more biogas in a smaller footprint with lower operating costs. High loads are good Though waste streams loaded with high levels of organic matter are challenging to treat, the anaerobic digestion process feeds off the high-strength waste. “Membrane bioreactors are not new to the food industry, nor are the membrane separation processes in wastewater treatment,” said Pentair X-Flow’s Product Manager Michiel Koelen. “But the concept of combining an anaerobic process with membrane separation is new. It generates much more energy from wastewater while producing high-quality effluent.” The traditional anaerobic process offers a partial solution for high-strength waste, but because these systems have a maximum efficiency of 85 percent, additional effluent treatment is required and biogas production is limited. “Conventional anaerobic processes require a final aerobic step to treat the remaining 15 percent of the effluent that wasn’t digested,” said Pentair X-Flow’s Area Sales Manager Thijs Wolbrink. “This increases the total treatment plant’s footprint and operating costs. The addition
of Pentair X-Flow’s membranes increases the yield of the anaerobic process, resulting in increased biogas production and it improves the quality of the wastewater effluent to a standard comparable to aerobic plants as we can convert almost all organic substance to biogas.”
The process The anaerobic process using Pentair’s X-Flow membranes is typically 99 percent efficient and the effluent can be easily brought to discharge water standard quality or further treated for reuse. The process begins when the wastewater enters the bioreactor via a heat exchanger. Micronutrients are added and the waste ferments, which produces biogas and gradually the organic matter is transferred into biogas. Using Pentair X-Flow’s Anaerobic MBR the liquid in the fermenter is cycled through the membrane separation plant, which assures that all the sludge remains in the reactor, which increases the efficiency of the system.
High gas yield equals cost effectiveness As almost all organic matter in the fermenter is turned into gas – methane and carbon dioxide – the biogas
yield is higher than in comparable processes. Energy recovery may be 15 to 20 percent higher than in conventional anaerobic wastewater treatment. Moreover, the costs for wastewater discharge tend to be zero given the “purity” of the effluent. “The system pays off mainly from the increased yield of fermenter gas and in addition to that there is a significant reduction of the post-treatment costs” Wolbrink said. “The gas can be used in the steam boiler or it can be introduced into the local grid after purification.” In conjunction with partner Biothane, Pentair X-Flow’s Anaerobic MBR is installed in anaerobic systems in the United States and Poland, which is currently under construction. In addition, several pilot tests are being executed in various market areas worldwide.
Toine Toten, Product Manager CO2 systems (right) and Johan Jongman, engineer
Biogas upgrading offers new possibilities written by toine toten
Pentair Haffmans recently supplied a biogas upgrading installation to the Hoogheemraadschap Hollands Noorderkwartier (HHNK) wastewater treatment plant in Beverwijk, the Netherlands. Here, biogas generated from sludge is upgraded to biomethane and carbon dioxide (CO2), thus producing two valuable products. In the wastewater treatment process water and sludge are separated. Biogas can be produced from the sludge that remains after the separation. In Beverwijk 70.6 million cubic feet (2,000,000 m3) of biogas are generated per year in three fermenters. Biogas can only be used efficiently when it is deployed near the place of its generation, for example in combined heat and power units. A better alternative is to upgrade the biogas to biomethane, which can be fed into the natural gas grid and thus contributes to an even more promising energy mix.
A model for future projects HHNK selected Pentair Haffmans’ biogas upgrading system to replace the existing one. Pentair Haffmans designed a compact solution, housed in two preassembled 40-foot containers that were placed at HHNK near the biogas fermenters. The system is scheduled to go into operation before the end of the year. HHNK and Pentair Haffmans calculated that after startup more than 42.4 million cubic feet (1,200,000 m3) of biomethane can be produced per year at Beverwijk. This is enough to supply 700 households for a year. Because the biomethane has the same specifications as natural gas it can be fed into the national gas grid. The
Dutch company Biogast provided its Bio2Net feed-in station to connect the system to the grid and guided the project through all procedures and permits. “Beverwijk started as a pilot project and is now developing into a profitable installation, which is financially selfsufficient, even without governmental subsidies,” said Fred Duineveld, head of HHNK’s Beverwijk Beheer Waterketen division. “Thus, it has the potential to serve as a model for additional projects and to promote the benefits of biogas upgrading in the Netherlands and beyond.” Pentair Haffmans state-of-the-art biogas upgrading technology offers two additional economic benefits, which are unique in the industry. The technique used by Pentair Haffmans makes it possible to recover 100 percent of the biomethane, so the environmentally harmful ‘methane slip’ that usually occurs when other upgrading techniques are used, is completely eliminated. Besides ecological benefits, this also means that more biomethane can be fed into the grid. In addition, Pentair Haffmans’ biogas upgrading installation allows the customer to recover the CO2 by-product. This results in an extra source of income as the recovered CO2 is foodgrade quality and can be sold for use in greenhouses or in food and beverage applications. (See additional text box)
Continued on page 18 >> knowhow 2011
wat e r
Biogas production and upgrading
Continued from page 17 >> Biomethane for the tank
Not all of the biomethane produced at Beverwijk is fed into the grid. Part of it is used to fuel HHNK’s car pool. The company placed a filling station on its premises, next to the upgrading system. Here the biomethane is pressurized so that it can be used to fill the cars’ tanks, thus providing a cost-effective alternative to ordinary fuel. Currently, HHNK has 19 biomethane-fueled cars. According to Duineveld, HHNK plans to add more than 50 biomethane-fueled cars in the coming years. At that point, seven percent of the biomethane produced at Beverwijk will be used to fuel cars. Meanwhile, other water authorities in the Netherlands have shown interest in running their cars with the biomethane produced at Beverwijk. The Beverwijk installation is a promising example for a flexible, sustainable and efficient use of multiple types of resources. “This project will gain a lot of attention as it shows the great potential of sustainable energies and a variety of options of how to deploy them in the best possible ways,” Duineveld concluded.
Waterfalls written by francois imhof
The new Waterfalls range from Pentair Residential Filtration consists of three different types of softeners, which are completely equipped and ready to be installed. Assembled from Pentair components, each softener was made in Europe and developed for customers who wish to promote a fully packaged solution. Aimed at supplying high quality water across the residential environment, each Waterfalls softener guarantees that every end user will benefit from all advantages that only a softener can provide, which include an unrestricted water flow from a free from calcium deposits shower, reduction of heat losses on heating elements due to formation of scale and a reduction of about 50 percent of soap, cleaning chemicals and detergents usage.
Unique biogas upgrading technology Biogas is a general term for gas produced from anaerobic fermentation and primarily consists of a mixture of methane (CH4) and carbon dioxide (CO2). Pentair Haffmans’ biogas upgrading technology makes it possible to recover 100 percent of the CH4, so the environmentally harmful ‘methane slip’ that usually occurs during this process is completely eliminated. This results in a higher CH4 yield and no emission of the harmful CH4 greenhouse gas. In addition, the CO2 by-product is recovered and can be sold as a valuable product. In Pentair Haffmans’ process, after the ammonia is washed out of the biogas, the biogas is cleaned by a Norit activated carbon filter and then the cleaned biogas flows through a membrane installation where it is separated into CH4rich and CO2-rich gases. The CO2-rich gas is then fed to the CO2 recovery system. Here, it is liquefied and the liquid CO2 flows through a stripper column where the remaining CH4 is removed and fed back to the membrane unit. The liquid CO2 flows out of the stripper and can then be stored in a buffer tank. Pentair Haffmans’ long-term experience in CO2 purification and liquefaction systems guarantees the quality of this process.
Similar to actual waterfalls which vary in height, all three softeners have been positioned with different equipment levels and performances in order to cover the various needs of the end user: Silver Falls is an entry level offering, providing an attractive and competitive solution Harmony Falls is ideally positioned as a mid-range and features a good balance between equipment level and price level Angel Falls is the highest quality offering and includes comprehensive equipment for an ultimate performance Customers will also have the opportunity to customize the softeners with different options, in order to meet their expectations. The Waterfalls range offers an extended service to those customers wishing to supply the full Pentair solution, with reliable and customizable products.
Pentair Industrial Driflex – An innovative, high capacity oil conditioning system written by lisa stich
The Pentair Industrial® team partnered with Turbo Filtration Corporation (Mobile, Ala., USA) to replace its traditional, vacuum dehydration systems with the state-of-the-art Driflex™ Oil Conditioning System. Turbo Filtration is a service provider for oil conditioning in many industries, including power plants and industrial sites. The partnership between the two companies has proved to be a win-win for both sides. Almost all electrical power on Earth is produced with a turbine of some type. A turbine is a rotary engine that extracts energy from a fluid flow and converts it into useful work. Turbines operate at a high speed and a key component of these systems are rolling elements and pressure surfaces which rely on a clean layer of oil to separate them. Oil quality deteriorates throughout use due to both particulate and moisture contamination. Reduced oil quality exhibits itself in many forms including rust, corrosion, oxidation, additive depletion, changes in viscosity and more. All of these negatively affect machinery efficiency and component life so oil quality must be addressed through effective oil conditioning programs. Turbo Filtration Corporation (TFC) provides lube oil system cleaning services to the power generation and other industrial markets. They have a long history and outstanding reputation in the industry. By helping to maintain absolute system oil cleanliness, TFC assists its customers in maximizing equipment life, minimizing system downtime and optimizing profitability. Traditionally, TFC and the industry as a whole have employed vacuum dehydrator oil purification systems for oil remediation and ongoing conditioning. This method essentially uses both heat and pressure to vaporize water, evaporating it into the air. A significant disadvantage to vacuum dehydration is that it requires the oil to be heated. This can damage oil additives and
cause process-contaminating breakdown products. Some vacuum dehydrators also contain filtration to remove particulate contaminants. Others do not and thus particulates remain in the oil after dehydration. The complexity and total cost to operate vacuum dehydrators can make outright purchase and permanent installation prohibitive for some customers. Companies may instead rent the units from firms such as TFC, or hire firms like TFC to periodically bring in a skid-based system and operator to perform a cleaning. Alternatively, the Pentair Industrial Driflex Oil Conditioning System utilizes particulate filtration and high efficiency membranes to thoroughly remove both solid contaminants as well as free, emulsified and dissolved water from the lubricant. The Driflex system has numerous advantages over vacuum dehydration methods, including: It offers customers the ability to achieve and maintain the best oil quality possible on a continuous basis, on their own remediation schedule or in response to an upset. It is compact and cost-effective enough to install permanently for dedicated use on a particular reservoir, moved for periodic use on reservoirs throughout a facility, or work as part of a third party service agent’s standard rental program. It does not require dedicated manpower to operate and a fully unattended operator version is available. It is conveniently sized and easy to install and maintain – no moving parts beyond its pump and no flow or level controls to continually adjust. It is available in flow rates up to 32 gpm to serve a wide variety of applications within a power plant or industrial site.
With its simple and reliable operation, the Driflex Oil Conditioning System is designed to enhance equipment performance, protect valuable machinery and optimize service life. knowhow 2011
p o o l & s pa
New systems, better application of technology, and progressive thinking bring sustainability to residential swimming pools
written by jose guillen
In the past, a pool was a blemish on an otherwise green home. The water waste, energy consuming pool pump, and chemical usage ran in direct opposition to the tenets of sustainability. But with recently adopted technology and a pool industry ready to move toward more holistic sustainable methods, it is possible for the pool buyers to own a restful water retreat without the environmental guilt. The implications of a sustainable pool industry are huge. According to the Natural Resources Defense Council (NRDC) in its report, “Synergies in Swimming Pool Efficiency”, in 2010 there were 4.5 million inground pools in US, which use $1.1 to $1.6 billion of energy per year.
Pentair Water Pool & Spa is making a strong commitment to develop the most environmentally responsible products available to pool users. The Eco Select™ brand is the cornerstone of Pentair Water Pool & Spa’s green program aimed at meeting the needs of a growing number of pool owners – simultaneously saving money while limiting their environmental impact. Pentair Water Pool & Spa’s Eco Select™ brand identifies its most eco-friendly products that contribute to a more environmentally responsible equipment system.
Eco Select IntelliFlo® Pumps The typical pool pump used today is single-speed. Unfortunately, it runs at the same tempo even when it’s not necessary – resulting in wasted energy and greater noise. With this in mind, Pentair Water Pool & Spa developed the Eco Select IntelliFlo® variable-speed pump. At the US Las Vegas IBS Show in January 2010, an Eco Select 180 watt IntelliFlo® pump demonstrated annual energy savings of US$ 1,100 versus a traditional 1.9 kW single-speed pump. The NRDC estimates that in a community with a fourmonth pool season, upgrading from a single-speed to a variable-speed pump can save the average homeowner $350 a year. The organization conducted a study on Pentair’s Eco Select IntelliFlo® variable speed pump and noted that the system reduces energy use by up to 90 20
percent. Pentair Pool & Spa reports customer savings as high as US$ 1,360 annually. Savings can be further improved when larger, straighter pipes; sweep elbows; lower pressure backwash valves and oversized filters are used. Skip Phillips, owner of US based Questar Pools and Spas, was an early adopter of variable speed pool pumps and calls them a success. “My pool has filtration, a 14 kW PV system, and 1/2 horsepower pump. Everyone said I would need more power to make it work,” he says. “The variable frequency keeps the operating costs down. You’re talking about an eight-hour turnover where the equivalent water is filtered and then it’s stagnant for 16 hours. With in-line sanitation and low chemicals and the variable speed pump, you can run at a low flow rate for less money.” In addition to the Eco Select IntelliFlo® variable speed pump, the Pentair Water Pool & Spa suite of environmentally friendly technologies includes the Eco Select IntelliBrite LED lighting system and the Eco Select IntelliPool™ and IntelliTouch® automation systems that automatically limit the operation of pool equipment to lower cost energy usage or “off-peak” times-of-day.
Pentair Porous Media’s HRT™ sour water pre-treatment process for refineries written by Ryan Bennett
In today’s oil refineries, water is prevalent throughout the complex process of turning crude oil into gasoline, diesel and jet fuels. Whether it is early in the process as wash water introduced in a desalter or later as a by product of hydro-treatment in diesel production, water is integral to refining fluid process streams. A by-product of these efforts is sour water or waste water contaminated with hydrogen sulfide and ammonia. Before it can be reused elsewhere in the plant or released safely into the environment, sour water must be treated to reduce contaminants. This is done by diverting sour water from its current process stream and sending it to a sour water stripper where the pollutants are removed or “stripped off”.
Sour Water Samples (1) Unfiltered Sour Water Feed (2) Sour water after particle filter
(3) Sour water after single pass through HRT™ hydrocarbon separator (4) Recovered Hydrocarbon/Organics
Sour Water Strippers frequently encounter heavy hydrocarbon or oil contamination from the incoming sour water feed. Oil emulsion in the sour water feed is known to cause instability within the sour water stripper and downstream sulfur recovery units (SRU) which recover elemental sulfur from gaseous hydrogen sulfide. This instability can result in shutdowns, furnace failures and sulfur emissions. Most refineries seek to mitigate hydrocarbon ingress into the sour water stripper and downstream SRU through pretreatment with conventional flash drums and large residence time tanks.
Pentair Porous Media’s HRT™ is an innovative hydrocarbon removal process that serves as an alternative to conventional sour water stripper pretreatment technology. The HRT™ process couples Pentair Porous Media’s optimized element technology for solids removal with high performance hydrocarbon separation techniques. Where conventional approaches to hydrocarbon removal such as flash tanks and residence time separators have proved largely ineffective, the HRT™ process creates a balanced system that effectively addresses hydrocarbon and particle contaminants and allows the refinery operator to achieve both optimal process stability and environmental compliance. In short, effective contamination control results in effective process and environmental controls.
A U.S. refinery was experiencing high change out rates on their pre-treatment particulate filters and liquid separator elements prior to the sour water stripper. It was initially thought that the high contaminant loading was due to start-up of a new SRU downstream in the process. The high rate of fouling continued for several months with particulate element change outs varying from once a day to upwards of several times per day and liquid separator element change out occurring every three to seven days.
By moving to the HRT™ hydrocarbon removal process, the plant was able to significantly reduce the operational cost of their sour water stripper pretreatment process. Prior to converting to the HRT™ hydrocarbon removal process, the plant was predicted to spend $250,000 annually in pretreatment. After upgrading to HRT™ the overall operating cost of pretreatment was less than $75,000 annually. The refinery benefitted from superior pretreatment while simultaneously reducing operating costs and increasing throughput downstream.
Pentair Südmo’s Friedrich Elz (left) and Konrad Nuber at the CSL Behring site in Marburg.
Sustainable progress in the therapy of coagulation factors written by friedrich elz
The company CSL Behring invested about 20 million euro in a new bio-technology plant at its site in Marburg, Germany. Currently the plant is used for the purification and formulation of re-combinable protein therapeutic drugs. CSL Behring also can process other biologic products due to its production flexibility. The central modules of the complex process technologies were planned, delivered and commissioned by Pentair Südmo. CSL Behring is a world leader in plasma protein based bio-therapeutic drugs. The company produces and globally sells a wide range of plasma based and recombinable therapeutic drugs. CSL Behring’s therapeutic drugs are used in cases where the coagulation system has been damaged including Haemophilia and von Willebrand syndrome, immune deficiency diseases and treatment of patients with hereditary pulmonary Emphysema. Other products are used in heart surgery, organ transplants, burn treatment, and prevention of haemolytic illnesses in newborns. CSL Behring reports that it has achieved sustainable progress in the therapy of coagulation factors with the commissioning of the new chromatography department at the Marburg facility. In May 2009, Pentair Südmo received the order. The project was completed in November 2010. Pentair Südmo was responsible for the following projects and, as a result, for the bulk of the current process technology.
Buffer production Mobile containers for product or buffer Panels and cooling and heating units CIP (Cleaning in Place) plant for mobile containers Water for injection storage, recipient vessel and distribution Supply with sterile air, pure steam and WSO (desalinated water) Process description/documentation for programming of the control and certification according to GMP or FDA
into the buffer recipient container via a distribution panel. CSL Behring uses either “bags” or two mobile containers in case of smaller buffer quantities. The buffer production is installed in a technical area, where all modules needing maintenance are located. This technical area is hermetically sealed from the actual production area and is built as a class C clean room. The process vessels are installed as part of this clean room wall so that related equipment can be operated from the production area.
Mobile container as “Stand alone“ process plant Automatic buffer production The largest part of the project was the automatic buffer production. The unit consists of three buffer preparation containers with volumes of 528, 264 and 132 gallons (2,000, 1,000 and 500 l). In addition, there is a buffer storage container with 528 gallons (2,000 l) and a caustic soda recipient vessel with a volume of 264 gallons (1,000 l). This recipient vessel is supplied with a caustic soda container station fitted with a dosing pump controlled by conductivity. The hydrochloric acid station is also equipped with a membrane dosing system. These pumps allow single stroke metering so that dosing is accurate to 10 ml and the pH-value of the buffer can be adjusted very accurately in small steps. During production the operator first selects, via the touch panel, the formula for preparing the buffer. The allocated water quantity is then fed into the preparation container. The operator can add salts by hand, possibly followed by a stirring step or by bringing the preparation to the right temperature. The pH-measuring system monitors the pH-value of the water solution and controls the addition of base or acid via this parameter, depending if an alkaline or acidic buffer has to be prepared. The three preparation containers can be released
The mobile containers operate as an independent process plant to be filled with the starting products and to be connected to the chromatographs or filter units by hoses. They serve as product storage and transport container as well as buffer recipient containers. The mobile containers have capacities between 13 and 80 gallons (50 – 300 l) and are installed on a mobile frame with fixed pipes. This design allows several process variations. They are pressure and vacuum resistant, fitted with a double shell and can be cooled and heated. They are fitted with magnet stirrers and have a number of connections for compressed air, sterile air and product feed. Central for the operation of the mobile units are five distribution panels. All panels are equipped with connections for Water For Injection (WFI), pure steam and a sterile air. Connections for buffer and base are also included. Drains for the product with conductivity and temperature control were provided. A heating and cooling system with each panel allows the mobile containers’ temperature to be raised or lowered. The nominal temperature of the product can be controlled within a wide range.
The container itself does not have an on-board controller; but can be connected via a bus or electrical cable to a panel. All functions including measuring instrumentation for pressure, temperature, conductance, or pH can be processed, controlled, monitored and documented in the control circuitry cabinet.
CIP plant and final rinse The CIP plant operates according to the principle of total loss cleaning and is exclusively allocated to the mobile containers. For this purpose the mobile container is connected to the CIP via a distribution panel. Cleaning is automatically carried out according to stored programs.
Both circuits can be cooled by heat exchangers, from a circulating temperature of 176 - 181 degrees Fahrenheit (80 to 83 degrees Celsius), to the desired application temperature. The WFI system is also used for rinsing the buffer preparation and storage container as well as the mobile containers. This final rinse is independent from the CIP plant. The WFI circuit has been equipped with its own automation control system. This also includes the complete monitoring, permanent in-line monitoring and documentation of the relevant parameters like temperature, flow, conductivity or total organic compounds.
ing and heating units. The connecting pipe work was installed later at the facility. All piping in contact with product was recorded, marked and every relevant welding parameter was documented by the assembly personnel. About 10 percent of the welds have been checked by endoscope. All other important factors, like measuring systems or sanitizing, have also been explicitly qualified. In this way, CSL Behring was not only given an extremely modern plant, but also â€œreliableâ€? process documentation for the important upcoming qualifying audit.
WSO is used as the primary cleaning medium for prerinsing and the chemical make-up water. The caustic soda solution concentrate is metered from a base station up to a specified conductivity. The temperature of the cleaning media can be set and controlled using the integrated heat exchanger. The pre-rinse water flow is directed through the mobile container. The specified rinsing water volume is the control parameter of the cleaning duration. The prerinse water is routed to drain, however the chemical wash is circulated. The final rinse is carried out directly from the hot WFI network through the CIP plant and distribution panel to the mobile container. The CIP offers the possibility to sanitize itself via a very pure steam connection. In addition, there is a pure sanitizing distribution panel in a neighboring room to which a mobile container can be connected and a sanitizing program can be carried out.
WFI supply from a new installed ring main Water For Injection is water with extremely high purity. A processing system was installed on the sixth floor of the production building in Marburg. Water for use in the new chromatography area is brought to the fourth floor using piping ducts and supplied via the newly installed ring main with two sub-loops. One of the sub-loops is part of the buffer preparation and the other supplies the distribution panels necessary for the operation of the mobile process containers.
The order also included the supply system for the white media. White media include pure steam, sterile air and WSO water. All supply channels installed are constructed from high-quality stainless steel and were documented during assembly.
High requirements for material, implementation and documentation The bio-technology plant is controlled by two PCS7 control units operating with a batch formula administration. Everything is visualized and operated via touch screen panels. Pentair SĂźdmo supplied the hardware and all process descriptions with all sequences and parameters. The software was programmed on this basis. The plant itself was, as much as possible, pre-manufactured as a unit. Some examples for this are the CIP plant, distribution panels, the containers, and the coolknowhow 2011
The best choice for today’s brewer written by mark mol
Beer filtration and stabilization are the final steps in the brewing process before the beer is stored in the bright beer tanks prior to packaging. After this filtration step brewers must be absolutely sure that the beer tastes fresh and is free of yeast and turbidity. For this, Pentair’s third generation Beer Membrane Filtration (BMF) system, the BMF-18, is the best choice to assure the beer quality and to offer major advantages for sustainability and flexibility compared to traditional filtration methods. Beer Membrane Filtration vs. Diatomaceous Earth Filtration BMF uses membranes instead of a diatomaceous earth (DE) to remove unwanted turbidity from the beer. This provides immediate environmental benefits as the DE can only be used once and then must be disposed, whereas membranes are used for several years. In addition, the health and safety risks caused by DE are eliminated. With BMF, brewers experience a consistent beer quality during a filtration run and produce a beer with longer shelf life and better taste stability. BMF also brings flexibility into the production as the system guarantees a continuous operation as well as fast and easy brand changes.
Innovations of the BMF-18 The BMF system incorporates two fundamental sustainability principles as it requires less stainless steel while providing a higher capacity and doesn’t use disposable or non-recyclable resources.
After it was first introduced in 2009, the BMF-18 continued to undergo development. “Product improvement is on-going,” said Pentair’s Dick Meijer. “We are constantly working to improve efficiency for our customers and at the same time contribute to a more sustainable environment.” The older generation BMF systems required back flushing that was executed five to 10 times before a more extensive cleaning procedure. With the BMF-18, the back flushing is a soak flush that reduces water consumption by 50 percent per flush while achieving the same result. Recent product enhancements have improved the ability to reuse chemicals in the cleaning procedure, which reduces the chemical consumption by 30 percent. Both cleaning improvements are part of any BMF-18 delivered today and are available as retrofit packages for existing filter lines. The third improvement of the BMF-18 is that it can be designed to run either in a batch or in a continuous operation mode, depending on the brewery’s specific requirements. With continuous operation, two sets of membrane filter skids alternate; one set is in filtration mode while the other one is in cleaning mode. Due to continuous operation systems can be sized smaller which helps to reduce CAPEX. These innovations make BMF-18 a more sophisticated product that offers a solution for the ever-increasing demands in the brewing industry in terms of economy, quality and sustainability for breweries of all sizes.
The influence of novel brewing raw materials on Beer Membrane Filtration
Since the introduction of Beer Membrane Filtration (BMF) much information has been gathered about the influence of the malt quality on filterability. All the constituents in the beer that influence filterability, find their origins in the ingredients used and the brewing process. Adding a certain amount of barley to malt during brewing or even using 100 percent barley in combination with enzymes is gaining more interest. Pentair X-Flow has recently investigated the effect on beer membrane filterability of these raw materials. In some breweries, small amounts of barley are already added to the malt prior to mashing. The main driving forces for this are lower costs and carbon footprint, and the better availability of barley. The amount of barley that can be added is limited by the reduced enzymatic activity of the un-germinated barley. To overcome this problem, exogenous activity can be obtained by adding enzymes during mashing. With the correct enzyme mixture, beer can even be made from 100 percent barley. It has been shown that the product results in a good drinkable beer. The question that remains is, ‘how does it affect the filterability of the beer?’
1,2 50/50 Blend
Transmembrane pressure (bar)
0,6 100% Barley + Ondea® Pro
ing the maximum allowed TMP increases significantly at the variant using 100 percent barley. In figure 1, the data of a blend of 50 percent malt and 50 percent barley is given as well. Also here the filterability could be im-proved compared to the 100 percent malt variant. Blending after fermentation is an option for the brewer to tune the taste and body of a beer. In Figure 2, all the data of the first comparison trials is given. The first periods are normalized to the first period of 100 percent malt. What can be clearly seen is that the fouling rate reduces with higher barley loading, resulting in an increased filterability.
Normalized 1st period
written by joris de grooth
1,00 0,50 0,00
20% Barley, 80% Malt
85% Barley, 15% Malt
Figure 2: Normalized filterability of the different trials. In the case of 100 percent barley, the first period is estimated to 32 hours.
Conclusion The research clearly shows that substituting barley for malt has a positive effect on the filterability of the product. The enhanced filterability is most probably due to the better conversion of the raw materials during brewing. It also shows that the fouling rate does not depend solely on the concentration of some specific components, but much more on the nature and specific interactions of the different components.
10:00 12:00 14:00 Filtration time (hh:mm)
Figure 1: Filtration data from a 1 hl BMF pilot plant of 100 percent malt, 100 percent barley and a 50/50 blend of the two.
For this research, several beers were brewed with various ratios of barley and malt. For malting, the same barley was used as for brewing.
This work was done in close collaboration with Dipl.Ing. Florian Schüll from the Center of Life and Food Sciences Weihenstephan and Dr. Sven Schönenberg from Novozymes. To review the detailed research paper of this abstract, please go to www.cptholding.com/bmf
Results In Figure 1, the transmembrane pressure (TMP) increase during filtration is shown for three different beer types (100 percent malt, 100 percent barley, 50/50 blend). In all cases, the same barley was used. It can be clearly seen that the filtration time till reach-
b e v e r ag e
Since opening its new remote service facility in September 2011, Pentair Haffmans serves more customers even faster than before. Pentair Haffmans meets the needs of customers who require a secure tool to reduce downtime and operating costs. Remote service is performed from a control center via a data connection line and instantly puts Pentair Haffmans’ experts online with carbon dioxide (CO2) recovery systems worldwide. “Remote service has become an integral part of our Service Level Agreements,” said Paul Verschuren, Product Manager Service at Pentair Haffmans. “If requested by the customer, the CO2 recovery system is equipped with a web-based eWon-router. In case of questions or technical issues, remote service enables us to gain a direct and detailed insight into the plant performance to identify the cause of the problem. This offers great benefits for both sides, including a very fast response time.”
However, remote service is more than a tool to troubleshoot performance issues. It is a reliable service to schedule preventive maintenance – an aspect that is becoming increasingly important. Pentair Haffmans sells and services its products in more than 150 countries worldwide. Based on many years of experience in the area of total CO2 management, the company’s professional service team has gathered extensive knowledge in the intricacies of servicing and maintaining CO2 plants. An increasing number of customers take advantage of this vast knowledge. “Remote service enables us to track the performance of a CO2 system, no matter where it is located,” Verschuren explained. “If we diagnose a deteriorating parameter, we are able to intervene before a system failure occurs. Moreover, if parts have to be exchanged, Pentair Haffmans original spare part packages ensure a fast availability of high-quality spare parts. All of this contributes to increased uptimes against the lowest total cost of ownership.” Pentair Haffmans continuously strives to offer its customers a ‘best of the best’ service standard through custom-made service plans. These range from mainte-
nance contracts to comprehensive service level agreements including remote service, data monitoring, data trending, stock consulting, and 24/7 technical support.
Direct contact with specialists Fast diagnosis and troubleshooting Increased uptime Lower total cost of ownership
Remote Service maximizes CO2 system availability
f o o d s e rv i c e
Pentair’s Everpure Claris responds to market demands for high volume water treatment solutions written by tony monks
With 65 percent more capacity than the original Claris™ system, the Claris XXL is available for steam and combi ovens and iced tea brewing. Pentair’s Everpure® recently introduced an extension to its line of popular Claris Water Technology systems, a family of filtration and softening cartridges that provides both unpleasant taste and odor reduction for hot beverages, and innovative scale control for foodservice equipment. The new Claris XX-Large Filter Cartridge (Claris XXL) extends customized scale prevention capabilities beyond standard coffee and espresso applications to include boiler and direct injection steam and combi ovens, and iced tea brewing equipment.
A simple solution to a costly problem Untreated hard water can be highly damaging to brewing and steam equipment by producing limescale which, over time not only significantly increases the equipment’s energy consumption, but also can cause increased service and life cycle costs. Some filter systems only control minerals by adding a scale-inhibiting agent that keeps the minerals suspended in the water. Claris selectively targets carbonate hardness using special ion exchange resin so that scale formation is almost completely eliminated. This reduces the need for costly delimings and service calls. In addition, the Claris blends a small amount of filtered water with the softened water, to create a “buffer” that keeps the water’s pH level from becoming too acidic which can cause corrosion, and negatively effect the taste of coffee, tea and other beverages. And because Claris is a quick change system with a cartridge that is easily replaced when it expires, there’s no need to add salt as with many softening systems, a task which is often neglected by staff.
Smart chemistry and ingenious engineering The new Everpure Claris XXL helps operators find the right water quality balance to capture the specific taste profile they desire. Specific features include: A 5-stage filtration process: • Prefiltration • Carbonate hardness adjustment • Fine filtration • Highly efficient carbon block removes unwanted contaminant, unpleasant odors and tastes • Solid membrane filter removes particles down to 5 microns for a fine water polish
Consistency – DUOBLEND™ bypass valve technology ensures a consistent and precise carbonate hardness level. Independent of the flow rate, the operator always gets the same water quality
Excellent contaminant reduction including scale-causing carbonate
Adds nothing to the water – Claris is unlike many scale-inhibiting systems that add polyphosphate and ion exchange softeners that add salt to the beverages. Salt softening systems require salt replenishment and when a traditional softening system regenerates, salt gets washed into the ecosystem along with the wastewater. The Claris softens without salt thus adds nothing to the water and no salt or water is sent to drain.
A great alternative to reverse osmosis The system also allows the operator to tailor the hardness to match the desired water recipe, a unique fea-
ture of the Claris design. This provides the benefits often associated with reverse osmosis blending of filtered and pure permeate water. The Claris blends filtered water with water that has had the carbonate hardness removed. Unlike reverse osmosis, there’s no need for power or a drain, there’s no water waste and there’s no need for a floor tank. “The Claris XXL is an excellent option for operators who want control of their water hardness, but don’t want the expense, space requirements or additional maintenance associated with reverse osmosis,” said Tony Fischer, product marketing manager of Pentair Everpure. “The Claris provides consistent and precise adjustment of the carbonate hardness, with the ease and simplicity of quick change point-of-use filtration.”
b e v e r ag e
Pentair Haffmans’ c-TPO Optical oxygen measurement at its best written by peter houwen
Every brewer wants to ensure that customers enjoy the carefully brewed beer, bottle after bottle. Contributing to an excellent beer is the fixed amount of carbon dioxide (CO2) and a minimized oxygen (O2) content. Pentair Haffmans’ Inpack TPO/CO2 Meter, a state-of-the-art product solution using optical O2 measurement technology, provides an advanced analysis of both Total Package Oxygen (TPO) and CO2. To ensure that bottled beer is of consistent high quality it is crucial to pay extra attention to the product after the filling line. This is where Pentair Haffmans’ Inpack TPO/CO2 Meter, type c-TPO, shows its advanced innovation. Unlike conventional methods, the c-TPO measures both CO2 and O2 content as the bottle is filled with the beer remaining in the package. The c-TPO pierces a hole in the bottle cap and the sensor enters the package through this hole.
Differentiated O2 measurement allows deeper insights
One important fact that must be taken into consideration is that a bottle is not filled with beer to the rim. The headspace between the beer and cap is not filled with air, but with an inert gas, usually CO2, which is present in the beer. There are many opportunities after fermentation, during processing as well as during bottling for O2 to enter the beer, which is why the brewer encounters O2 in the bottle; in the beer and in the headspace. Oxygen pick up into the beer itself can happen during filling and in the headspace during bottle capping. Considering the fact that O2 in the bottle causes severe damage to the beer, it is highly important to know where the O2 originates from – the headspace or the liquid. Up to now, it was impossible for the brewer to pinpoint the source of the O2. Pentair Haffmans proven optical O2 measurement technology now makes this possible. The c-TPO’s advanced sensor provides a differentiated measurement of headspace oxygen and the O2 content in the liquid. This helps to identify the Total Package Oxygen (TPO) source. Pentair Haffmans’ c-TPO allows brewers to obtain a complete picture of the filling process. In case of a deviation in the O2 level, fast and effective intervention is possible, providing the highest process security for the filling process.
f o o d s e rv i c e
Pentair Foodservice helps Stirrings, LLC produce simply better cocktails
written by kevin carlson
Established in Nantucket , Mass., USA, in 1997, Stirrings is an innovative provider of premium cocktail mixers that is redefining the way people enjoy cocktails. Believing that better ingredients are the only way to achieve a better tasting cocktail, Stirrings uses the finest real fruit juice, triple purified water and cane sugar to create a diverse collection of super-premium Cocktail Mixers, Rimmer® brand cocktail garnishes and Classic Bar Ingredients. Its customers are used to ordering premium Stirrings mixers in cocktails such as Jose Cuervo Especial® Gold Margaritas and Jeremiah Weed® Sweet Tea Lemonade at their favorite bar or restaurant but, thanks to Stirrings’ recent partnership with Pentair Foodservice, those drinks are now available “on tap” like many beers and even some wines are today.
Pentair Foodservice has been a long-standing supplier of SHURflo® pumps to Stirrings’ parent company, Diageo® Europe, for wine delivery and other applications. Given Pentair Foodservice’s fluid solutions expertise, Stirrings approached them to help develop the new “Cocktails on Tap” program. The goal being to design and produce a cost-effective system that dispenses a consistent, ratio-controlled spirit and cocktail mix – finished drink – that is ultimately delivered via a traditional beer-style tap. Once Stirrings finalized its product specification, the Pentair Foodservice team’s design ideation process revealed that the majority of the key components required to build the tap-based system already existed within Pentair’s “tool kit”, among them: SHURflo’s modular filtration system platform was modified to create a spirit well (each holds up to three liquor bottles in parallel). SHURflo’s bag-in-box (BIB) rack holds the BIB-style packaged cocktail mixes. Two SHURflo BIB pumps and two Porous Media Air Vents form the fluid delivery system. A shut-off mechanism was created by modify ing a Residential Flow Group strainer product.
Cocktails on Tap Program – Stirrings Customer Benefits
unique design benefits the bar operator because it makes the system sanitization process easier and results in less product waste (i.e. more cost savings) given that the spirit and cocktail mix remain separate until the point of dispense. Pentair Foodservice’s engineering group also developed a new tap specifically for the Stirrings project, and its unique dual fluid stream design is potentially patentable intellectual property for Pentair. Stirring began marketing the “Cocktails on Tap” system in North America in June 2010 and both Pentair Foodservice and Stirrings are excited about its potential for market success. Pentair’s Foodservice team had more than the usual reasons to commemorate the launch of this inventive new product as Stirring’s June purchase order represented the highest dollar total for a single order ever received in Hanover Park location’s history. Now that’s something to celebrate.
The Pentair Foodservice team simply configured these items together in a new way. Its innovative thinking extended beyond putting what was essentially “puzzle pieces” together in a new and creative way. Pentair’s
Improved control over beverage inventory and related costs Higher, more consistent beverage gross profits Faster dispensing and intriguing “style factor” promotes increased cocktail sales More controlled dispensing capability reduces spirit/mix waste and expense Eliminates concern over incomplete pour sizes at the end of a bottle Conserves space and manpower by eliminating both full and empty bottle stock from the bar area Spirit/mix reserves ensure bartenders will not run out of product during their shift
Successful footprint reduction strategy implemented with Pentair Südmo
Ganter Brewery’s new cold block on smallest possible area even more effective than before
Katharina Ganter Fraschetti
written by hans lange
The Ganter Brewery in Freiburg, Germany has implemented an efficient concept for a new cold block in cooperation with Pentair Südmo that emphasises “quality not quantity”. This “size reduction concept” cuts energy consumption and total operating costs allowing brewers to react to changing market requirements and run cost effective production even at lower output levels.
From left: Ganter’s Managing Director Detlef Frankenberger, Helmut Joas, Pentair Südmo, Markus Dessecker, Ganter Brewery, Helmut Wittmann, Pentair Südmo’s responsible project engineer
At the Ganter Brewery, Pentair Südmo was responsible for the entire concept, implementation and commissioning. The goal of the new plant design was to meet the demand in terms of energy and cleaning agent consumption, while minimizing wastewater quantities in a reduced footprint. In addition to saving energy and total operating costs, production area was freed up for other purposes. Construction of the plant took only six months and after production started earlier this year positive results were seen in just a few weeks.
combined in a minimum footprint, including yeast handling, connection of the tank farm for fermentation and storage of unfiltered beer and after filtration connection of the Bright Beer Tanks (BBT) with all secondary functions. The new keg system and tank unloading station for the bottling facility are connected from here. In addition to integrating and using existing parts of the production plant, the advantage of Pentair Südmo’s concept is the compact installation and the arrangement of the entire production line on the same level.
Entire production on one level
The brewery’s control concept is based on the “Proleit” process control system that was programmed by Pentair Südmo and is used by a growing number of breweries. This user-friendly system allows the operator to easily adjust all parameters as each of the plant’s components is clearly shown in a separate flow chart.
In a brewery the cold block is located downstream of the brew house and includes all operations of the brewery from fermentation, maturation to filtration. At Ganter the compact cold block is installed in a new production hall on one level. All necessary functions are 30
Drawing on Pentair Clean Process Technologies’ wide range of solutions for the brewing industry, Pentair Haffmans’ carbonator was included in the project to control the carbonization process. In addition, Beer Membrane Filtration with Pentair’s membrane technology is also possible at a later stage. “We were able to collect very good experiences after the first few weeks of operation,” said Katharina Ganter Fraschetti, member of the brewery’s management. “We could already notice significant savings in the energy area as well as in operating costs.”
Pentair at Aquatech 2011
Pentair at Brau Beviale 2011
This year’s Aquatech Amsterdam, the world’s leading trade exhibition for process, drinking and wastewater, taking place at the RAI Exhibition Centre from November 1-4, will be Pentair’s stage to showcase its latest innovations and applications, present its new subsidiary companies and introduce its new corporate design on more than 7,000 ft2 (650 m2) of exhibition space.
Brau Beviale, the world’s leading exhibition for the beer and beverage industries, opens its doors again from November 9-11 in the Exhibition Center Nuremberg, Germany. With approximately 32,000 expected visitors, Brau Beviale 2011 provides the perfect platform for Pentair to showcase its latest innovations. Pentair will be prominent in two halls:
Major innovations on display include: Pentair Nijhuis’ fish-friendly pump Pentair Haffmans’ biogas upgrading system recovers 100 percent of the methane and the CO2 by-product Pentair Water’s 9100TS Twin Sensor Water Treatment System for water conditioning In addition, Pentair X-Flow will launch its hollow fiber nanofiltration membranes, anaerobic Membrane BioReactor (MBR) concept, and the compact Airlift™ MBR Megablock.
In hall 6.321, Pentair Food & Beverage will display the latest products and solutions in the field of beer membrane filtration, CO2 systems, high gravity brewing, quality control equipment, valve technology, and membrane water treatment. Hall 9 is dedicated to drinks dispense. Here, at booth 433, Pentair Foodservice will present its latest innovations including the Claris Water Treatment cartridge, Bottled Water Delivery system, Beer Ace II – a universal beer dispense pump, and a high efficiency reverse osmosis system.
Learn more about Pentair by visiting our booth located at 01.428 and 01.428A in the Water Treatment sector.
Pump supply for the Huascacocha water transfer project in Peru
Pentair Nijhuis’ first pump order in South America written by inge sluijter
Pentair Nijhuis’ pumps have been selected as part of the water transfer system to feed the Peruvian Huachipa drinking water treatment plant benefitting 2.4 million residents in Lima and neighboring Callao. Pentair Nijhuis received an order from the Brazilian construction firm Constructora OAS Ltd. for the supply of four 855,000 gallons per hour (3,240 m3/h) capacity split case pumps for this project. The project includes building a 49 foot (15 m) dam wall that will store almost 21 billion gallons (79 million m3) of water and building 14 miles (22.5 km) of concrete channel, a 1.3 mile (2,1 km) tunnel and a 3.2 mile (5.1 km) long pipe line that is 4.9 feet (1500 mm) in diameter. The water transfer system leads from the Huascacocha Lake, via the Marca III system, to the Rímac River in Lima, Peru. The end customer of this project is Sedapal, Peru’s state-controlled water utility. “From the Huascacocha facility the Pentair Nijhuis pumps feed the Huachipa drinking water plant with a capacity of up to 695 gallons per second (2.63 m3/s),” said Damián Sciarra, Product Manager at Pentair’s Argentina sales office. “OAS chose Pentair Nijhuis’ pumps, based on low energy consumption and low life cycle costs for operation over a 25-year period.” “The combined efforts of our partner Enerquímica in Peru, colleagues in the Argentina sales office and Pentair Nijhuis to penetrate the South American pump market resulted in the first pump order in this continent,” concluded Frans Staring, Senior Area Sales Manager, Pentair Nijhuis.
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