CERA-PURE Ceramic Filtration Systems Brochure › Asset › TEA Cera... · recycled or treated....

2250 W. WetmoreTucson, AZ 85705 U.S.A.Phone: (520) 888-4000 Fax: (520) 888-4457Email: [email protected]

CHEMICAL FREEWASTEWATER RECYCLING

ANDWASTEWATER TREATMENT

�CERA-PURE�W A S T E W A T E R C L E A N - U PD

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Wastewater Heat RecoveryTEA�s wastewater heatrecovery systems arecompletely factoryassembled, serviceproven and engineered for maximum wastewaterheat recovery. Ourexclusive plate & frameheat exchangers offerthermal efficiencies 300 � 500% greater than continuous shell & tube heat exchangers.

DC HeaterTEA�s SuperHeater provides near100% energy efficiency for themost economical water heatingavailable. Fully assembled watermanifolds, exclusive inlet freshwater distributor, combustion zonecooling, and Smart Touch controlsmake the TEA SuperHeater theUltimate in Direct Contact WaterHeating.

TanksTEA makes stainless steeltanks ranging from 15gallons up to 30,000gallons. Our unmatchedquality tanks have weldedseams, hydraulicallyformed fittings and rolledflanges on both top andbottom heads to eliminateweld distortion.

Shaker ScreenTEA�s Shaker Screen has beenproven to be the most effectivemethod of filtering wastewater.Our stainless steel construction,including the base, makes itideally suited for wastewater

filtering application. With sizes ranging from 24� to 60� and meshsizes down to 38 micron, TEA Shaker Screens can handle most anywastewater filtering application.

Pumping PackagesTEA offers efficient, space saving pumpingpackages precisely engineered for yourapplication. Single, dual, triplex and quadpumping packages are available to meetyour plant�s specifications. Stainless steelpiping with anti-slam check valves andisolation valves, UL Control Panels,compact design, and pre-assembledpackages are all standard features.

DimensionsSize Length “A” Width “B” Height “C”

100 GPM 95” 48” 93”

150 GPM 99” 52” 96”

200 GPM 103” 60” 100”

Top Elevation

Elevation View

Elevation End View

Tel: 866-777-6060 Fax: 866-777-6383

Springer Pumps, LLC Website: www.springerpumps.com Int'l: +001 267 404 2910

The heart of the Cera-Pure systemis the ceramic elements. They areround rods with multiple internalchannels. The channels are coatedwith a porous membrane, which areengineered to pass liquids below 0.2microns and reject all media above.The coatings are fused into theelements to make a robust filter,unaffected by heat or chemicals, andcapable of pressures over 1000 PSIand years of service.

In operation, liquids to be processed are pumped at highpressure and velocities through the channels. Theporous membrane allows clear water to pass through,

while rejecting all oversizedparticles. The high velocity ofthe flowing liquid sweeps thesolids off the membrane andkeeps it in the circulatingstream. Near sized particles,which may be lodged in thepores, are flushed out during theair pulse backwash.

The filtered water, called filtrate,is discharged into the filtrate

header for use as recycled water. The recycled water isperfectly suited for use as process water in mostoperations, will not contain any chemical additions, oreffect any plant equipment.

THE CERAMIC ELEMENT

All plants that use water in their processing haveconcerns regarding water; whether it be ever increasingwater and sewer costs, scarcity of water, or dischargecompliance issues. Cities do not want the wasteproducts in your sewer water and assess fines &surcharges directly related to what your wastewatercontains. Traditionally wastewater treatment systemsusing chemicals have proven to be a double edge sword.Wastewater can be discharged under the limits, but thesystems and their chemical/labor costs have risen tounacceptable levels.

Ceramic filtering systems have changed the game! Forplants with discharge compliance issues, the Cera-Puresystem can be used for chemical free wastewatertreatment and clean up the wastewater for discharge.Plants facing limited water supplies or exorbitant water &

sewer costs can use the Cera-Pure system to recycleand reuse a significant portion of their water, therebyreducing water & sewer costs. Plants using hot waterwill enjoy additional savings in water heating costsbecause the heat in the recycled water is recovered aswell.

Is Cera-Pure right for your plant? An engineering studycan evaluate how much of your wastewater can berecycled or treated. Whether you are looking to reduceyour sewer fees, recycle a portion of your waste water,or both, a Cera-Pure system may be the perfect solutionfor you.

TEA�s staff is available to assist you in making thisevaluation. Contact us for further information.

THE FILTRATION SPECTRUM

CERA-PURE Filtration Level

WASTE WATER TREATMENT SYSTEMPlants with sewer discharge compliance issues can usethe ultra-filtration capabilities of the Cera-Pure Systemfor chemical free treatment of the wastewater. Theresultant filtered water can be used as recycled water inthe plant. Recovery rates for recycled water can be ashigh as 90% of the water processed through the Cera-Pure system, with the remaining being sludge fordisposal.

To use the Cera-Pure System most effectively,wastewaters should be segregated into black water anddischargeable gray water. In laundries, split trencheswork best. The black water is processed through aShaker Screen to the finest micron level possible,generally about 150 microns. This filtered black water isdischarged into a cone bottom equalization tank.Wastewater is pumped, from an intermediate level in theequalization tank, to the Cera-Pure System, where pre-filters remove entrained solids down to the 5-10 micronlevel.

This filtered water is then pressure fed into the circulatingloop of the ceramic filter module for final separation. Bothhigh pressure and high velocities are used to separatethe wastewater into filtrate water, and unfilteredconcentrate water. Continuous reverse flow shockwaves dislodge accumulated material from membranepores maintaining filtrate flows. The filtrate can now berecycled for use in the plant. The filtrate water is usuallywithin a few degrees of the incoming unfiltered watertemperature. Concentrate water is returned to theequalization tank for mixing with incoming black watersand re-processing.

At the end of the processing day, the equalization tank isallowed to settle out. Most suspended solids will settleout over night. Any free oils will float to the top. Beforestart up in the morning, the settled sludge is pumped outto a sludge storage tank along with floating oils.

At this time, the system is ready to begin processingplant wastewater again.

WASTE WATER RECYCLING SYSTEM

CERA-PURE SYSTEM

CONCENTRATE TO WASTE FILTRATE

PROCESS WATER

STORAGETANK

FEEDPUMP

WASTEWATER

PIT

SHAKERSCREEN& TANK

CONCENTRATE RETURN FILTRATE

PROCESS WATER

STORAGETANK

EQUALIZINGSTORAGE

TANKWITH SHAKER

SCREENSLUDGE

STORAGETANK

WASTE REMOVALCONNECTION

SLUDGEPUMP

WASTE WATER

WASTEWATER

PIT

FEEDPUMP

CERA-PURE SYSTEM

WASTE WATER RECYCLING SYSTEMWASTE WATER TREATMENT SYSTEM

In areas that lack sufficient supplies of water, or waterand sewer costs are excessive, the �Cera-Pure� waterrecycling process is ideal. Wastewater can be processedinto recycled water and a concentrated waste streamthat contains all of the removed contaminants. Plantsthat do not have sewer discharge compliance issues caneffectively recover 50%, or more, of the total dischargevolume.

The wastewater is first processed through a ShakerScreen to the finest micron level possible. This filteredwastewater is discharged into a tank that acts as bufferstorage before feeding into the Cera-Pure System.

The pre-filtered wastewater is then pumped to the �Cera-Pure� system where self- cleaning finer filters removes

entrained solids down to the 5-10 micron level. Thisfiltered water is then pressure fed into the circulating loopof the ceramic filter module for final separation. Both highpressure and high velocities are used to separate thewastewater into filtrate water, and unfiltered concentratewater. The filtrate can now be recycled for use in theplant, and is usually within a few degrees of the incomingwastewater temperature. The concentrate water isdischarged to the sewer.

Continuous reverse flow shock waves dislodgeaccumulated material from membrane pores maintainingfiltrate flows. The automatic periodic chemical cleaning ofthe elements can be scheduled during plant down time,and will maintain the elements in pristine condition.

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Tel: 866-777-6060 Fax: 866-777-6383


Fresh water is becomingincreasingly expensive to use, andafter being used for processing, isexpensive to discharge to the sewer. Itis now possible to economicallyprocess wastewaters into recycledwater and remove contaminantsbefore discharging to the sewer.

TEA�s �Cera-Pure� Ceramic ElementFiltration System can filter mostwastewaters to the sub-micron level,separating the stream into recycledwater and disposable wastes. Oils &greases, total suspended solids,COD/BOD, and a host of otherundesirable elements are separatedfor disposal. The resultant clarifiedwater stream is fully capable of beingre-used in your processing.

Ceramic element filtration is the onlyrecycling system that can operatewithout expensive chemicals andconstant operator monitoring. The fullyautomatic operation reduces operatorsupervision from startup in the morningto shutdown at the end of the day.

Plants that do not have sewerdischarge compliance issues caneffectively recycle 50%, or more, of thetotal discharge volume. The ceramicelements will separate the water intorecycled water and a concentratedwaste stream. The waste stream willcontain all of the removedcontaminants for discharge to sewer.

If sewer discharge compliance issuesare a problem, a waste watertreatment approach can beimplemented that will recover up to90% of the water processed for re-use,and concentrate the waste products assludge for separate disposal. Thesesystems are more complex but thefinancial returns can be most attractive.

Ceramic element fi ltration ofwastewater is a quick and continuousprocess and will recover most of theheat contained in the water foradditional energy savings.

�CERA-PURE�PROVEN TECHNOLOGY FOR WATER TREATMENT

AND RECYCLING

At the heart of the Cera-Pure Systemare the aluminum oxide ceramicelements, which can remove particlesdown to 0.1 microns. This means allbut the smallest organic molecules orsoluble ions are removed.

Ceramic Element Filtration is ideallysuited for treatment for discharge orrecycling from a wide range ofindustries, including laundry and textilefinishing plants, concrete processingfacilities, metal finishing plants, carwashes, automotive processingindustries, poultry and egg processingplants, and other food processing.

Servicing of the elements isautomatically performed periodicallydepending on the quality of thewastewater. Pneumatic reverse flowshock waves are used to dislodgeaccumulated material from the surfaceof the filtering membrane. Theautomatic periodic chemical cleaning ofthe elements can be scheduled duringplant down time, and will maintain theelements in pristine condition

In the basic system, liquid is pumpedfrom a pit or tank, through a ShakerScreen (about 150 micron screening),and into a feed tank. A pump thensupplies this pre-screened liquid to theCera-Pure system. Another finer filter isused to refine the liquid for the finalceramic filtering step. The liquid is thenfed into the main re-circulation loopwhere it is circulated at high pressureand velocity through the �Cera-Pure�module. In the module, the liquid isfiltered through the elements andfiltrate is discharged into the filtrateheader. The liquid in the loop iscontinuously circulated through themodule. As impurities build up in there-circulation loop, a portion of theliquid in the loop is bled off as areject/concentrate stream to the sewer.

The fully automatic operation reducesoperator oversight from startup in themorning to shutdown at the end of theday.

CeramicElementModule

Back-PulseChamber

FiltrateDischarge

ConcentrateDischarge

Pre-Filters

Feed Pump

CirculationPump

Clean InPlace Tank

Wastewater Inlet

Drain

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Tel: 866-777-6060 Fax: 866-777-6383


CASE HISTORIESTEQUILA PROCESSING PLANT

During the Tequila making process the agave plant is boiledto make a mash and extract the agave liquor. This liquorwas then cooled so it could be filtered to remove agavefibers. The liquor was then re-heated to start thefermentation process. This was a time consuming andenergy intensive process

A Cera-Pure System was installed to filter the agave fibersfrom the liquor while still hot.

Because they are impervious to heat the ceramic elementfiltration system eliminated two unit operations and savestime. Eliminating the cool down and re-heating process hasreduced energy costs by 40%.

FOOD PROCESSING PLANT

An egg processing plant produces 3000 gallons of wastewater perday with high levels of BOD, TSS, and TKN, resulting in sewersurcharges of $4000.00 per month.

A Cera-Pure System was installed to treat the wastewater to removeproteins and other organic matter that contribute to the high readings.

The filtrate produced is of such quality that it falls below municipaldischarge limits. BOD was reduced 99%, TSS was reduced > 99%,and TKN was reduced 98%. Because the process does not requireany chemical pre-treatment, the concentrate is suitable for otherrendering. The sewer surcharge was reduced from $4000.00 permonth to less than $400.00.

COMMERCIAL LINEN PLANT

A large commercial laundry was unable to grow due to alimited water supply. Increasing the size of the water servicewould be cost prohibitive.

A Cera-Pure System was installed to filter and recycle thewastewater back into the laundering process.

The plant is reusing 50% of the wastewater without anyadverse effect on product quality. This has allowed the plantto take on additional accounts and increase daily productionusing the same total volume of water. In addition to recyclingthe water, the heat in the water is also recycled thus reducingthe energy required for water heating.

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� What is the quality of the water produced by a ceramic filter system?

Ceramic filtration is a mechanical process thatoperates near the ultra filtration levels. Whenblended with fresh water, it should be usable inmost industrial applications. Initial testing shouldidentify any products that could reduce thequality and quantity of recycle water used.

� What is the expected life of ceramic elements?

The elements are made from a fired ceramic thatis quite robust and should last indefinitely. Theporous membrane that separates the filtrate fromthe waste stream should last at least 10 yearswhen the system is operated according to theInstallation and Operating Manual. Care shouldbe taken to avoid silica-based chemicals in thewaste stream which could damage the ceramicelements.

� Do the ceramic elements require cleaning?The Cera-Pure ceramic elements do requireperiodic cleaning because of a slow buildup ofcontaminants. Cleaning is usually done with analkaline detergent with a final weak acid rinse.Cleaning is fully automatic. It can be scheduledor done based on performance degradation. Fora system that runs every day for two shifts perday, typically cleaning is performed once or twiceper week.

� How much operator interaction is required?

TEA�s Cera-Pure system is fully automatic, andcan be scheduled to do all routine operationsfrom startup and shutdown, to cleaning withoutany operator interaction. The system featuresremote monitoring and data logging, allowingplant managers and engineers to see the systemperformance in real time. As with mostequipment, some minor infrequent maintenanceis required (greasing pump bearings forexample). The only regular maintenance actionrequiring an operator is the weekly inspection orreplacement of the fine micron bag filters.

�CERA-PURE�Frequently Asked Questions

� How much water can be recycled?Recycled water should be added to the incomingplant fresh water. Since ceramic filters do notremove ions, any recycling will result in anadditional buildup of TDS. Too high a buildupand water quality will degrade. It is safe to saythat initially, most plants can recycle 50 � 60% oftheir total wastewater. Testing of TDS in the finalcombined plant process water will determinehow much recycle rates can be increased.

� What temperature is the recycled water discharged at?

When used for water recovery/recycling, ceramicfilters retain virtually 100% of the heat input,resulting in both energy savings as well as watersavings. The high velocity flows in the systemactually add temperature to the water making itwarmer at discharge than the incomingtemperature.

� How much expansion is built into each system?

Available modules sizes are 100, 150 and 200gallon per minute influent capacities. Somegrowth is usually available by changing thebackwash cycle times and element cleaningcycle times, but growth is very limited. Testing ofequipment in actual use can evaluate if higherthrough put rates are possible. Equipmentshould be sized when ordering so that possibleadditional capacity already exists.

� What other benefits can be achieved?It should also be noted that in addition to thewater, sewer and energy savings, there aresavings in avoidance of impact fees or the cost ofnew construction that would otherwiseaccompany the same increase in water volume.Many municipalities and/or utility companieshave grant monies or rebates available forconservation of water and energy.

Tel: 866-777-6060 Fax: 866-777-6383


CASE HISTORIESTEQUILA PROCESSING PLANT

During the Tequila making process the agave plant is boiledto make a mash and extract the agave liquor. This liquorwas then cooled so it could be filtered to remove agavefibers. The liquor was then re-heated to start thefermentation process. This was a time consuming andenergy intensive process

A Cera-Pure System was installed to filter the agave fibersfrom the liquor while still hot.

Because they are impervious to heat the ceramic elementfiltration system eliminated two unit operations and savestime. Eliminating the cool down and re-heating process hasreduced energy costs by 40%.

FOOD PROCESSING PLANT

An egg processing plant produces 3000 gallons of wastewater perday with high levels of BOD, TSS, and TKN, resulting in sewersurcharges of $4000.00 per month.

A Cera-Pure System was installed to treat the wastewater to removeproteins and other organic matter that contribute to the high readings.

The filtrate produced is of such quality that it falls below municipaldischarge limits. BOD was reduced 99%, TSS was reduced > 99%,and TKN was reduced 98%. Because the process does not requireany chemical pre-treatment, the concentrate is suitable for otherrendering. The sewer surcharge was reduced from $4000.00 permonth to less than $400.00.

COMMERCIAL LINEN PLANT

A large commercial laundry was unable to grow due to alimited water supply. Increasing the size of the water servicewould be cost prohibitive.

A Cera-Pure System was installed to filter and recycle thewastewater back into the laundering process.

The plant is reusing 50% of the wastewater without anyadverse effect on product quality. This has allowed the plantto take on additional accounts and increase daily productionusing the same total volume of water. In addition to recyclingthe water, the heat in the water is also recycled thus reducingthe energy required for water heating.

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� What is the quality of the water producedby a ceramic filter system?

Ceramic filtration is a mechanical process thatoperates at ultrafiltration levels. The quality of thefiltrate is high enough to reuse in industrialapplications. However, initial testing will identifyany products that could reduce the quality andquantity of recycled water that can be used.

� What is the expected life ofceramic elements?

The elements are made from a fired ceramic thatis virtually impervious to chemical or biologicalattack. Unlike RO and NF membranes, whichonly last a couple of years, the ceramic elementswill last virtually indefinitely when operatedaccording to the Installation & Operation Manual.

� Do the ceramic elements require cleaning?

The Cera-Pure ceramic elements do requireperiodic cleaning due to slow buildup ofcontaminants. Cleaning is done with an alkalinedetergent with a final weak acid rinse. Cleaningis fully automatic. It can be scheduled or donebased on performance degradation. For asystem that runs every day for two shifts cleaningis typically performed once or twice per week.

� How much operator interaction isrequired?

TEA�s Cera-Pure system is fully automatic andperforms all routine operations, from startup toshutdown, without any operator interaction. Thesystem has controls that automatically react tothe constantly changing demands of the plant toachieve optimum performance. The systemfeatures remote monitoring and data logging,allowing plant managers and engineers to seethe system performance in real time. As withmost equipment, some minor, infrequent,maintenance is required (greasing pumpbearings for example). The only regularmaintenance action requiring an operator is theweekly inspection or replacement of the bag filtermembranes.

�CERA-PURE�Frequently Asked Questions

� How much water can be recycled?

Ceramic filters do not remove ions, so recyclingceramic-filtered water can result in an increase ofTDS. Too high a TDS level will impact productquality. Based on operating experience, mostplants can recycle at least 50 � 60% of their totalwastewater. Testing of the final combined plantprocess water, in consultation with your chemicalvendor, will determine how much recycle ratescan be increased.

� What is the temperature of the recycled water?

When used for water recovery/recycling, ceramicfilters retain virtually 100% of the heat input,resulting in both energy savings as well as watersavings. The small amount of ambient heat lossexperienced in the system is more than offset byheat generated by the pumps on the system.The water discharged from the Cera-PureSystem usually a few degrees warmer than theincoming water.

� How much expansion is built into each system?

Modules are available in 100, 150 and 200 gallonper minute influent capacities. Some growth isusually available by changing the backwashcycle times and element cleaning cycle times,but growth is limited. Testing of equipment inactual use can evaluate if higher throughputrates are possible. Equipment should be sizedwhen ordering so that possible additionalcapacity already exists.

� What other benefits can be achieved?

It should also be noted that in addition to thewater, sewer, and energy savings, there aresavings in avoidance of impact fees or the cost ofnew construction that would otherwiseaccompany the same increase in water volume.Many municipalities and/or utility companieshave grant monies or rebates available forconservation of water and energy.

Tel: 866-777-6060 Fax: 866-777-6383


CHEMICAL FREEWASTEWATER RECYCLING

ANDWASTEWATER TREATMENT

�CERA-PURE�W A S T E W A T E R C L E A N - U P

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CERA-PURE DimensionsModel Flow “A” “B” “C”

WR/WT 100 100 GPM 108” 48” 93”

WR/WT 150 150 GPM 114” 52” 96”

WR/WT 200 200 GPM 128” 60” 100”

5/16" ADJU

STING5/16"

ADJUSTING

5/16" ADJU

STING

1/2" ADJUS

TING

A

B

12"CONTROL PANEL

Wastewater Heat RecoveryTEA�swastewaterheat recoverysystems arecompletelyfactoryassembled,serviceproven andengineered for maximumwastewater heat recovery. Our exclusiveplate & frame heat exchangers offer thermalefficiencies 300 � 500% greater thancontinuous shell & tube heat exchangers.

DC HeaterTEA�s SuperHeaterprovides near100% energyefficiency for themost economicalwater heatingavailable. Fully assembledwater manifolds,exclusive inlet freshwater distributor,combustion zone cooling, and Smart Touch controls make the TEA SuperHeater the Ultimate in Direct Contact Water Heating.

Pumping PackagesTEA offers efficient, space saving pumping packages precisely engineeredfor your application. Single, dual, triplexand quad pumping packages are availableto meet your plant�s specifications.

Stainless steel piping with anti-slam check valvesand isolationvalves, UL ControlPanels, compactdesign, and pre-assembledpackages are allstandard features.

TanksTEA makes stainless steel tanks ranging from15 gallons up to 30,000gallons. Our unmatchedquality tanks have weldedseams, hydraulicallyformed fittings and rolledflanges on both top andbottom heads to eliminateweld distortion.

Shaker ScreenTEA�s Shaker Screen has been proven to be the most effectivemethod of filtering wastewater. Our stainless steel construction,including the base, makes itideally suited for wastewaterfiltering application. With sizesranging from 24� to 60� andmesh sizes down to 38 micron,TEA Shaker Screens canhandle most any wastewaterfiltering application.

TOP VIEW

END VIEWSIDE VIEW

Other TEA Products

PSI

PSI

5/16" ADJUSTING5/16" ADJUSTING 5/16" ADJUSTING 5/16" ADJUSTING

5/16" ADJUSTING

5/16" ADJUSTING 5/16" ADJUSTING 5/16" ADJUSTING

5/16" ADJUSTING

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Tel: 866-777-6060 Fax: 866-777-6383


CERA-PURE Ceramic Filtration Systems Brochure › Asset › TEA Cera... · recycled or treated....

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Transcript of CERA-PURE Ceramic Filtration Systems Brochure › Asset › TEA Cera... · recycled or treated....