Krauss-Maffei dynamic crossflow filter DCF

Process know-how and innovation for the production of insulin

Technological advantages

• Highest possible yields by processing of highly concentrated suspensions up to viscosities of 7,000 mPas
• Optimum product quality due to single-pass filtration concept, short residence times, no contact with gases, and minimum thermal and mechanical impact
• Highly accurate membranes with different cut-offs achieve a clear filtrate, typically with residual turbidity of less than 1NTU
• Smaller installed filtration area due to higher permeate flux
• 80% reduction in energy consumption compared to traditional membranes
  • Reduced thermal product treatment
  • Lower energy costs
  • Little or no suspension cooling
• Substantial savings, in any subsequent evaporation or drying
• Reduced operating costs and wider range of applications
• Reduced feed pressure due to more effective prevention of clogging layer
• Homogeneous trans-membrane pressure across the entire surface (no inlet or outlet zones in membranes)
• Easy inspection as the filtration surface is on the outside of the membrane

Machine benefits

• Very low retention volume in relation to the membrane surface
• Hermetic design
• Designs for basic chemical to high-end, sterile pharmaceutical applications
• Full CIP and SIP available, GMP enabled
• Small footprint, easy transport and installation
• Easy maintenance
• Hanging shaft design eliminates the risk of gases at the membranes and in the permeate
• Lowest mechanical stress on product due to minimized process volume
• Feed bottom and discharge top: easy cleaning due to hygienic design
• Avoidance of retentate recirculation by means of dead-end operation (single-pass process)

Applications

In traditional cross-flow filtration, the development of a clogging layer on the surface of the filter membranes is prevented by pumping the feed. When handling sensitive or highly viscous products, this method is not efficient or not even feasible. In this case, traditional, circulating cross-flow filtration technologies would not be able to concentrate liquids to a highly viscous sludge. As dynamic cross-flow filtration (DCF) is able to concentrate the retentate to a sludgy consistency, the efficiency of the separation process and yield of the valuable compound are higher than from any other cross-flow technology. ANDRITZ KMPT has made further advances in the DCF process.

In this technology, overlapping, rotating discs generate a differential speed in relation to one another. This design creates a turbulent crossflow without using a pump to circulate the slurry. By applying wall shear stress that is at least 50% higher than in conventional crossflow systems, the formation of a clogging layer, which obstructs the permeate flow, can be avoided or at least reduced significantly. Ceramic filter membranes are installed as standard, but metal filter membranes can also be installed. Upgrades for existing plants, with a DCF being included downstream of a traditional crossflow filter, enhance the process, reduce energy costs, and increase the throughput. In any event, removal of bottlenecks is often the main reason for installing a DCF, and in some cases, the reduction of energy consumption is motivation enough.

Every drop counts – higher solids concentration, higher yields for recovery of liquids. With its dynamic crossflow filter (DCF), ANDRITZ SEPARATION provides a highly efficient separation solution that fulfills the latest standards and is bridging gaps that common technologies have to bypass. Recovery of tank lees in wineries during vintage or wine purification, for example,  is only one of the various applications of the DCF. It is a smart solution to increase yield, optimize quality, reduce costs, and improve working conditions.

Next level optimization of your DCF performace with Metris addIQ digital twin for DCF

For most of the players in food and chemical industries, using a Dynamic Crossflow Filter (DCF) is an efficient way to filtrate different products but today, operations need significant improvement to gain in productivity and reduce OPEX, which is now possible thanks to Metris addIQ digital twin solution.

A digital twin is a digital replica of the physical process using asset-specific information such as actual physical dimensions and equipment characteristics. It runs in parallel with operations, continuously calculating key process parameters which sometimes cannot be measured or are difficult to measure by traditional instrumentation. Through proven simulation capabilities, combined with live plant data as an input provides virtual transmitters, it calculates continuously the optimal flow setpoint, and performs what-if scenario analysis.

• Real-time process optimization: Optimization of throughput by advanced process control, in real time
• Ease of use: Self-learning digital solution, no need for highly qualified staff
• Safe operation
  • Prediction of optimum transmembrane pressure
  • Fast reacting adaptive control behavior in case of process conditions changes (anomaly detection)
  • Stabilizing process with less fluctuations in the permeate flow-rate

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