Giving you a cleaner quality of process water than any other conventional self-cleaning technology.
Crossflow-HEMF High Efficiency Filtration for Users of Water
Water is the lifeblood of many industries and processes without which they cannot function. But as environmental pressures push the price paid for this natural resource ever higher, it is increasingly becoming a major operating cost. Finding cost effective water filtration technology that will provide significant cost reductions in water spend has been a real issue for many years... until now!
- Extrusion Line Calibration
- Cleaning and Re Use Of Cutting Fluids (Water)
- Induction Furnace Cooling Loops
- Effluent Conditioning for Re-Use
- Cooling Of Data Bank - Back Up Power Supplies
- Cooling Tower Control and Chemical Minimisation
- Robotic Cooling
- River & Lake Water Filtration
- Cooling Ponds
- High Pressure Pump Pre Filtration
- Heat Exchanger Protection
- District Heating Systems
- Flush Water Filtration
- Effluent Management
- RO & UF Pre-Filtration
- De-salination Plants
- Cooling Tower Make Up Water
- Rinse Water Filtration
- Removal of Iron from Boreholes
- Ornamental Water Features
- Removal of Products of Corrosion
- Leisure Pools & Spas
- Moulding Machine Protection
The Crossflow HEMF patented technology can give you cleaner process water than any other conventional self cleaning filter systems on the market today, and all at a very competitive cost.
As a process water user you can save money by the installation of CrossFlow AMF Technology, and at the same time reduce operating costs. The filtration of water down to levels below 1.0 micron will produce a supply of clean water not only free of solids contamination such as sand, grit and iron, but also this system can reduce bacteria, phages and spores such as cryptosporidium.
By reducing the total biological and organic loading from water, chemical dosing is more effective as there is less of a challenge. This in turn often results in significant chemical use reduction which is better for the water user, better for the environment and reduces operational costs.
The CrossFlow AMF system is extremely simple but highly effective technology which brings a more effective way of water filtration then has previously been available, and all at very competitive prices. Many clients who have installed CrossFlow AMF systems have reported a return of investment in less than 6 months; in fact some have achieved payback in 3 months.
Industries that benefit from CrossFlow AMF include:
- Plastic moulding shops
- Oil and Gas exploration
- Power generation
- Oil Gas exploration
- Paper manufacturing
- Automotive manufacture
- District heating/cooling
- Pollution control
- Data Centres, Banks, Hotels, Universities
- UPVC Extruders for pipes and windows
- Potable Water production
- High performance heating cooling loops
- Brick, marble stone cutting
- Brewing and distilling
- Nuclear Power & processing
HOW YOUR PLANT WILL BENEFIT
The CrossFlow AMF technology has brought water filtration into the 21st century through patented innovations. These innovations provide significant process benefits to many industrial and commercial sectors and applications.
These benefits include:
- Filtration of process water down to 0.45 micron with efficiencies up to 99%
- Filtration up to 5 times more water as a conventional filter achieving only 20 micron filtration
- Achieving a longer “on line” filtration time than most other comparable technologies reduced costs
- Acceptance of solid challenges sometimes in access of 200 ppm because of the patented Vortex flow
- Giving high performance filtration through a combination of a unique inlet and special formulated media
- Ensuring very short backwash times
- Enabling high flows with high performance of filtration
- Enabling more effective chemical treatment with less chemicals
- Ensuring heat transfer efficiencies are maintained over the life of your system
- Cleaning up older already contaminated systems and achieving improved performance
- Reducing backwash loss of process water by up to 95%
- Reducing costs by reducing your loss of chiller and or heater kW input during backwash
- The requirement of inlet pressure of only 1.0barg to operate
- Ensuring minimum energy losses for pumping and processing through high flow low pressure
To put it simply – you will:
- Reduce your Carbon Footprint
- Reduce your Energy Consumption
- Lower your Plant’s Environmental Impact
- Benefit from Higher Process Safety and Security
- Lower Operating Costs
- Enhance Performance
- Reduce Waste
- Increase Productivity
Please note: figures given are dependent on application, system and minimum operation conditions.
Savings on one time reuse
50% Reduction on Process Water Costs If a company has the ability to clean up its process water and re use it ONLY ONCE then a staggering 50% saving will be made on both fresh water and effluent costs. At the same time you will effectively reduce your company’s carbon footprint. As an example, a modest use of 50 m3/hr can, if reused once, make a saving on fresh water of over £200,000.00 per annum. If this water is normally sent to drain then these costs can also be reduced by 50%.
CrossFlow AMF Single Filter systems and Mini System up to 1201 System
These can be used on smaller full flow process water or alternatively can be very successfully applied as side stream filtration systems.
CrossFlow AMF Special Constructions
The 600, 900 and 1200 ranges can be manufactured to meet many international pressure vessel codes including ASME, PED. There are also versions for specific applications including sea water filtration, with the use of special coatings such as glass or rubber supplied with all plastic valves and manifolds.
CrossFlow AMF 900 up to 1200 Modular Systems
This range caters for the single pass process filtration where larger water volumes are being dealt with. This range of units, having a deeper bed offering a high degree of filtration at high flow rates, are ideal for the large process industries, where water quality requires to be of a higher standard for process protection. These systems come complete with fabricated base for easy on-site assembly, and are supplied complete with fabricated inlet and outlet manifold sets as well as backwash and drains manifolds. These manifolds can be manufactured in stainless steel or plastic as standard, other materials available as options. Supplied complete with all automatic two way inlet and outlet valves, process pump ( duty or duty standby as required) for working pressure of 1-7barg ( higher pressures available on request) and are completed with a bespoke control panel to IP 65 complete with PLC control as standard
HOW IT CAN BENEFIT YOU
The CrossFlow AMF technology has brought water filtration into the 21st century through patented innovations. These innovations provide significant process benefits to many industrial and commercial sectors and applications.
Steve Cupples, Managing Director of UK based Industrial Purification Systems, discusses how organisations within the commercial and leisure industries can reduce energy usage and associated costs simply by cleaning up and reusing water.Read More
In a volatile market many industries avoid investing in research and development. In fact, a sound investment will often give you a significant return whatever the economic outlook as was the case for UK based Custom Extrusions.Read More
One of Europe's largest and most innovative manufacturers of plastic piping systems has made a significant move towards energy and production savings through the installation of the latest high efficiency water filtration technology.Read More
The CrossFlow-HEMF bridges the gap between conventional water filter systems and the more advanced membrane technology at a fraction of the capital cost. Now you can keep control of energy consumption whilst enhancing profitability.Read More
Don’t Muddy the Water when it comes to Saving Energy!
In many operations, within the commercial and leisure industries, the use of water is often an accepted process cost. There is scant attention paid to reducing such a significant service cost with fixing leaking taps often being the extent of energy saving in this area.
Industry uses water in many different ways and in different amounts, therefore water saving technology, in many cases, is used in multiple applications. The commonalities however are that highly efficient water saving techniques are proven to not only reduce an organisations carbon footprint but to also make huge savings on energy bills.
The simple fact is that if an organisation can clean up this process water and re-use it just one more time it will effectively reduce its process water costs by a staggering 50%.
True, the re-use of process water involves the installation of additional filter technology to provide the necessary clean water. However, modern technologies and techniques can provide a significant return on investment.
If a process only uses 10 m3/hr (10,000 litres) and is a 24 hour operation, the water bill for this modest operation could well be in the region of six figures. Yet having the ability to remove solids of 1.0 micron and less, plus any additional treatments, to enable process water re-use would cost just £30,000 to £40,000 giving a payback within 6 months. Even with today’s interest rates this is a fantastic return on investment.
For Stadiums and Arenas that have large space cooling or heating systems the cost reductions are not based on the cost of the water, so much as the cost of electricity. These systems are often closed loop water heating or cooling systems. Typically, a chiller for a medium sized building with computers may well have installed refrigeration chillers which have 200-300kw of electrical energy. Larger buildings with areas also used by the public will be much bigger.
Many public buildings require heating in winter and so use a combined system of chilled water and hot water. On the hot water systems this would be connected to the hot water boiler, very often driven by oil or gas. On the cooling side there is a cool a water circuit, connected to refrigeration chillers to enable cooling to occur.
The energy input by the boiler or the chiller is significant whether using gas, oil or electricity to achieve the heating/cooling.
Ask any maintenance engineer what colour the water is in this system and this will range from pale straw (usually found in a new system) to black (found in a typical system). This discoloration is not just ‘yucky’ it is actually having a major negative effect on the system.
From our experience, it is not uncommon to see large commercial buildings lose between 15-20% of its total heating energy input just because the water is dirty.
The discoloration is a product of the corrosion which is taking place naturally within the system, and this corrosion reduces the heat transfer from the heat source to the water, and then from the water to the heating/cooling outlet. A double energy whammy!
In addition, if chemicals are used to treat this dirty water, then the effectiveness of the chemical treatment will be reduced because of the high solid load within the water. Past examinations of this process have shown filtration to remove particulates down to 10 micron can improve heat transfer significantly, but our tests on many systems also shows that the majority of this contamination is between 1.0 micron and 10 micron. We believe that saving of 15-20% in total energy costs in this process can be readily achieved
The solution is to clean up the heating/cooling water using reliable filtration to less than 1.0 micron connected to both the hot and cold water system. If the water in the system is anything but clear then energy is being wasted. The darker the water the more it is costing a business.
So what are the savings against the cost of the technology?
A typical system using 100kw chiller and equivalent heater can use 250,000 kw per annum for a nine hour operation, five days a week. Many systems are running continuously to minimise energy losses so this figure could be as high as 870,000 kw hrs per annum.
Assuming the losses are only 15%, this means a loss of 35,000 kw per hour per annum. If the system is on 24 hours a day this cost increases to over 130,000 kw per hour per annum, all of which could be recovered through cleaning up and reusing water. Remarkably, a return on investment can be possible within 10 months.
Investing In Latest Water Filtration Technology Reaps Rewards
In a volatile market many industries avoid investing in research and development. In fact, a sound investment will often give you a significant return whatever the economic outlook and not necessarily just in the places you would expect, as was the case for UK based Custom Extrusions.
As part of the Epwin Group, Gwent based Custom Extrusions produces 10,000 tonnes of profile per year, supplying PVC building products to some of the best known brands in new build, social housing and home improvements, all of which come under the Epwin Group brand.
Despite the recent economic downturn, Custom Extrusions was on a mission to be the best in the market. Part of the strategy was to invest in water filtration to clean up its process water in order to reduce customer complaints about surface scratching and reduce down time. As it turned out, the results of this investment actually far exceeded any of the company’s expectations.
Traditionally the company had had problems with surface scratching caused by biological matter in the process water. Although this was seen not to be a major issue it was something that the company felt they should address as part of its drive to be the best.
On closer scrutiny it was identified that in actual fact 80% of the problems were surface related with up to 20 minutes down time per incident being recorded.
A representative from the management team at Custom Extrusions, said: “As part of our quality drive we wanted to have the best quality process water. To do this we wanted to eradicate the bacteria present in the water rather than just treat it.
“For the past 15 years our SpinClean filter has been filtering down to 50 microns but our filtration specialists, Industrial Purification Systems (IPS), had developed more advanced filtration technology specifically to filter out microscopic contaminants. IPS was able to provide us with its new high efficiency Crossflow AMF sand filter which had the ability to reliably filter to down to 0.45 micron.
“But there has been a lot more to this investment, far more. Not only did we see a dramatic 75% drop in customer complaints but since its installation we have had no issue with surface scratching whatsoever so the increase in production time has been phenomenal and process scrap has been reduced by 20%. Putting these factors together Custom Extrusions is seeing a staggering financial saving in excess of £100,000.00 per annum.
“We recognise that customer expectation on quality is greater than it used to be so we have invested to meet the expectations of these customers and the market. In so doing our company has seen a significant saving in our running costs and environmentally we are saving as well which has gone a long way to reducing our carbon footprint.
“For me IPS is a highly innovative company. Like us, it is customer focused and interested in the challenge of every project – not just for the sale. They always engage with all the other contractors involved and know the right questions to ask to help clients, like ourselves, understand the complexities of the project. IPS is happy take on such an advisory role between the client and other contractors to ensure everything runs smoothly which only works because of the personalities within IPS.”
HIGH QUALITY WATER FILTRATION – A COOLER WAY TO ‘CURE’
One of Europe's largest and most innovative manufacturers of plastic piping systems has made a significant move towards energy and production savings through the installation of the latest high efficiency water filtration technology. Steve Cupples, managing director of Industrial Purification Systems, explains:
“The company concerned uses the manufacturing method called thermosetting plastics for the manufacture of products for residential, commercial and infrastructure sectors. The whole process is very much an exacting one with the ability to cool the thermosets playing a vital part in total plant capacity. This is a high temperature moulding process whereby product is manufactured at temperatures above 200 degrees C. The cure or cooling time required to achieve physical stability therefore dictates this production capacity.
“By applying chilled water through fine cooling tracks found in the moulding head the thermosets can be hardened quickly. If this cooling system blocks or becomes fouled for any reason the thermosets take longer to harden which effectively slows down production. In reality this could translate into a slow down of just 10 seconds. However if you multiply this slow down across an entire production line, this would seriously affect production capacity and ultimately the bottom line.
“In this particular instance, the maintenance team had been trying to control a number of issues they were experiencing with its closed loop cooling system which was not only displaying discolouration through red deposits but had become a breeding ground for bacteria.
“They were mainly concerned about the dreadful water quality in the cooling system which was giving out an extremely unpleasant odour. A continuous programme of chemical treatment to kill the bacteria had been put in place but this was causing a build up of dead bacteria, the resultant slime consequently blocking the system. Production then had to be stopped for cleaning purposes. As this was a repeating cycle of events it was causing a lot of problems.
“The issue here was not necessarily to do with wastage of product but more to do with wastage of time.
“A SpinClean filtration unit was already in place but this was clearly not capable of handling a problem such as this. We therefore recommended that they installed our new high efficiency media filtration technology called the Crossflow-HEMF which was fitted as a side stream filter during the summer months.
“The maintenance team were expecting quite a large piece of technology to be installed for the type of problem they were experiencing which necessitated having to cope with a cooling system operating across 30 machines in the moulding shop. They were surprised at how compact the filter actually was and how easy it was to install.
“The effects of the filter were seen quite quickly with clean water established within 3 to 4 weeks. Of course this meant that there were savings to be made against the reduction of chemical use but the real savings were on the cycle times. The build up of slime had been affecting the cooling capacity thereby extending curing times; by cleaning up the water the flow rates increased, stoppages for cleaning time were reduced and production speed on the moulding machines could be maintained at original levels.
“The maintenance team had also been on the receiving end of numerous complaints about having to stop the machines and clean them out. Since the installation of the CrossFlow-HEMF these have stopped
“Whilst those working in the moulding plant will be enjoying a much better working environment having eradicated the odour emanating from the water, it is too early to establish other benefits. However, from experience we know that the company will see a big improvement in energy savings and with maintenance down time now being practically non-existent we would expect the company to see a quick return on their investment.”
CrossFlow-HEMF: THE LATEST AND MOST RELIABLE HIGH EFFICIENCY MEDIA FILTRATION TECHNOLOGY
GETTING A BALANCE BETWEEN COST EFFICIENCY, PERFORMANCE AND THE ENVIRONMENT
Industry worldwide will have to account more and more for its use of energy and other resources as a global carbon reduction policy is developed. Steve Cupples, managing director of water filtration specialists Industrial Purification Systems, talks about the latest technology which is revolutionising the water filtration process. Called the CrossFlow-HEMF this technology bridges the gap between conventional water filter systems and the more advanced membrane technology, or ultra filtration, at a fraction of the capital cost. Now any organisation can keep control of its energy consumption whilst enhancing profitability.
“With the need to be more cost efficient, and global warming now a real issue, many companies are increasingly looking at ways to enhance both performance and their ‘green image’ but many find difficulty in reducing their carbon footprint.
“Having the capability to re-use process water or municipal waste water, or being able to draw on alternative water sources such as borehole and rainwater harvesting, we all know will go along way to provide a sustainable environmental solution and save on energy consumption.
“There are a number of strategies that can be implemented to make this happen yet there are also a number of reasons why this has not yet taken place.
“For example, for years it has been believed that the filtration of heating or cooling water in open or closed systems is not such a big issue.
“However the costly damage caused by a build up of contamination, often not even picked up on by the human eye, shows this is not the case. Additionally, big energy gains of up to 30% can be achieved by cleaning up “dirty” process water used in heating or cooling applications.
“Most industrial and commercial water sources tested to date show an expected contamination above 20 micron. However, the distribution and population of particulates is consistently higher at less than 20 micron, much of which is biological. Significantly this is even more pronounced below 10 micron which is the traditional cut off point for main stream filtration technologies and is the key reason why a business can lose this 30% in energy performance on heating, ventilating and air conditioning systems.
“As a further example, for industry to have the ability to re-use process water for secondary or even primary applications will go along way to help reduce a global reliance on valuable potable water resources. Such a strategy can give a significant return on investment when you take into account the cost to purchase and dispose of water in its many applications. However, there has not been a reliable method of filtering out fine contamination to make the introduction of such a strategy workable… until now.
“The CrossFlow-HEMF provides a very real solution because is will effectively remove contamination to less than 1.0 micron, without the prohibitively high capital/revenue costs normally associated with water polishing applications.
“The CrossFlow-HEMF has been developed to filter below 1.0 micron - reliably – even achieving down to 0.45 micron to ensure cleaner process water which in turn can reduce a businesses carbon footprint. The reuse of process water just once can reduce the carbon footprint on potable water by a staggering 50%!
“Plus, it is not only direct energy costs that will be affected, but also secondary costs including: the ability to produce and distribute potable water for non potable application; the reduction in the use of water treatment chemicals; the reduction in electricity bills by improving heating and cooling systems efficiencies.
“Operationally, the CrossFlow-HEMF filter system utilises a unique patented vortex bed stabiliser which maintains flat bed filtration with high surface turbulence. This ensures that no bio-fouling can be seeded whilst holding filtered contamination in suspension above the media bed. This gives lower pressure drops, longer filtration and shorter backwash cycles making direct savings on operational costs.
The high interstitial void volume of the media allows for greater dirt holding capacity and contamination interaction for the Zeta potential of the media to remove the finer particulates down to 0.45 micron
Compared with conventional media filtration, the inlet configuration allows for high flow rates, these being 5 times higher than the normal accepted flux rates of conventional filters. Backwash volume used is also significantly lower, especially when the longer operational period is taken into consideration. It is also more effective with backwash times per unit being as low as 2 minutes.
This new technology has been shown to provide a high efficiency removal rate of over 86% at 1.0 micron in one single pass whereas conventional filters have to undertake multiple passes to get anywhere such efficiency.
So, by reducing the load on the filter in this way you are increasing the cycle between cleaning and reducing the amount of times the process has to stop for the membranes to be cleaned. In addition, the need for chemical filtration is reduced which therefore reduces the impact on the environment. It also solves the problem of bacteria build up when using sand filtration.
The effects on industry will be huge. For example, in their bid to meet quality standards set by major supermarket chains, food growers are using mains water for crop spraying, which is extremely expensive and environmentally not sound practice. This new technology means that mains water can be re-processed by cleaning it to meet these quality standards and re-used again and again.
Corporations will be able to reap the benefits. The life of a membrane filtration system could be extended considerably, this being anything from 20% - 30 %. There will be less backwashing, less chemical use and longer membrane life span. And most importantly, for a relatively small cost the improvements in efficiency and reduction on environmental impact will be too significant to be ignored.
CROSSFLOW IS USED INDUSTRIALLY WORLD WIDE
The CrossFlow AMF worked a treat. Within a matter of days the filter technology had fixed the problem and, on-going, we believe the same water quality is being achieved. Quite honestly it was the best thing we could have done because it has saved us the loss of production time.
Through applying high efficiency water filtration as a bolt on to the overall operation of our plant, the backwash process becomes very efficient and reliable. With the volume of water needed for a successful backwash being less and because it is automatic, operative site visits are now down to every two weeks.
When this filtration technology was first installed our contractors were sceptical of how well it would perform on the dirty coloured water within the system. However, after only two weeks we noticed a considerable improvement in the water quality.