Membrane filtration apparatus and process for reuse of industrial wastewater

1. A water filter comprising a ceramic microfiltration system and a reverse osmosis filtration system, comprising:

a programmable logic controller, PLC;

said ceramic microfiltration, CMF, system includes:

a source of water to be filtered;

a CMF recirculation pump;

a pretreatment element;

a CMF recirculation loop;

a CMF feed pump pumping said water from said source of water to be filtered through said pretreatment element and into said CMF recirculation loop;

a CMF three-point proportional controller;

a CMF acid metering pump;

said CMF three-point proportional controller outputs a signal to said CMF acid metering pump adapted to control acid flow into said source of water to be filtered and adapted to control the pH of said source of water to be filtered before said water to be filtered enters said CMF recirculation pump of said CMF recirculation loop;

said CMF recirculation loop includes said CMF recirculation pump, a CMF module, a return conduit carrying CMF concentrate back to said CMF recirculation pump, and a CMF concentrate reject conduit interconnected with said CMF return conduit for disposal of a CMF concentrate reject;

said CMF concentrate reject conduit includes a CMF concentrate reject valve adapted to control the amount of said CMF concentrate reject flow discharged;

a CMF concentrate reject flow meter adapted to measure CMF concentrate reject flow in said CMF concentrate reject conduit;

said CMF module includes a ceramic element and said ceramic element includes abrasion resistant ceramic filter membranes;

said CMF recirculation pump supplies water to and through said abrasion resistant ceramic filter membranes of said ceramic element;

said CMF module includes a CMF concentrate reject port adapted to communicate CMF concentrate reject to said CMF return conduit;

said CMF module includes a filtrate port; a CMF filtrate conduit in communication with said filtrate port of said CMF module;

a RO feed tank:

said CMF filtrate conduit in communication with said RO feed tank;

a CMF filtrate flow meter in said CMF filtrate conduit adapted to measure CMF filtrate flow to said RO feed tank of said reverse osmosis filtration system;

said PLC adapted to include a desired CMF concentration factor;

said PLC configured to compute an actual CMF concentration factor based on said CMF filtrate flow measured by said CMF filtrate flow meter and based on said CMF concentrate reject flow measured by said CMF concentrate reject flow meter; and,

said PLC configured to modulate said CMF concentrate reject valve varying said reject flow rate based on said computed actual CMF concentration factor in relation to said desired CMF concentration factor;

said reverse osmosis, RO, filtration system includes:

a reverse osmosis pretreatment element;

said RO feed tank adapted to store and receive CMF filtrate water from said ceramic filtration system and is interconnected with a RO feed pump configured to pump said CMF filtrate water through said reverse osmosis pretreatment element and into a RO recirculation loop;

a RO three-point proportional controller;

a RO acid metering pump;

said RO three-point proportional controller outputs a signal to said RO acid metering pump adapted to control acid flow and adapted to control the pH of said water to be filtered before said water to be filtered enters said RO feed pump and said prefilter element before entering said RO recirculation loop;

said RO recirculation loop includes a RO recirculation pump, a first stage of RO filter banks comprising a first stage of RO filter housings and a second stage of RO filter banks comprising a second stage of RO filter housings; a RO return conduit carrying RO concentrate back to said RO recirculation pump, a recirculation control valve in said RO return conduit, and a RO concentrate reject conduit interconnected with said RO return conduit for disposal of a RO concentrate reject;

said RO concentrate reject conduit includes a RO concentrate reject valve adapted to control the amount of said RO concentrate reject flow;

a RO concentrate reject flow meter in said concentrate reject conduit adapted to measure RO concentrate reject flow;

said RO recirculation pump configured to supply water to and through said first and second stages of said RO filter banks and said first and second stages of said filter housings;

each of said RO filter housings of said first and second stages includes a high temperature low fouling RO membrane, an RO inlet port configured for the admission of water to be filtered, a filtrate port adapted to discharge clean water, and a RO concentrate reject port adapted to communicate RO concentrate therefrom;

said reject ports of said first stage of RO filter housings of said first stage of banks discharge to a common discharge conduit which communicates with said RO inlet ports of said second stage of said RO filter housings of said second stage of banks;

said reject ports of said second stage of said RO filter housings communicate with said RO return conduit;

first stage RO filtrate conduits in communication with each of said filtrate ports of said first stage RO filter housings for the discharge of clean water from said first stage RO filter housings;

second stage RO filtrate conduits in communication with each of said filtrate ports of said second stage RO filter housings for the discharge of clean water from said second stage RO filter housings;

said first stage RO filtrate conduits and said second stage RO filtrate conduits are joined together and form an output RO filtrate conduit;

a RO filtrate flow meter in said output RO filtrate conduit adapted to measure RO filtrate flow;

said PLC adapted to include a desired RO concentration factor;

said PLC adapted to compute an actual RO concentration factor based on a said RO filtrate flow and based on said RO concentrate reject flow;

said PLC modulates said RO concentrate reject valve based on said computed actual concentration factor in relation to said desired RO concentration factor;

an inlet pressure transmitter configured to measure and transmit the inlet pressure of said RO concentrate flow to said first stage of said reverse osmosis housings to said PLC; an intermediate pressure transmitter configured to measure and transmit the intermediate pressure of said RO concentrate between said first stage of said housings and said second stage of said housings to said PLC; and, an outlet pressure transmitter configured to measure and transmit the concentrate outlet pressure of the second stage of said reverse osmosis housings to said PLC;

said RO concentrate outlet pressure is the inlet pressure to said recirculation control valve in said RO return conduit; and,

said PLC is configured to compute a difference in pressure measured between said inlet pressure and said outlet pressure across said first and second stages of said banks of said reverse osmosis housings; said PLC is configured to form a ΔP which is compared to a setpoint ΔP; said PLC computes a setpoint error signal, e(t), which is operated on by a control function of the PLC which outputs a signal to a positioner which is configured to position said recirculation control valve in response to said error e(t) of said differential pressure across said banks of said reverse osmosis housings and the position of said recirculation valve dictates the amount of concentrate flow through said recirculation control valve which, in turn, is configured to adjust the flow and the differential pressure across said first and second stages of said banks of said reverse osmosis housings.

2. The water filter comprising a ceramic microfiltration system and a reverse osmosis filtration system as claimed in claim 1 , further comprising:

said abrasion resistant ceramic filter membranes of said ceramic filter module are tubular and oriented in-line with the direction of the flow of the concentrate;

said tubular abrasion resistant ceramic filter membranes have pores, and said pore diameter size is 0.05 microns; and,

particles in said water having a diameter greater than 0.05 microns are retained within said recirculation loop.

3. The water filter comprising a ceramic microfiltration system and a reverse osmosis filtration system as claimed in claim 1 , further comprising:

said CMF filtrate is removed perpendicularly to said water flow.

4. The water filter comprising a ceramic microfiltration system and a reverse osmosis filtration system as claimed in claim 1 , further comprising:

said PLC is adapted to monitor and process a transmembrane pressure of said CMF module, said transmembrane pressure is calculated as: (inlet plus outlet pressures of the concentrate)/2 minus the (pressure of the filtrate).

5. The water filter comprising a ceramic microfiltration system and a reverse osmosis filtration system as claimed in claim 1 , further comprising:

said high temperature low fouling RO membrane is a spiral wound thin film polymeric membrane in a cross-flow configuration.

6. The water filter comprising a ceramic microfiltration system and a reverse osmosis filtration system as claimed in claim 5 , further comprising:

a RO membrane assembly including:

a perforated central tube which carries permeate axially therein; and,

a concentric membrane separated by a spacer which carries concentrate therein.

7. The water filter as claimed in claim 2 , further comprising:

said actual CMF concentration factor is computed as the (CMF filtrate flow plus the CMF concentrate reject flow) divided by the (CMF reject flow); and,

said actual RO concentration factor is computed as the (RO filtrate flow plus the RO concentrate reject flow) divided by the (RO reject flow).

8. The water filter as claimed in claim 1 , further comprising:

said PLC adapted to control said CMF concentrate reject valve based on said concentration factor includes a proportional plus integral controller; and,

said PLC adapted to control said RO concentrate reject valve based on said concentration factor includes a proportional plus integral controller.

9. The water filter as claimed in claim 1 , further comprising:

the CMF feed pump and the CMF recirculation pump are driven by variable frequency drives; and,

the RO feed pump and the RO recirculation pump are driven by variable frequency drives.

10. The water filter as claimed in claim 9 , further comprising:

said CMF feed pump supplies make-up water to said CMF recirculation loop to replace CMF filtrate and CMF concentrate removed from said CMF recirculation loop.

11. The water filter as claimed in claim 9 , further comprising: said RO feed pump supplies make-up water to said RO recirculation loop to replace RO filtrate and RO concentrate removed from said RO recirculation loop.

12. The water filter as claimed in claim 1 , further comprising:

another CMF module in series with said CMF module.