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Ullmann Filtration Fundamentals
Ullmann Filtration Fundamentals
Filtration, 1. Fundamentals
SIEGFRIED RIPPERGER, Gonbach, Germany
WALTER GoSELE, Heidelberg, Germany
CHRISTIAN ALT, Munchen, Germany
1.
2.
2.1.
2.1.1.
2.1.2.
2.2.
2.2.1.
2.2.2.
2.2.2.1.
2.2.2.2.
2.2.2.3.
2.2.2.4.
2.2.3.
2.3.
2.3.1.
2.3.2.
2.3.3.
2.4.
2.4.1.
2.4.2.
2.5.
3.
3.1.
3.2.
Terminology . . . . . . . . . . . . . . . . . . . . .
Filtration Models . . . . . . . . . . . . . . . . . .
Calculation of the Pressure Drop over the
Filter Medium and/or the Filter Cake . .
Definition of Filter Resistance and Cake
Permeability: The Darcy Equation . . . . . .
The Equation of Kozeny and Carman . . . .
Cake Filtration . . . . . . . . . . . . . . . . . . .
The Cake Filter Equation . . . . . . . . . . .
Evaluation of Experiments with
Linear Diagrams . . . . . . . . . . . . . . . . . . .
Linear Diagram in the Differential Form. .
Linear Diagram in Integrated Form . . . . .
Example . . . . . . . . . . . . . . . . . . . . . . . . .
Deviations from Linearity . . . . . . . . . . . .
Compressible Cake Filtration . . . . . . . . . .
Blocking Filtration and other Modes of
Filtration . . . . . . . . . . . . . . . . . . . . . . . .
Complete Blocking Filtration . . . . . . . . . .
Intermediate and Standard Blocking Filtration
Simplified Evaluation of Experimental Data
Depth Filtration . . . . . . . . . . . . . . . . . . .
Depth Filtration Mechanisms . . . . . . . . . .
Cleaning and Sizing of Deep Bed Filters .
Cross-Flow Filtration. . . . . . . . . . . . . . .
Washing of Filter Cakes . . . . . . . . . . . .
Basic Effects, Mass Balances . . . . . . . . .
Example of Experimental Results . . . . .
678
681
3.3.
3.4.
681
4.
4.1.
4.1.1.
4.1.2.
4.1.3.
681
681
682
682
4.1.4.
683
683
684
684
685
686
7.
687
687
687
688
688
688
690
691
693
693
694
Symbols
A:
a:
aH :
a m:
B:
b:
C:
c:
4.1.5.
4.2.
5.
6.
8.
8.1.
8.2.
8.3.
8.4.
8.5.
694
696
696
696
696
698
699
700
701
702
703
704
705
706
707
707
707
707
707
References . . . . . . . . . . . . . . . . . . . . . . . 708
c V:
dh :
dpore:
dS :
E:
e:
H:
I:
678
Filtration, 1. Fundamentals
J:
KH:
Km:
KN:
k:
L:
l:
m:
mi:
N:
n:
h:
p L:
pS :
Dp:
pc:
pce:
pci:
q:
r:
rD:
SR:
S:
S v:
S:
treg:
Q:
U c:
V:
_
V:
V/A:
zi:
z:
Y:
Indices
av:
e:
H:
L:
average
end of filtration
related to cake thickness (height)
liquid
Vol. 14
loc:
m:
N:
S:
w:
pore:
local
related to cake mass
number
solid
wash liquor
pore (volume)
1. Terminology
Filtration is the separation process of removing
solid particles, microorganisms or droplets from
a liquid or a gas by depositing them on a filter
medium also called a septum, which is essentially
permeable to only the fluid phase of the mixture
being separated. The particles are deposited
either at the outer surface of the filter medium
and/or within its depth. The permeation of the
fluid phase through the filter medium is connected to a pressure gradient.
This chapter deals only with filtration processes of solidliquid mixtures (suspensions, slurries,
sludges). For the treatment of gases by filtration
see ! Dust Separation.
Sometimes, however, purification of a liquid
or gas is called filtration even when no semipermeable medium is involved (as in electrokinetic
filtration).
The liquid more or less thoroughly separated
from the solids is called the filtrate, effluent,
permeate or, in case of water treatment, clean
water. As in other separation processes, the
separation of phases is never complete: Liquid
adheres to the separated solids (cake with residual moisture) and the filtrate often contains some
solids (solids content in the filtrate or turbidity).
The purpose of filtration may be clarification
of the liquid or solids recovery or both. In clarification the liquid is typically a valuable product
and the solids are of minor quantity and are often
discarded without further treatment. If however,
the solids are to be recovered, they very often
have to be washed, deliquored and dried (see
Fig. 1). In this article, washing means the
cleaning of a product (filter cake) and it is
distinguished from cleaning parts of the filter
itself, which will be called rinsing (e.g., rinsing
a filter screen or a filter cloth by jets of water). A
further distinction is to be made between washing
and extraction or leaching. Washing eliminates
liquid contaminants from the pores between the
Vol. 14
Filtration, 1. Fundamentals
679
680
Filtration, 1. Fundamentals
Vol. 14
Deep Bed or Depth Filtration. Solid particles are retained in a deep filter layer. This takes
place for example in sand filters for clarification
of drinking water, which retain even colloidal
particles. The typical effect of deep bed filtration
is adhesion of solids to the grains of the filter
layer. Only rather big particles are retained by
the screening effect. When the filter bed has been
saturated with solids, the solids concentration
in the filtrate leaving the bed progressively
approaches that of the incoming suspension.
Cross-Flow Filtration. In cross-flow filtration the suspension flows with high speed tangentially to the filter medium surface, preventing
the formation of a filter cake. Only a small flow of
liquid passes through the filter medium. A certain
layer of solids accumulates in the boundary layer
on the filter surface, and reduces the flow of
filtrate. After an initial period, a dynamic equilibrium is established between convective
transport of solids to the filter surface and removal of solids by hydrodynamic forces acting
on the particles due to turbulence and diffusion.
Surface filtration is the antonym to depth
filtration. The solids are retained on the surface
of a filter medium. Generally the models of cake
filtration or of blocking filtration can be applied.
Screening designates a classification process,
which retains the particles below a certain
size and lets pass the smaller ones through the
Vol. 14
Filtration, 1. Fundamentals
2. Filtration Models
2.1. Calculation of the Pressure Drop
over the Filter Medium and/or the
Filter Cake
2.1.1. Definition of Filter Resistance and
Cake Permeability: The Darcy Equation
V_
HhaH
A
1
m2
aH
681
V_
m
ham
A
A
"
1"Sv
6
dS
682
Filtration, 1. Fundamentals
Vol. 14
area. One can see that the specific surface and the
hydraulic pore diameter depend strong on the
particle sizes.
Based on a laminar flow inside a porous
system with pores of a hydraulic diameter dh
one get in combination with the Darcy equation
(1) an useful approximation for the specific
resistance of a porous medium:
1"2 36
1"2
aH 5
5 3 2 :
" Sv
"3 dS2
V_
A
V_
V_
bh
A
A
or
Figure 5. Filter resistance vs. particle size
The range of usual values is compared to the calculated lines
according to KozenyCarman, Equation (3)
Dp Dp1 Dp2 am h
V_
mV_
bh
2
A
A
Vol. 14
Filtration, 1. Fundamentals
cv
HA
1"
V
Km
m
V
or
DpA2
dV
DpA
aH hKH
dV bh dV
V
A2
dt
A
dt
Dp
am hKm
dV bh dV
V
A2
dt
A
dt
or
hV_ aH KH
Vb
A
A
bh
Dp
hV_ am Km
Vb
A
A
aH h
am hKm 2 bh
V
V
2A2 Dp
ADp
DV
A2
KH
dt
D Dp
dV
DV
AV
H
13
and
10
or
t
dt
D Dp
dV
dt
A
D Dp
dV e He
ahK
bh
VdV
dV
A2 Dp
ADp
aH hKH 2 bh
V
V
2A2 Dp
ADp
dt
D Dp dV
ahK
2
DV
A
12
am hKm
bh
V
bVa
DpA2
DpA
or
Dp
683
11
am h
dt
D Dp
dV
DV
A2
Km
2
dt
A
D Dp
dV e me
dt
D Dp
dV
DV
A2 V
m
14
684
Filtration, 1. Fundamentals
Vol. 14
Figure 7. Linear plots according to Equation (12) and (15) [7] A) Linear diagram in the differential form; B) Linear diagram in
the integrated form
If the pressure is constant during the experiment, a straight line should be obtained
t
am hKm
bh
V
2
2A Dp
V
ADp
aH hKH
bh
b
V
Va
2A2 Dp
ADp 2
15
2.2.2.3. Example
The interpolation of the test results shown in
Figure 7 leads to the intercept a and the slope b
a 3:6 s=mL 3:6 106 s=m3
and
b
28 s=mL
1:871011 s=m6
150 mL
Vol. 14
Filtration, 1. Fundamentals
Cake height He 37 mm
Cake mass me 24.3 g
Volume of
filtrate
Ve 154 cm3
685
A2 Dp
400108 105 2
0:1871011
m
Km h
158103
m
4:731011
kg
am b
Concentration factors:
KH
0:481
Ve
154106
or
Km
me 24:3103 kg
kg
158 3
Ve
m
154106 m3
DpA
105 20104 1
m
3:6106
h
103
7:21011 m1
AHe 1"
KH 1" 0:289
Ve
A2 Dp
400108 105 2
0:1871011
m
KH h
0:481103
1:561014 m2
Figure 8. Typical deviations from linearity [7] A) Differential plot according to Equation (12); B) Integral plot according to
Equation (15)
686
Filtration, 1. Fundamentals
Vol. 14
aav
Dp
Rp dp
0
aloc
Normally however, it is much easier to measure aav directly with filtration experiments in a
pressure filter as described in ! Filtration, 2.
Equipment, Chap. 2.. The uneven distribution of
local porosity and filter resistance is then included in the measured value. In this case the pressure
difference during the experiment must be the
same as in the factory equipment.
The dependence of filter resistance aav or aloc
on pressure can be approximated with different
equations. Over a limited pressure range Equation (16) can be used
a a0
n
pS
po
16
17
Vol. 14
a0;av 1na0;loc
Filtration, 1. Fundamentals
18
687
Nt N0 1KN VL
1
1expKN V_ 0 t
KN
const
dV 2
dV
19
20
688
Filtration, 1. Fundamentals
Vol. 14
21
22
Vol. 14
Filtration, 1. Fundamentals
689
c c0 expl0 L
qc
lc
qL
690
Filtration, 1. Fundamentals
Vol. 14
Figure 12. Laboratory test equipment for sand filters A) Test filter; B) Pressure profiles in test filter [15]
1m
0.51 mm (as uniform as possible)
510 m3 m2 h1
60 m3 m2 h1 for 10 min
1530 m3 m2 h1 for 38 min
after air scour
During backflow the sand grains are classified, the smallest ones are entrained to the top, the
coarse ones sink to the bottom of the filter bed.
This effect is undesired, since it leads to premature blocking of the top layer. Therefore it is
important to use sand with grain sizes as uniform
as possible.
The sizing of a deep bed filter consists of the
following steps:
1. Preselection of the filter material by comparative laboratory tests with small layers of
different materials under standard conditions
and with the filtrate quality as a criterion
2. Selection of the right grain size in pilot
tests with a filter column of 1 m height and
a realistic flow rate and pressure drop
The minimum diameter of the cylindrical bed
is 150 mm. If necessary the grain size must be
adapted so that the bed is saturated (the filtrate
gets turbid) at the same time as the maximum
pressure drop is reached. If the maximum pressure drop is reached first, the grains should be
coarser and vice versa. The ability to clean the
filter bed by back-flushing should also be tested.
As mentioned above the sand grains are
classified during back-flush and the uppermost
layer is most efficient in collecting and becomes
Vol. 14
clogged rapidly by captured solids. This disadvantage is diminished when a second layer of
coarse material with lower specific weight is
added on top of the sand layer. During backflow
these low density grains collect at the bed surface
and form a coarse layer able to retain a great
quantity of dirt (so-called multimedia filters or
dual media filters, e.g., with a layer of anthracite
particles 12 mm in size on top of a main layer of
sand grains 0.51 mm in size.)
Other designs of sand filters convert the disadvantage of classification into an advantage by
operating in the upflow mode with filtering and
back-flushing from below. This offers the advantage that large quantities of incoming dirt are
retained in the lower layer of sand, which contains the coarser grains and larger pores. These
upflow filters however need special safeguards
against breakthrough of dirt when the pressure
drop becomes high.
In order to increase the retention capacity in
a given volume, it has also been proposed to use
porous grains instead of sand grains. Small pieces
of polymeric foam have indeed this effect [19].
Cleaning by simple back-flush is, however, not
possible with this material, it must be cleaned
by back-flush combined with compression.
Therefore this method has not yet found practical
application.
Quasi-continuous operation can be achieved
using two ore more conventional deep bed filters
in parallel. Truly continuous deep bed filters
operates in the normal manner expect a portion
of the filter bed is continuous or intermittently
removed from the lower layer, cleaned to removed the contaminant and then automatically
returned to the top of the filter bed. The cleaning
and transport of the particles is mostly realized in
the same time form of a hydraulic transport from
the bottom to the top of the filter bed.
Filtration, 1. Fundamentals
691
692
Filtration, 1. Fundamentals
Vol. 14
Ultrafiltration
Nanofiltration
Reverse osmosis
Cut-off size
> 100 nm
0.020.5 MPa
501000 L m2 h1
26 m/s
screening by the pores
of the membrane
hydrodynamic lift
force
> 1 nm
200103 g/mol
0.53 MPa
< 100 L m2 h1
12 m/s
electrostatic repulsion
and screening
back-diffusion
Transmembrane pressure
Permeate flow
Cross-flow speed
Important mechanism
of retention
Important mechanism
of transport
10100 nm
103105 g/mol
0.21 MPa
< 100 L m2 h1
16 m/s
screening by the membrane
and the gel layer
back-diffusion
220 MPa
1035 L m2 h1
< 2 m/s
solubility and diffusion
in the membrane
back-diffusion
Vol. 14
Filtration, 1. Fundamentals
693
cdV c0 Vpore
0
Figure 14. Concentration of contaminant in the effluent of a filter cake during washing a) Idealized piston flow; b) Effect of
axial dispersion; c) Effect of diffusion from dead-end pores; d) Effect of contaminant extracted from the solid
694
Filtration, 1. Fundamentals
Vol. 14
Figure 15. Residual concentration of salt in filter cakes of kaolin A) Test results reported as a function of the quantity of wash
water; B) Test results reported as a function of washing time [22]
Vol. 14
Filtration, 1. Fundamentals
695
696
Filtration, 1. Fundamentals
Vol. 14
Vol. 14
Filtration, 1. Fundamentals
697
Figure 19. Test installation for measuring the capillary pressure pk [25] a) Filter vessel; b) Filter cake; c) Semipermeable
membrane; d) Draine; e) Entry for gas
4scosd
dpore;neck
23
4scosd
dpore;waist
Figure 20. Example of a capillary pressure curve for imbibition and for deliquoring [25]
698
Filtration, 1. Fundamentals
Vol. 14
kw
a
k
aw
kn
a
k
an
Figure 21. Kinetics of deliquoring A) Deliquoring by gas blowing; B) Deliquoring by gravity or a centrifugal field
Vol. 14
Filtration, 1. Fundamentals
699
reduced saturation
SR
S
1S
dimensionless time
Q
pce t
aH hH 2 1S "
pentry pexit
pce
pce
According to this approach, the cake is characterized by its porosity e, the filter resistance aH
(of the saturated cake) and the capillary pressure
curve which itself is approximately described by
the capillary entry pressure pce and the irreducible saturation S (see Fig. 20). The relative
permeabilities are described by generalized interpolation formula. With these approximations
the residual saturation and the theoretical gas
flow rate can be read from the dimensionless
charts, shown in Figures 23 and 24. An example
how to apply these charts is given in [29]. However, the validity of these charts is limited to
pce p and to incompressible cakes. Also the
gas flow rate indicated on the chart does not take
into account the possibility of cracks in the cake
which can increase the gas flow tremendously
(see Section 4.1.5).
700
Filtration, 1. Fundamentals
Vol. 14
Dpt
Dpt
const 2
hHaHb
H
Here Dp pentry pexit is the pressure difference applied. This approach gives generally
good results for centrifugal dewatering, as shown
in Figure 25 (the pressure difference being calculated from the centrifugal force) [30]. For
dewatering by gas blowing, the fit is, however,
often unsatisfactory (see Fig. 26) [30]. A dimensionless time taking into account the capillary
entry pressure pce will always permit a good fit.
Two equations are proposed in the literature [30]:
Q1
Dpt
pentry
hHaHb pexit
const
Dpt pentry
H 2 pexit
1 pDp
ce
1 pDp
ce
Figure 25. Residual saturation of filter cakes dewatered by centrifugal force as a function of dimensionless time Q0 [30]
Vol. 14
Filtration, 1. Fundamentals
701
Figure 26. Residual saturation of filter cakes dewatered by gas blowing as a function of dimensionless time Q0 [30]
and [31]
1 pDp
Dpt
p
const
1
H Dp
Q1
Dpt 2
ahH 2 "
ce
ce
Figure 27. Residual saturation of filter cakes dewatered by centrifugal force as a function of the modified dimensionless time
Q1 [30]
702
Filtration, 1. Fundamentals
Vol. 14
pressed by lateral forces. This and the capillary forces may lead to lateral compression of
the cake and hence to cracks (Fig. 29 (3-4)).
The criterion for cracks to occur thus probably
depends on the lateral compressive strength of
a cake after monoaxial consolidation. But until
now the precise mechanism of crack formation
is not understood and the great variety of crack
patterns shown in Figure 28 [32] cannot be
explained.
Cracks in a filter cake are very detrimental
to further deliquoring and also to subsequent
washing (see Chap. 3) because gas and wash
liquid flow through the cracks without great
Vol. 14
Filtration, 1. Fundamentals
H1 Ht
1BexpCt
H1 H
703
Figure 30. Optimal cycle time derived from the yield curve;
topt,1 for maximal flow per time and topt,2 for maximal yield per
cost
the filter (extracting the cake from the previous cycle, cleaning the filter, rearranging
the filter elements, etc.). The highest overall
throughput is obtained when the straight line
from the start of this regeneration to the end of
filtration is tangential to the yield curve. In
other words: the filtration should be stopped
when the instantaneous flow (as indicated by
a flow meter) falls below the mean throughput
according to the definition:
V_ mean
V
ttreg
24
This criterion can for example be implemented in a computerized process control. For design
purposes it can be useful to calculate the optimal
cycle time in advance. For this purpose a rule-ofthumb will be derived assuming cake filtration
and negligible resistance of the filter medium
(b 0). The quantity of filtrate according to
Equation (10) or (11) is then
V c1 t1=2
25
c1 t
V_ mean
ttreg
704
Filtration, 1. Fundamentals
V
filtrate
t
t
filtrate c1 opt;2 c1 opt;2
Vol. 14
forces between suspended particles of equal material are described by repulsion due to electrostatic charges and attraction due to van der
Waals forces:
Repulsion. Particles in suspension (especially in polar liquids like water) have an electrically charged surface due to adsorption and
dissolution of ions. The order of magnitude of
this charge z is 120 mV < z < 120 mV, and it
depends on the pH of the liquid. The charge
reaches relatively far, depending on the ion content of the surrounding liquid. The reach is
characterized by the Debye length rD. In pure
distilled water this length is exceptionally long
with 0.9 mm. In most technical aqueous solutions
it is much smaller, in sea water for example only
0.4 nm [37].
Attraction. Van der Waals forces are part of
the cohesive forces between the molecules within
the solid particle. They reach also a certain
distance beyond the surface, but their range is
less than that of electrostatic forces. The decline
is proportional to the distance according to
Eattraction
const
r
Interparticle
contact. Electrostatically
charged particles repulse one another. In com-
c2 topt;2 creg
Vol. 14
Filtration, 1. Fundamentals
705
7. Mathematical Simulation of
Filtration and Cake Formation
706
Filtration, 1. Fundamentals
Vol. 14
A comprehensive simulation of cake formation has not yet been proposed. The above
mentioned approaches are restricted to spherical particles with uniform surface charge.
Often, however, the electric charge is unevenly distributed, and there may even exist oppositely charged spots on the same particle. This
would explain why many suspensions form
loose flocs when the stirrer is stopped. This
is quite often observed even if the pH is not
exactly at the isoelectric point (the term isoelectric range would therefore be more appropriate than isoelectric point). The flocs disappear when the stirrer starts again, but nevertheless they probably have an impact on filterability because the particles are prearranged
in a way that they touch with their rough,
adhesive spots and have less tendency to slip
into densely packed positions when deposited
on the filter cake.
8. Handling of Unfilterable
Suspension
In industrial filtration often suspensions are encountered with a high filter resistance. Several
possibilities for handling of these unfilterable
suspensions are given below.
Vol. 14
Filtration, 1. Fundamentals
707
8.3. Adaptation of pH
As explained in Chapter 6, the interparticle
forces depend on the pH of the surrounding
liquid. With a pH in the isoelectric range the
particles can aggregate and their filter resistance
and settling speed is increased.
708
Filtration, 1. Fundamentals
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osele, Filtrieren Separieren 9 (1995) no. 1, 14 22.
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17 K. J. Ives, in A. Rushton (ed.): Mathematical Models and
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18 G. Dierckx in: La Filtration Industrielle des Liquides,
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19 A. Palinski, W. Uhl, R. Gimbel, Vom Wasser 89 (1997)
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20 J. Altmann, S. Ripperger, J. Membrane Sci. 124 (1997)
119 128.
21 S. Ripperger, J. Altmann, Filtrieren Separieren 11 (1997)
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22 W. Bender, Chem. Ing. Tech. 55 (1983) no. 11, 823 829.
23 K.-H. Steiner, Chem. Ing. Tech. 61 (1989) no. 1, 1 8.
24 H. Anlauf, Fortschrittsber. VDI, Reihe 3, 114 (1986) .
25 H. Schubert: Kapillarit
at in por
osen Feststoffsystemen,
Springer Verlag, Heidelberg 1982, p. 184.
26 H. Anlauf, Maschinenmarkt 95 (1989) no. 8, 26 30.
27 R. J. Wakeman: Cake Dewatering, in L. Svarovsky
(ed.): Solid Liquid Separation, Butterworths, London
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28 R. J. Wakeman, Filtr. Sep. 16 (1979) no. 6, 655 669.
29 A. Rushton, A. S. Ward, R. G. Holdich: Solid Liquid
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Vol. 14
Further Reading
G. G. Chase, E. Mayer: Filtration, Kirk Othmer Encyclopedia of Chemical Technology, 5th ed., vol. 11, p. 321
397, John Wiley & Sons, Hoboken, 2005, online: DOI:
10.1002/0471238961.0609122019220118.a01.pub2
(March 2003)
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