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Filtration, 1. Fundamentals
SIEGFRIED RIPPERGER, Gonbach, Germany
WALTER G€oSELE, Heidelberg, Germany
CHRISTIAN ALT, M€unchen, Germany
Symbols
c V: solid concentration as a part of total
A: cross-sectional area, filter area, m2 volume
a: resistance of a porous medium dh : hydraulic pore diameter of a porous
aH : cake resistance relative to cake structure
thickness, m2 dpore: capillary diameter, m
a m: cake resistance relative to dry mass, dS : Sauter mean diameter of particles, m
m/kg E: electrostatic potential at the solids
B: creep constant surface, V
b: resistance of the filter medium, m1 e: porosity of the porous medium
C: creep constant H: cake thickness
c: Concentration of the suspension I: ionic strength, mol/L
particles of a filter cake. Extraction recovers in air). In some cases the liquid is allowed to flow
soluble matter out of the solid particles them- through the filter medium only by gravity (gravi-
selves (! Liquid–Solid Extraction). The term ty filtration). Centrifugal filtration is done in
drying means thermal drying, while the elimina- perforated centrifuge rotors (! Centrifuges,
tion of liquid from the filter cake by mechanical Filtering).
forces is called deliquoring or dewatering, e.g., In case of vacuum filters the cake is freely
deliquoring by a pressurized gas or by expres- accessible. This facilitates automatic cake han-
sion. dling. However, vacuum filters cannot handle hot
Filtration processes can be classified in accor- liquids, or solvents with high vapor pressure. The
dance with different criteria: pressure difference across vacuum filters is very
limited, and the residual moisture of the filter
1. Location of particle retention cake is higher than with pressure filters. Pressure
The particles can be separated on the outer filters allow high pressure differences. They are
surface of the filter medium (surface filtra- preferred when the product must be kept in
tion, cake filtration) or inside of the filter a closed system for safety reasons, or if the
medium (depth filtration, deep bed filtration) residual moisture content is important. The han-
2. Generation of the pressure difference dling of the filter cake is obviously more difficult
Pressure filtration, vacuum filtration, gravity in a pressure filter. Filtration by centrifugal
filtration, centrifugal filtration force requires more technical equipment, but as
3. Operation mode a general rule it yields solids with lower residual
discontinuous, continuous, quasi-continuous. moisture (! Centrifuges, Filtering).
Dynamic filtration and static (normal) filtra- During a dynamic filtration the collected
tion. In case of dynamic filtration are during solids on the filter media are continuously
the filtration process mechanisms active removed, mostly with a tangential flow to the
which helps to reduce the build up of a filter filter medium (cross-flow filtration). Cross-flow
cake. The most common dynamic filtration filtration is a standard operation with membranes
process is cross-flow-filtration as a filter medium. The flow parallel to the filter
4. Application medium reduces the formation of a filter cake or
For example water filtration, beer filtration
keeps it at a low level. So it is possible to get Deep Bed or Depth Filtration. Solid par-
a quasi-stationary filtrate flow for a long time. ticles are retained in a deep filter layer. This takes
Various models have been developed to place for example in sand filters for clarification
describe the physical process of filtration. This of drinking water, which retain even colloidal
chapter concentrates on four idealized filtration particles. The typical effect of deep bed filtration
models depicted in Figure 3. is adhesion of solids to the grains of the filter
layer. Only rather big particles are retained by
Cake filtration is the most frequently used the screening effect. When the filter bed has been
model. Here it is assumed that the solids are saturated with solids, the solids concentration
deposited on the upstream side of the filter me- in the filtrate leaving the bed progressively
dium as a homogeneous porous layer with approaches that of the incoming suspension.
a constant permeability. As soon as the first layer
of cake is formed, the subsequent filtration takes Cross-Flow Filtration. In cross-flow filtra-
place an the top of the cake and the medium tion the suspension flows with high speed tan-
provides only a supporting function. Thus, if the gentially to the filter medium surface, preventing
flow rate dV/dt is constant, the pressure drop will the formation of a filter cake. Only a small flow of
increase linearly, proportional to the quantity of liquid passes through the filter medium. A certain
solid deposited. This model can be applied espe- layer of solids accumulates in the boundary layer
cially for all hard, particulate solids. on the filter surface, and reduces the flow of
filtrate. After an initial period, a dynamic equi-
Blocking Filtration. The pressure drop is librium is established between convective
caused by solid particles blocking pores. Soft, transport of solids to the filter surface and re-
gelatinous particles retained by a sieve exhibit moval of solids by hydrodynamic forces acting
such a behavior. If the flow rate dV/dt is constant, on the particles due to turbulence and diffusion.
the pressure drop increases exponentially with Surface filtration is the antonym to depth
the quantity filtered, the number of open pores filtration. The solids are retained on the surface
asymptotically approaching zero. The pores may of a filter medium. Generally the models of cake
belong to a filter medium (screen or filter layer) or filtration or of blocking filtration can be applied.
it may be pores within a filter cake of coarse Screening designates a classification process,
particles, which are blocked by migrating fine which retains the particles below a certain
particles. size and lets pass the smaller ones through the
Vol. 14 Filtration, 1. Fundamentals 681
openings of the screen (! Screening). Often the of the filter resistance aH is also called perme-
term screening-filtration is also used to designate ability k of the filter cake:
a surface filtration with a screen as a filter medi-
1
um. Its mode of action resembles screening (or k¼ ½m2
aH
straining) as long as the filter medium is clean,
but it is clearly a cake filtration as soon as a layer
of solids has formed. Sometimes it is more convenient to define
cake thickness in terms of solid mass m per unit
filter area am (unit kg/m2). This leads to a slightly
2. Filtration Models different definition of filter cake resistance. A
corresponding equation to the Darcy equation
2.1. Calculation of the Pressure Drop can be written with a constant am with the unit m/
over the Filter Medium and/or the kg describing the resistance of the cake.
Filter Cake Then the following expression is obtained
instead of Equation (1)
2.1.1. Definition of Filter Resistance and
V_ m
Cake Permeability: The Darcy Equation Dp1 ¼ ham ð2Þ
A A
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:
ð1"Þ2 36 ð1"Þ2
aH 5 5 3 2 : ð3Þ
"3 dS2 " Sv
or
Figure 5. Filter resistance vs. particle size
mV_ V_
The range of usual values is compared to the calculated lines Dp ¼ Dp1 þDp2 ¼ am h 2
þbh
according to Kozeny–Carman, Equation (3) A A
Vol. 14 Filtration, 1. Fundamentals 683
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
2.2.2.2. Linear Diagram in Integrated Form In case of a short filter cycle, the evaluation of
the real beginning of filtration and the determi-
Another approach starts from the integrated filter nation of the filter medium resistance could be
Equations (10) or (11). The experimental results problematic. Tichy [8] showed, that the crossing
are plotted according to point of the combined graphs of Equation (12)
and (15) gives a realistic starting point. He also
t
¼ f ðVÞ showed, that the filter medium resistance based
V
on filter experiments is much higher than the
filter medium resistance evaluated on the pres-
If the pressure is constant during the experi- sure drop of a clean liquid (water). The reason for
ment, a straight line should be obtained that the increase is an additional resistance based
t am hKm bh on a partial pore blocking of the filter medium
¼ 2 Vþ during the first layer formation.
V 2A Dp ADp
ð15Þ
aH hKH bh b
¼ Vþ ¼ Vþa 2.2.2.3. Example
2A2 Dp ADp 2
Concentration factors:
AHe 20104 0:037 2.2.2.4. Deviations from Linearity
KH ¼ ¼ ¼ 0:481
Ve 154106
or Experimental data very often differ from the
linear characteristic shown in Figure 7. The kind
me 24:3103 kg kg of deviation indicates the nature of secondary
Km ¼ ¼ ¼ 158 3
Ve 154106 m3 m effects (see Fig. 8):
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
2.3. Blocking Filtration and other A summary of the corresponding equations for
Modes of Filtration flow rates and filtrate quantities is given in [12,
13]. Figure 10 visualizes some examples: Surface
2.3.1. Complete Blocking Filtration straining represents the classical example of com-
plete blocking (q ¼ 2), but also depth straining
According to the idealized idea of complete follows the same characteristic. Normal depth
blocking filtration, every particle in the suspen- filtration in contrast (with particles much smaller
sion is retained on the filter medium and blocks than the filter pores) leads to pressure drop by
(seals) one pore. The remaining number of open diminishing pore size and can be described by the
pores is then given by standard blocking equation (q ¼ 3/2).
688 Filtration, 1. Fundamentals Vol. 14
c ¼ c0 expðl0 LÞ
Figure 12. Laboratory test equipment for sand filters A) Test filter; B) Pressure profiles in test filter [15]
required flow cannot be maintained and the filter This effect is undesired, since it leads to prema-
should be cleaned. ture blocking of the top layer. Therefore it is
important to use sand with grain sizes as uniform
as possible.
2.4.2. Cleaning and Sizing of Deep Bed The sizing of a deep bed filter consists of the
Filters following steps:
Depth filters in form of deep bed filters (e.g., sand 1. Preselection of the filter material by compar-
filters) [16, 17] can be cleaned by back-flushing. ative laboratory tests with small layers of
The flow is reversed to wash off deposited solids different materials under standard conditions
and flush them, e.g., to a wastewater station. and with the filtrate quality as a criterion
Often air scour is used to increase the movement 2. Selection of the right grain size in pilot
of the particles and reduce the amount of water tests with a filter column of 1 m height and
necessary for fluidization. A typical set of data of a realistic flow rate and pressure drop
a sand filter for cleaning of water could be [18]:
The minimum diameter of the cylindrical bed
is 150 mm. If necessary the grain size must be
Medium depth 1m adapted so that the bed is saturated (the filtrate
Medium size 0.5–1 mm (as uniform as possible)
gets turbid) at the same time as the maximum
Flow rate during filtration 5–10 m3 m2 h1
Flow rate air scour 60 m3 m2 h1 for 10 min pressure drop is reached. If the maximum pres-
Flow rate water backflow 15–30 m3 m2 h1 for 3–8 min sure drop is reached first, the grains should be
after air scour coarser and vice versa. The ability to clean the
filter bed by back-flushing should also be tested.
During backflow the sand grains are classi- As mentioned above the sand grains are
fied, the smallest ones are entrained to the top, the classified during back-flush and the uppermost
coarse ones sink to the bottom of the filter bed. layer is most efficient in collecting and becomes
Vol. 14 Filtration, 1. Fundamentals 691
clogged rapidly by captured solids. This disad- is discharged from the filter. The cross-flow
vantage is diminished when a second layer of stream over the filter media has often a linear
coarse material with lower specific weight is velocity in the range of 1 to 6 m/s. This cross-flow
added on top of the sand layer. During backflow is achieved in most cases by pumping the sus-
these low density grains collect at the bed surface pension through a membrane module, which e.g.,
and form a coarse layer able to retain a great contains the membrane in form of a bundle of
quantity of dirt (so-called multimedia filters or membrane tubes (! Filtration, 2. Equipment,
dual media filters, e.g., with a layer of anthracite Section 10.1.). Alternatively the cross-flow is
particles 1–2 mm in size on top of a main layer of achieved by rotating inserts. The limitation of
sand grains 0.5–1 mm in size.) the deposition of particles and macromolecules
Other designs of sand filters convert the dis- on the membrane surface enables to filter very
advantage of classification into an advantage by fine particles, which otherwise would form a cake
operating in the upflow mode with filtering and with prohibitively high resistance. Even submi-
back-flushing from below. This offers the advan- cron, nonparticulate matter can be retained by
tage that large quantities of incoming dirt are membranes with a corresponding separation
retained in the lower layer of sand, which con- characteristic according to this principle. The
tains the coarser grains and larger pores. These shearing action on at the membrane surfaces
upflow filters however need special safeguards limits the deposition of retained matter due to
against breakthrough of dirt when the pressure lift forces and diffusion processes back from
drop becomes high. the membrane. In normal operation the filtrate
In order to increase the retention capacity in (respectively permeate) is collected and the con-
a given volume, it has also been proposed to use centrate is re-circulated until the desired concen-
porous grains instead of sand grains. Small pieces tration of retained components is achieved, or
of polymeric foam have indeed this effect [19]. pumping can not be longer performed due to
Cleaning by simple back-flush is, however, not raised viscosity of the suspension. Typical units
possible with this material, it must be cleaned comprise one ore more membrane modules and
by back-flush combined with compression. a recirculation pump.
Therefore this method has not yet found practical In this chapter a short overview will only be
application. given, covering both the filtration of particles and
Quasi-continuous operation can be achieved the separation of nonparticulate matter. For more
using two ore more conventional deep bed filters details see ! Membranes and Membrane Sepa-
in parallel. Truly continuous deep bed filters ration Processes, 1. Principles. Depending on the
operates in the normal manner expect a portion size of the species retained, a distinction is made
of the filter bed is continuous or intermittently between microfiltration, ultrafiltration, nanofil-
removed from the lower layer, cleaned to re- tration, and reverse osmosis. Typical parameters
moved the contaminant and then automatically of cross-flow filtration are summarized in
returned to the top of the filter bed. The cleaning Table 1.
and transport of the particles is mostly realized in
the same time form of a hydraulic transport from Cross-flow Microfiltration. Microfiltration
the bottom to the top of the filter bed. retains particles and microorganisms down to
0.1 mm in size. In steady-state cross-flow filtra-
tion these particles are conveyed onto the mem-
2.5. Cross-Flow Filtration brane by convection due to the filtrate flow and
transported away from it by hydrodynamic lift
Cross-flow filtration is a form of a dynamic forces due to the parallel shear flow (forces FY
filtration. In cross-flow filtration the build-up of and FL in Fig. 13). For particles below a certain
a filter cake on the surface of the filter media is size the lift force becomes smaller than the
hindered by a strong flow tangentially (parallel) convection, FL < FY, and they are deposited on
to the filter surface. Clear liquid passes through the membrane [20]. After deposition they are
the filter medium (mostly a membrane) and retained by van der Waals’ adhesion forces FA
the concentrate (respectively the retentate) with and not easily swept away even if there is no
higher concentrations of the rejected components filtrate flow (irreversible cake formation). In case
692 Filtration, 1. Fundamentals Vol. 14
of a steady-state microfiltration there is an away from the filter medium by diffusion. This is
equilibrium between the lift force and the drag why in ultrafiltration the smaller particles are
force due the convection by the filtrate flow and preferably swept away and the bigger ones are
a critical particle size. This steady-state flow is collected on the membrane (contrary to micro-
often mentioned as critical flux. In most practical filtration). The cut-off size of an ultrafiltration
applications also colloidal particles are present membrane is usually defined as the molar mass
and they are transported according to the me- (in g/mol) of a test solution (generally protein or
chanisms of ultrafiltration or they are able to dextran molecules of defined molar mass in the
permeate through the microporous membrane of range of 103–105 g/mol). In practical application
microfiltration. The cut-off size of a microfiltra- the cut-off size depends not only on the pore size
tion membrane is usually defined as the size of of the membrane, but to a large degree on a gel
particles of a test suspension (generally a sus- layer on the membrane consisting of retained
pension of microorganisms) which are nearly colloids.
absolute retained.
Nanofiltration combines features of ultra-
Ultrafiltration retains colloidal particles or filtration and reverse osmosis with a high selec-
macromolecules. The cut-off sizes are ca. < 0.1 tivity. Its name is derived from its approximate
mm. Such particles are subject to Brownian dif- cut-off size of some nanometers or more exactly
fusion (Br in Fig. 13) and only weakly influenced molar masses of 200–600 g/mol. This is
by the hydrodynamic lift force [21]. The smaller achieved with special nanofiltration membranes
these particles are, the more they are transported which still have pores of a defined size, but their
retention depends also on the electrostatic charge
of the molecules to be separated (bivalent anions
are typically retained).
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
particular process. The validity of such empirical quantity of wash liquid becomes better for thick
correlation is, however, restricted to the particu- cakes than for thin ones.
lar equipment and operating parameters. Figure 15 B shows how at the end of an
experiment the washing time is the most relevant
parameter for the result. In this example this
3.2. Example of Experimental Results seems to be true below a residual concentration
of
An illustrative example of a washing process is c
given in Figure 15 A and B [22]. A kaolinite 103
c0
suspension contaminated with NaCl was filtered
to varying cake thickness and washed with vary-
ing quantities of water. After every test the
residual salt content in the cake was measured 3.3. Test Procedures and Pitfalls
and the results are reported as a function of
washing time and of wash ratio. (In contrast to As can be seen in Figure 15, washing of filter
Fig. 14 the wash-ratio is related to the solids cakes gives scattering results even under labora-
mass, not the pore volume. Also the residual tory conditions. This explains why only few
content of the cake is reported, not the concen- experimental results are found in the literature:
tration in the filtrate) many experimentators are discouraged by incon-
Figure 15 A shows how at the very beginning clusive test results and never publish them. The
of the washing process the residual concentration reason of scattering results are stochastic
depends on the wash ratio, disregarding the cake influences:
thickness. In this example this is true up to the
dash-dotted line which corresponds to less than Fingering. In most washing processes the
a one-fold displacement of the pore volume. As wash liquid has a lower viscosity than the mother
the wash ratio increases to several times the pore liquor. It tends to flow through the cake in finger-
volume, the mechanism of axial dispersion be- like streams past isles of viscous fluid, as shown
comes more important, and the effect of a given in Figure 16 [22]. This is a stochastic process,
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
and the local concentration in the cake and the not surprising because the contact forces between
momentary concentration in the effluent will the particles change dramatically when the ion
vary stochastically. Scale-up from a laboratory content of the surrounding liquid is washed off
test filter with only small-scale fingering can be (see Chap. 6). The phenomenon has not yet been
misleading as well as the results of few small investigated thoroughly, but its stochastic effects
samples taken from a big cake. on the washing results should be similar to the
above-mentioned fingering.
Instabilities Shrinking. If small electrodes If shrinking during washing presents a serious
are placed in a filter cake during the washing problem, it can be helpful to reslurry the cake in
process, they indicate wildly varying local con- wash liquid and filter it again. Many nutsche
ductivity. This reveals the existence of small filters (! Filtration, 2. Equipment, Chap. 3.) are
cracks in changing size and positions even in used this way. The second cake (with less ions in
cakes with no visible fissures or shrinkage. This is the liquid during cake build-up) is often less
porous and less prone to shrinking (but also less
permeable) than the original one.
In order to get meaningful results from wash-
ing experiments in spite of all these pitfalls,
the following procedure is useful (see Fig. 17).
Wash liquid flows at constant pressure through
the cake. The quantity of filtrate and its compo-
sition are recorded automatically. Often the pH
and the conductivity Q of the filtrate are used as
indicators for concentration; sometimes its color
may be more informative. The washing is con-
tinued until the filtrate reaches a pre-set criterion
for purity (chosen according to some preliminary
experience so that cake purity is near to the
required specification). At this point the flow of
wash water is automatically stopped. This should
be done automatically, since it will probably
happen during the night. The next morning, the
cake is deliquored by air blowing and its residual
content is analyzed. In small-scale experiments
the whole cake should be analyzed, in large-scale
experiments several samples must be taken from
different parts of the cake.
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
water). Starting from the completely saturated at the neck of the pores with a diameter dpore,neck:
cake (S ¼ 1) the gas pressure is slowly increased,
4scosd
at each set point the equilibrium is established pce ¼ ð23Þ
dpore;neck
and the quantity of displaced liquid is registered,
yielding a point of the deliquoring curve. Liquid
is displaced from the pores when the pressure Further increase of the pressure displaces liquid
exceeds a certain threshold pressure. This is the from finer pores and reduces the moisture down to
capillary entry pressure pce (in this example an irreducible saturation S¥ after infinite time
0.062 bar). Each time when a pore is emptied, beyond which no further reduction is reached. This
the gas pressure overcomes the capillary pressure corresponds to the amount of liquid, which is
trapped in isolated domains within the cake.
Figure 20 also shows the imbibition curve.
When the pressure is reduced again, and provid-
ed that the bottom of the cake is still in contact
with the expelled liquid, then the cake will be
reimbibed by capillary suction. At equal mois-
ture content the suction pressure will be smaller
than the capillary pressure difference for deli-
quoring. This is easily explained because the
capillary pressure for imbibition depends on the
larger waist-diameter of the pores (see Fig. 20):
4scosd
pci ¼
dpore;waist
but not for the deliquoring itself. No gas flow The gas exerts capillary pressure onto the adjacent
is necessary if the cake is placed on a semi- liquid and both gas and liquid flow in the same
permeable membrane, which is impermeable direction, however, with different speeds and
for gas. (This principle can also be used different pressures (the local pressure difference
technically for dewatering without gas flow between gas and liquid is equal to the local capil-
[26]) lary pressure). The difference in saturation be-
2. A certain threshold pressure must be exceeded tween bottom and top of an incompressible filter
before liquid is displaced from the pores; this cake is normally rather small, see Figure 21 A.
is the capillary entry pressure pce. This implies This is in contrast to the deliquoring by gravity (or
technical consequences: by a centrifugal field), shown in Figure 21 B. In
3. Vacuum filters are restricted to pressure dif- this latter case always a saturated bottom layer
ferences < 1 bar. This means that cakes can- exists, corresponding to the capillary suction
not be deliquored by suction if their pce is near height of the cake. Even in equilibrium this
or above this limit. A pressure filter with layer remains saturated. Sometimes this height
Dp> 1 bar has to be considered for such is negligibly small. In scraper-type centrifuges
cakes, even if its installation is much more (! Centrifuges, Filtering) for example, the satu-
expensive than that of a vacuum filter. Theo- rated bottom layer must be smaller than the resid-
retically suction can dewater filter cakes with ual layer which the scraper does not remove.
pores > ca. 3 mm: with pure water and a small The permeability of a completely saturated
contact angle (d 0) Equation (23) yields cake is the same if either liquid or gas flows
p ¼ 1 bar for dpore ¼ 2,9 mm. through the pores. When, however, gas and liquid
flow simultaneously through the cake, the pores
Filter cakes of submicronic particles like filled with liquid and the pores filled with gas
wastewater sludge have such a high capillary form two separate capillary systems, each of
entry pressure that their pores cannot be dewa- them with reduced permeability. The local per-
tered mechanically: with pure water and a small meabilities (for liquid or air) in relation to the
contact angle Equation (23) yields p > 10 bar permeability of the saturated cake are called
for dpore < 0.29 mm. relative permeabilities krel. They depend on the
local saturation of the cake and can be repre-
sented as:
4.1.2. Kinetics of Deliquoring by Gas for the wetting fluid (the liquid)
Pressure kw a
krel;w ¼ ¼
k aw
In most cases there is no semipermeable mem-
brane below the cake but a normal filter medium for the nonwetting fluid (the gas)
that is permeable for gas, like a filter cloth. Gas kn a
krel;n ¼ ¼
and liquid flow simultaneously through the cake. 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
S
SR ¼
1S¥
dimensionless time
pce t
Q¼
aH hH 2 ð1S¥ Þ"
4.1.4. Practical Scale-Up of Deliquoring by Here Dp ¼ pentry pexit is the pressure dif-
Gas Pressure ference applied. This approach gives generally
good results for centrifugal dewatering, as shown
The deliquoring kinetics are normally investigat- in Figure 25 (the pressure difference being cal-
ed by measuring the residual moisture as a func- culated from the centrifugal force) [30]. For
tion of cake thickness, blowing time, and pressure dewatering by gas blowing, the fit is, however,
difference. The results are interpolated to give the often unsatisfactory (see Fig. 26) [30]. A dimen-
parameters necessary for scale-up. Extrapolation sionless time taking into account the capillary
beyond the investigated range of cake thickness, entry pressure pce will always permit a good fit.
blowing time, and pressure should be avoided. In Two equations are proposed in the literature [30]:
addition it is important to measure and to scale-up
the gas flow from realistic experiments, since in Q1
Dpt
pentry
hHðaHþbÞ pexit
ð1 pDpÞ
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]
H ð Dp Þ
Dpt p ce cake. As described in Section 2.2, only the
const 2
1
layer near the filter medium is subjected to the
full amount of pressure, while the ‘‘upper’’
Here pentry and pexit are the pressures applied layer of the cake remains uncompressed (Fig.
above and below the cake and pce is the capillary 29 (1)). When filtration is finished, the liquid
entry pressure. This pce is not measured, but surface reaches the cake surface (Fig. 29 (2)).
derived as a ‘‘best fit’’ to the experiments (this Before gas enters into the capillaries of the
is why the fit is generally rather good, see Fig- cake, the capillary entry pressure pce must be
ure 27 [30]). overcome. The surface tension of the liquid
thus exerts a pressure p pce onto the cake,
comparable to an elastic membrane spread
over the cake. As long as pce is not exceeded,
4.1.5. Shrinking and Cracks in Filter the cake is compressed monoaxially like by
Cakes action of a piston, the cake thickness is re-
duced, but no cracks appear. However, when
Deliquoring of compressible filter cakes by pce is exceeded, gas penetrates into the largest
gas pressure very often produces cracks in the capillaries, and the solid structure is com-
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 capil- resistance and without effect. The only sure
lary forces may lead to lateral compression of remedy against cracks is compression of the
the cake and hence to cracks (Fig. 29 (3-4)). cake before gas blowing. When the remaining
The criterion for cracks to occur thus probably shrinking potential (this is the remaining
depends on the lateral compressive strength of shrink when the cake is reduced to total dry-
a cake after monoaxial consolidation. But until ness) is small enough, no cracks will appear
now the precise mechanism of crack formation anymore [33]. Some filters are equipped for
is not understood and the great variety of crack this purpose with membranes or with pressure
patterns shown in Figure 28 [32] cannot be belts (! Filtration, 2. Equipment, Section
explained. 7.3.). According to a proposal of SHIRATO and
Cracks in a filter cake are very detrimental coworkers this compression can also be
to further deliquoring and also to subsequent achieved by adding a layer of very fine mate-
washing (see Chap. 3) because gas and wash rial (hence a cake layer with high pce) onto the
liquid flow through the cracks without great surface of the cake [34].
Some remedy against cracks is also possible
with nutsches equipped with agitators (! Fil-
tration, 2. Equipment, Chap. 3.). With their
paddles they smear over the surface of the cake
during deliquoring so that the cracks are closed
as soon as they appear. This does, however, not
eliminate the cracks totally but only down to a
certain depth below the surface of the cake, so
that some cracks can exist invisibly below the
surface. Without such equipment the formation
of cracks can be reduced (but only to a very
limited degree) if the cake is formed with high
final filtration pressure, and hence with some-
what less porosity.
This leads to the rule-of-thumb for maximum forces between suspended particles of equal ma-
throughput: terial are described by repulsion due to electro-
topt;1 ¼ treg static charges and attraction due to van der
This rule is valid if the influence of the filter Waals’ forces:
medium resitance is neglected (b ¼ 0).
2. Quite analogous considerations are valid Repulsion. Particles in suspension (espe-
for the optimal cycle time in terms of cost cially in polar liquids like water) have an electri-
per quantity filtered. During filtration, the cally charged surface due to adsorption and
running cost is proportional to time (capital dissolution of ions. The order of magnitude of
cost and pumping energy), cost ¼ c2t. In this charge z is 120 mV < z < 120 mV, and it
Figure 30 all costs are converted with this depends on the pH of the liquid. The charge
proportionality factor c2 into an equivalent reaches relatively far, depending on the ion con-
running time: t ¼ cost/c2.Regeneration re- tent of the surrounding liquid. The reach is
presents a considerable cost, including characterized by the Debye length rD. In pure
downtime, labor, new filter elements, and distilled water this length is exceptionally long
disposal of waste. If this cost is called creg, with 0.9 mm. In most technical aqueous solutions
the mean specific cost is it is much smaller, in sea water for example only
0.4 nm [37].
cost c2 tþcreg
¼
filtrate V
Attraction. Van der Waals forces are part of
With the approximation of Equation (25) this is the cohesive forces between the molecules within
cost c2 1=2 creg 1=2 the solid particle. They reach also a certain
¼ t þ t distance beyond the surface, but their range is
filtrate c1 opt;2 c1 opt;2
less than that of electrostatic forces. The decline
The minimum is defined by is proportional to the distance according to
d cost c2 1=2 creg 3=2 const
¼0¼ t t Eattraction ¼
dt filtrate 2c1 opt;2 2c1 opt;2 r
As result the rule-of-thumb for maximal yield When two particles approach to distance zero,
per cost is obtained: these attractive forces become very strong and
c2 topt;2 ¼ creg should in principle become equal to the cohesive
force inside the particle. The reality is, however,
or cost for the filter run ¼ cost for regenerating more complicated because there are always ab-
the filter. sorbed molecules on the surface.
An example of the superposition of both
forces according to DLVO theory is represented
These rules have been derived here for con- in Figure 31. The graph shows the resulting
stant pressure filtration. They can also be derived energy potential. A positive gradient of the
for filter runs with different but constant flow curves describes attraction, negative gradient
rates until a pre-set final pressure. Practitioners repulsion. At very small distances, attraction
therefore apply the rule-of-thumb rather gener- prevails. At larger distance electrostatic repul-
ally (e.g., also for filtration with a pump with sion prevails (if it is not zero).
a characteristic curve anywhere between con- Attraction and repulsion between two parti-
stant pressure and constant flow). cles in suspension. The superposition of electro-
static repulsion and attraction by van der Waals
forces is represented by the resulting energy
6. Interparticle Forces and Forces potential. High ion content in the surrounding
Between Particles and Filtermedia, liquid reduces the reach of electrostatic repulsion
DLVO Theory (Debye length)
7. Mathematical Simulation of
Filtration and Cake Formation
Different attempts have been made to simulate
numerically the structure and porosity of filter
cakes. Until now such calculations are restricted
to spherical particles with homogeneous surface.
Starting from randomly chosen locations the
trajectories of particles in a filter flow are calcu-
lated. When they touch the cake surface, the
deposition is simulated using either a sticking
angle [39, 40], or a friction angle and an adhesive
force [41, 42], or by estimating the interparticle
forces from van der Waals’ and electrostatic
forces according to the DLVO theory [43]. After
calculating the deposition of a large number of
particles, the packing density of the resulting cake
Figure 32. A particle in suspension is found (see Figure 33 A and B). These calcula-
706 Filtration, 1. Fundamentals Vol. 14
fine enough to prevent the dirt particles from 17 K. J. Ives, in A. Rushton (ed.): Mathematical Models and
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pp. 90 ff.
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18 G. Dierckx in: La Filtration Industrielle des Liquides,
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layer is broken in half. The dirt should form 19 A. Palinski, W. Uhl, R. Gimbel, Vom Wasser 89 (1997)
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22 W. Bender, Chem. Ing. Tech. 55 (1983) no. 11, 823 – 829.
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Vol. 14 Filtration, 1. Fundamentals 709