Automated Fouling Mitigation System for Dairy Filtration Membranes
U.S.D.A. Phase II Contract No. 2003-33610-14035
The overall goal of the Phase II program was to develop the first generation automated pilot-scale membrane cleaning system based on the electrolytic cell technology established in Phase I. This system was to be scaled up and automated to produce cleansing solutions for cleaning and disinfecting filtration membranes used in dairy processing. The system was designed to produce acid, caustic and hydrogen peroxide solutions on-site and on-demand at the necessary concentrations and be easily appended to a clean in place (CIP) system. Consumables are only water, electricity, and oxygen in air, in the presence of small amounts of supporting electrolytes. The primary benefit that this technology provides is a substantial cost savings in producing the cleansing chemicals. This technology also eliminates the costs, logistics and permitting required to ship, handle, and store large quantities of strong chemical concentrates (acids, caustics, bleach or hydrogen peroxide) as well as eliminate the use and discharge of chlorine or chlorinated byproducts. The cleansers produced by this technology are effective without surfactants and are safe to use in filter plants and CIP systems.
During the first year of the Phase II program cleanser solution performance was studied in detail, design of the electrolytic technology and its operating conditions were optimized, the technology output performance was defined, and scale-up of the technology was tested in a 1/3 scale prototype system. Design and construction of a mobile demonstration unit had begun for making a practical user-friendly system. Test results of cleaning ultrafiltration membranes fouled with whey and microbial loadings were completely successful in demonstrating the viability of the technology for the targeted application. The use of chlorine and surfactants was effectively eliminated.
During the second year of the Phase II program construction of the demonstration unit was completed. The demonstration unit was used to further refine system design, packaging, operating parameters, and cleanser production performance for a full scale system. The demonstration unit was also used to determine how certain dynamic variables (mass and charge transport) control hydrogen peroxide production rate and concentration limits, a major breakthrough for the technology. The oxygen reduction process that occurs at the cathode surface was also studied in some detail. Procedures for cleaning fouled electrolytic cells and idle system storage were finalized. A 1/3 scale membrane cleaning system was re-constructed using the modular packaging approach defined during the first year of the program resulting in a durable cleanser generation system. Both the demonstration unit and 1/3 scale system are suitable for field trials with minor modifications.
Business development and marketing activities for this technology have been fruitful. A new trade name for Eltron’s electrolytic hydrogen peroxide production technology, PEROXEGEN™, was created. Non-proprietary marketing brochures have been created for various applications and distributed to a number of Eltron’s potential clients. Multiple patents for various technology features are being developed while technology licensing will be a primary method for generating revenues. No less than 14 potential clients have been identified and several are being actively pursued for Phase III partnering. Several of these clients have approached Eltron for particular applications that benefit from an on-site hydrogen peroxide source. Field trial test sites for three different water treatment applications have been identified and one opportunity is in process.