A P P L I C AT I O N N O T E

Recent Advances in Spiral Wound Ultrafiltration Technology for E-Coat Paint

Dr. Mark Rizzone, Henia Yacubowicz and Kevin Donahue, Koch Membrane Systems, Inc., Wilmington, MA

Abstract When considering a new ultrafilter system for e-coat paint, the most economic choice utilizes spiral wound membrane technology. Todays e-coater is faced with many choices when selecting spiral wound ultrafiltration membranes. In the past, these choices included tailed, brine seal, and flanged spiral configurations. In each case, the membrane element is a separate part from the housing. Each membrane has to be fitted in the housing during installation and then removed from the housing after use. A new design has been developed which offers a potted membrane element in a PVC shell. This new potted spiral design eliminates the need for fitting of the membrane in the housing and removal of the membrane from the housing after use. Advantages are described and performance data are shown for this potted spiral design. Case histories are presented for 8-inch and 10-inch diameter potted spirals. Introduction A variety of membrane configurations has been used in the past for e-coat paint ultrafiltration. These include tubular, hollow fiber, and spiral wound configurations. Each configuration has its own advantages and disadvantages. Nearly all e-coat ultrafilter systems being installed today utilize spiral wound technology, since they provide the lowest capital and operating costs.

Spiral Description A spiral-wound module is shown in Figure 1. Feed solution (i.e., e-coat paint) enters the module under pressure, typically at 50 psi. E-coat paint is a colloidal dispersion of pigment and resin in water, and its components having larger molecular weight are rejected by the ultrafiltration membrane. Water, dissolved salts, solvent, solubilizer, and low molecular weight resin pass through the membrane as ultrafiltrate or permeate. As the paint travels through the membrane, it becomes slightly concentrated as permeate is withdrawn. The exiting paint is known as the concentrate. It typically exits at 20 psi. The permeate generally leaves through a central permeate tube at atmospheric pressure.
FIGURE 1

The spiral-wound module consists of flat membrane sheets glued together and wrapped around a central permeate collection tube in a spiral fashion. The membrane sheets are separated by spacers to allow feed and permeate flow inside the spiral element. The feed spacer may be used at different thicknesses and geometries to promote turbulence and to ensure unrestricted paint flow. The spiral-wound structure is wrapped on the outside with a hard layer, to prevent loosening or unwinding from occurring during operation. This outer wrap may consist of tape, netting material, or a fiberglass/epoxy composite. Traditionally, the spiralwound element is inserted into a cylindrical pressure vessel or housing made of PVC, fiberglass, or stainless steel.

Spiral-Wound Module
Permeate Pipe Containing Collection Holes Anti-telescoping Device Concentrate Permeate Out Concentrate Permeate Out Feed Flow Across Feed Channel Spacer Feed Solution Membrane Permeate Collection Material Membrane Converting Permeate Flow (After passage through membrane into permeate collection material)

Feed Solution

Feed Channel Spacer

P R E S E N T E D at the Electrocoat 2006 Conference in Orlando, Florida and first published in the Conference Proceedings. Reprinted with the permission of Gardner Publications, Inc.

Ultrafiltration spiral elements are available in different membrane materials such as polyvinylidene fluoride, polysulfone, polyacrylonitrile, and cellulose acetate. The most commonly used material for e-coat paint ultrafiltration is polyvinylidene fluoride due to its chemical resistance and ability to withstand a wide pH range. Production-size elements for e-coat paint are typically available in 4-inch, 6inch, and 8-inch diameters. Lengths can range from 33 to 40 inches. Feed channel spacers vary in size and design depending on membrane manufacturer and product. Those used for e-coat typically range in thickness from 0.030 to 0.043 inches. Spirals used for e-coat paint are generally mounted vertically to avoid paint settling on the membrane in case of a power outage and stoppage of paint flow. In France, some e-coat spirals have been installed with a horizontal orientation. Spiral-wound elements for e-coat paint ultrafiltration are available in different construction designs and configurations. Each has its advantages and disadvantages, as will be described in the following sections. Tailed Spiral The tailed spiral-wound module (also known as a netted module) was among the first spiral ultrafilter elements to be applied to electrocoat paint. See Figure 2. The outer wrap of this element is made of plastic netting material. It comes with extra outer wrap net called tail. By slicing off part of this tail when installing the module, its diameter may be adjusted to ensure a snug fit inside the module housing. This is especially good for PVC housings which have a noncontrolled inside diameter. Even with a good fit, a significant amount of paint can bypass the feed channels, which means it requires a

paint feed rate of 120 gpm or more for an 8-inch diameter spiral module. If the tailed spiral is not properly fit inside the housing, the modules feed spacer can shift inside the spiral element, causing non-uniform paint flow. The result is inefficient use of total membrane area along with increased fouling in certain channels.

Brine Seal Spiral A conventional brine seal spiral has a fiberglass/epoxy outer wrap and an end seal to reduce bypass. See Figure 3. The seal (often called a brine or U-cup seal) is a rubber gasket that presses against the inside of the housing and reduces but does not eliminate paint bypass around the spiral element. In e-coat

FIGURE 2

Tailed Spiral and Housing

Retrofit Adapter for Permeate (Thru hole adapter) ATD Permeate End

Outlet/Permeate End Cap

Spiral

VEXAR Tail (Trim to fit) Flow

Housing

Plugged End ATD Plug/Support Adapter (Blind hole adapter) Inlet End Cap

FIGURE 3

Brine Seal Spiral and Housing

End Cap Cap End (Permeate removal end) (permeate removal end)

Brine Seal Spiral Brine Seal Spiral

PVC Housing PVC Housing

4 O-rings for End Adapters 4 O-rings

for End Adapters Coupling Coupling

Permeate Plug Permeate Plug (Bottom)
(bottom)

End Cap End Cap (Dead end)

(dead end)

Bypass Bypass Seals (Use one seal on spiral-top or bottom (use one seal on spiraltop or bottom)

Gasket Gasket

paint ultrafiltration, the seal is usually placed at the top or exit end of the spiral rather than at the bottom or feed end for ease of installation. The required paint feed rate for 8-inch diameter brine seal elements can range from 60 to 100 gpm depending on element diameter, feed spacer size, and desired crossflow pressure drop. Larger diameter elements (e.g., 7.9 inches) are used for thinner wall, 8-inch stainless steel housings whereas smaller diameter elements (e.g., 7.2 to 7.4 inches) are used for thicker wall, 8-inch PVC housings. Greater paint feed flows will be required for larger diameter elements, thicker spacers, and larger crossflow pressure drops. Potential problems with this design include difficult or improper fitting of the membrane element with brine seal in the housing; seals which flip during installation; and large bypass of paint feed. These can occur as a result of a non-controlled inside diameter for PVC housings. In addition, stagnant or low flow areas between the outside of the fiberglass wrap and the inside of the housing can cause paint to settle or set up which could be a source of dirt and cause difficulty during membrane removal (i.e., the membrane becomes stuck inside the housing). A variable productivity due to channeling or preferential flow around the membrane during processing is not uncommon with the brine seal spiral element. Flanged Spiral The flanged spiral is patented and utilizes an integral rubber flange at each end of the module. See Figure 4. Each flange acts as a gasket at the housing end cap to eliminate bypass and directs all the paint (or cleaning solution) through the module. The flanged spiral is more efficient at utilization of paint to generate permeate than either the tailed or brine seal spiral. The paint feed rate is low (typically, 50 gpm per 8-inch spiral) enabling smaller pumps, valves, fittings and piping to be used compared

FIGURE 4

Flanged Spiral and Housing

Permeate Piping

eter spirals to eliminate membrane fitting problems during installation and reduce the labor involved when removing spirals. See Figure 5. The potted design has been in existence for years for tubular, hollow fiber, and 4-inch spiral membranes but has now been developed for 8-inch and 10-inch diameter spirals. With this new design, the spiral wound membrane is secured by epoxy to the inside of a PVC shell. The membrane and shell form one integral unit. No field fitting of the membrane in the shell is required. The potted spiral is easily connected to its stainless steel end caps by common couplings. The potted spiral design offers the following benefits over other spiral element configurations: Equivalent or higher permeate output. Zero bypass design ensures that 100 percent of the paint flow is used to generate permeate. The potted spiral design allows more membrane area to be placed into the shell.
FIGURE 5

Outlet Union

Outlet End Cap (Top) ATD (Points go against end cap)

Permeate Connector

Housing

Spiral Element Elements Fiberglass Hard Over Wrap ATD (Points go against end cap) Inlet End Cap (Bottom)

By-pass Prevention Flange Plugged Permeate Tube End

Inlet Union Housing Drain Plug

Potted Spiral

Top Endn dCap T op E Cap

to other spiral configurations. A hard, fiberglass/epoxy outer wrap is used similar to the conventional brine seal spiral. Use of the fiberglass/epoxy outer wrap enables the rubber flanges to be integral with the element. Antitelescoping devices and positive seals at both ends of the flanged modules enable cleaning by reverse flow. New Potted Spiral Design Each of the previous spiral configurations (tailed, brine seal, and flanged) has a spiral element which is separate from its housing. During installation of these spirals, the membrane must be fit inside the housing. A new potted spiral design has been developed for large diam-

P e rm e a t e O ut Permeate Out

Paint uOut P a int O t

C ou p li ng Coupling

8-inch Potted t Spirall 8 -i n c h P o t e d S p i ra

G a sk e t

Gasket

Plug P lug Bottom P a i nt In End Cap

B o t to m E n d C a p

Paint In

 Equivalent or higher flux recovery after cleaning. Zero bypass design enables higher turbulence during cleaning. Easier membrane installation and replacement. No need to fit membrane into housing during installation or remove membrane from housing during replacement. Membrane is integrally attached to PVC shell. Stainless steel end caps are easy to connect and disconnect. Reduced work strain and safety hazards. Installation or removal of membranes is done at floor level; no ladder is required.

white cathodic acrylic paint. The permeate rate of the potted spiral exceeds that of the conventional tailed spiral. Case Studies
8-INCH POTTED SPIRALS Auto Parts Manufacturer

containing 296 tubular membranes with two spiral racks, each containing six 8-inch diameter potted spirals to treat their unleaded black cathodic epoxy paint. See Figure 8. Their reasons for switching from a tubular to spiral configuration included a newer technology, better and more permeate output relative to floor space,

In January, 2004, an automotive parts supplier replaced their tubular cabinet

FIGURE 6

Permeate Flow of an 8-inch Potted Spiral vs. an 8-inch Brine Seal Spiral
4.0 3.5 3.0

Permeate Flow (gpm)

Lower system fabrication costs. The cost of permanently installed stainless steel or PVC housings is eliminated. The potted spirals are currently manufactured in 8-inch and 10-inch diameters. The membrane area for the 10-inch potted spiral is about 60 percent greater than that of the 8-inch potted spiral. They operate at a similar pressure profile to other conventional spirals (e.g., 50 psi- inlet and 20 psioutlet). The design paint flow rate at a 30 psi crossflow pressure drop for an 8-inch potted spiral is 65 gpm and that for a 10-inch potted spiral is 105 gpm. Performance The performance of an 8-inch potted spiral vs. a conventional 8-inch brine seal spiral at an automotive assembly plant is shown in Figure 6. Each spiral has a 0.030-inch feed spacer and operates on unleaded gray cathodic epoxy paint. The permeate rate of the potted spiral exceeds that of the conventional brine seal spiral. The performance of an 8-inch potted spiral vs. an 8-inch tailed spiral at an appliance manufacturer is shown in Figure 7. Each spiral has a 0.030-inch feed spacer and operates on unleaded

2.5 2.0 1.5 1.0 0.5 0.0 12/10/03

Potted Spiral Brine Seal Spiral

12/30/03

1/19/04

02/08/04

02/28/04

03/19/04 04/08/04 04/28/04 05/18/04

Date

FIGURE 7

Permeate Flow of an 8-inch Potted Spiral vs. an 8-inch Tailed Spiral

6 5.5 5

Permeate Flow (gpm)

4.5 4.0 3.5 3.0 2.5 2.0 1.5 1 0.5 0 07/07/04 07/27/04 08/16/04 09/05/04 09/25/04
Potted Spiral Tailed Spiral

10/15/04

11/04/04

Date

and easier maintenance (i.e., easier membrane replacement). Prior to the conversion, the tubular system produced 10 to 20 gpm of permeate. Cleaning would occur about twice a year. Complete retubing would occur about every 3 years. After the conversion to 8-inch potted spirals, the plant produces 36 gpm of permeate and cleans once a year. Flux recovery after cleaning has been nearly 100 percent. The 8-inch potted spirals are currently over 2 years old.
Recreational Vehicle Manufacturer

In May, 2004, a recreational vehicle manufacturer replaced their 4-inch spiral rack containing thirteen 4-inch potted spirals with an 8-inch spiral rack containing two 8-inch potted spirals. See Figure 9. The driver for this change was an increase in permeate rate necessary when the plant converted from leaded to unleaded black cathodic epoxy paint. Funds were made available for the purchase of new equipment. The user purchased the new equipment in order to reduce long term membrane replacement cost and to permit cleaning of individual elements during normal production hours, which would reduce overtime labor expenses.

The original 4-inch potted spiral system with thirteen 4-inch diameter spirals was designed to produce 3.5 to 5 gpm of permeate. The permeate rate was allowed to drop to 1 gpm and the membranes were never cleaned since the entire rack would have to be brought offline, which was not practical given a heavy production schedule. The new system with two 8-inch diameter potted spirals has generated an average total permeate rate of 4 gpm. The 8-inch diameter potted spirals have been cleaned twice since May, 2004. The original set was replaced after a year of operation. The replacement cost was 80 percent less compared to replacement of the original thirteen 4-inch diameter spirals.
Auto Assembly Plants

10-INCH POTTED SPIRALS Auto Assembly Plant

In January, 2006, an auto assembly plant replaced their tubular cabinet with two spiral racks, each containing four 10-inch potted spirals. See Figure 10. Prior to the conversion, the permeate rate for the 264 tube cabinet ranged from 18 to 25 gpm. Cleaning occurred every 6 months for the first two years after a complete retube and then every 3 to 4 months for tubes older than 2 years. Since the entire ultrafilter had to be cleaned all at once, cleaning would occur during non-production time, requiring overtime labor. Tubular membrane life was about 4 to 5 years. Since the changeover to the potted spirals, the auto manufacturer has achieved 60 gpm from six 10-inch diameter potted spirals. Each spiral rack is designed to have individual module cleaning which allows cleaning of an individual element while the others remain in production. The cleaning can occur during production, without incurring overtime labor costs. Each rack is operated with three spirals online and one spiral offline. Every week, one spiral is taken offline and flushed with deionized water while another is placed online. As of this date, the membranes have not been cleaned.

During 2004 2005, two auto assembly plants completely replaced their 8-inch drop-in, brine seal type spirals with 8-inch potted spirals. In both cases, there was a substantial increase in permeate rate. One of the plants needed an increase in ultrafilter permeate rate to ensure adequate feed flow to their nanofilter downstream of the ultrafilter. The other plant has been able to take one of their three spiral racks offline.

FIGURE 8

FIGURE 9

F I G U R E 10

Spiral Rack Containing Six 8-inch Potted Spirals

Spiral Rack Containing Two 8-inch Potted Spirals

Spiral Rack Containing Six 8-inch Potted Spirals

Lawn & Garden Equipment Manufacturer

In October of 2005, a lawn and garden equipment manufacturer replaced their two tubular units, each containing 162 tubes, with two spiral racks, each containing four 10-inch potted spirals. The reasons they changed were easier maintenance (i.e., membrane replacement) with the spiral system versus the tubular system and increased permeate rate. The paint type is an anodic acrylic. There are two paint tanks. Colors are changed in each tank every few days. Colors include orange, red, green, blue, and black. Prior to the conversion to potted spirals, the permeate rate from each tubular ultrafilter unit was 8 gpm, after 8 years of operation. They were designed to produce 20 gpm each. After the conversion, the permeate rate per spiral rack, with four 10-inch potted spirals operating, has ranged from 35 to 40 gpm. Each rack is set up for individual module cleaning. To date, there have not been any cleanings required.

Conclusions The potted spiral configuration offers significant advantages over other more conventional spiral configurations. These include equivalent or increased permeate output, equivalent or increased flux recovery after cleaning, easier/safer installation and replacement of spirals, and lower cost systems. Potted spirals have been used to successfully retrofit other spiral configurations on existing systems. New systems with 8-inch or 10-inch diameter potted spirals have successfully replaced tubular and conventional spiral wound ultrafiltration systems. Biography
Dr. Mark Rizzone is Sales Manager, Spe-

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