Filtration Technology
liquitec ag www. liquitec .ch
liquitec
Filtrationstechnik
Mixing Technology
Foam Separators
Fermenter Systems
Process Vessels
Colloiding Mills
Engineering
Service
1. Filtration Technology
...when high demands are placed on
manufacturing quality and reliability,
liquitec provides the solutions:
•• If the filtrate or solid matter must not come into contact
with the environment, such as with toxic, inflammable or
sterile suspensions
•• If the suspension is highly corrosive with respect to normal
materials
•• If the suspension is difficult to filter
•• If a high degree of automation is required
•• If there must not be any residual volume
•• If additional processing stages such as: rinsing or drying of
the filter cake, or extracting and dissolving are required
•• If the suspension must be filtered at high temperatures
•• If the suspension requires heating or cooling
•• If maximum filter cleanliness is required
2
liquitec
The following table provides an overview of our comprehensive range of products:
Description
Press filter
Name
merkur
Explanation
Page
Single sheet filter with filter layer, filter cloth or
metal fabric
6
Suction filter
terra
Press filtration, washing of product, pre-coating, displacement, agitation with lift/clockwise and counter-clockwise
8
Filter dryer
wega
Multi-purpose plant: reaction, precipitation, crystallization,
filtration, washing and drying in a single system
10
Multi-sheet filter
orion
With vertical square filter elements
12
With round filter elements
14
Horizontal plate filter with centrifugal cleaning,
sealed, can be automated
16
Horizontal plate filter
Pre-coat and dry residue filter
Plant technology
radium
disc
pharma
Complete plant systems / skids for the pharmaceutical
industry, compliant with GMP and FDA requirements
2.Fundamental Filtration Technology
The processes considered here are the separation of liquids from solids, clarifying
and disinfection filtration. With this type of filtration, a solid phase is separated
from a liquid phase by the use of a medium. This apparatus is used for particle
filtration, i.e. the solid phase consists of particles with sizes ranging from approx.
1 μm to approx. 1 mm.
The separating medium can either hold back the particles on its surface (surface
filtration), or within it (depth filtration). In the case of depth filtration, the medium can also consist of the particles to be separated, i.e. a medium holds back the
larger particles by surface filtration and a filter cake builds up. This filter cake then
holds back all particles by the process of depth filtration.
3
2.1 Filtering Tasks
There are many varied types of filtration problems to be solved. In
some cases the filtrate is of primary interest, in others the solids,
and sometimes it's both. Batch sizes may range from as small as
one liter, all the way up to a magnitude of several tons per hour.
Typical tasks include:
Separation of active carbon
Active carbon is used for clarifying or discoloring liquids or as a
catalyst carrier
Separation of crystalized products
In this case washing of the solid material is often subsequently
carried out
Clarifying filtration of foodstuffs
e.g. edible oils, cocoa butter, honey, vinegar, etc.
Filtration under sterile conditions
e.g. infusion solutions, insulin, albumin, antibiotics, alginate, etc.
Filtration of toxic substances
e.g. photographic chemicals, galvanization baths, electrolysis baths, chromic acid, fungicides, dichlorbenzole, etc.
4
liquitec
2.2 Process Technology Consulting
As there are an almost unlimited number of filtering applications,
and a large number of filtration devices of various shapes and sizes,
competent consulting is essential. Using our customer's specifications and description of the filtering application, we can design the
appropriate filtering device in a suitable size.
The process data required for this may be seen on our filtration
questionnaire, which can be downloaded from our homepage
www.liquitec.ch. The consultation provided by liquitec also includes
advice on the construction of the peripheral plant (pipework, instrumentation, automation, etc.)
Filtering tests
Since the filtering behavior of most suspensions is not predictable,
it is often necessary to carry out filtration tests.
These tests are usually carried out at the customer`s site.
Various trial filters and filter media are available for this purpose.
Together we design a concept for the entire plant, draw up flowcharts for each filtration process for you, and document and program the processing stages.
5
3. merkur Press Filters
Single layer filter for a variety
of applications
merkur press filters are single layer filters with a filling space in the
form of a pressure vessel, suitable for insertion of a filter element
(filter layer, filter cloth or metal composite screen).
With this you can separate and wash solid materials from suspensions after they have been precipitated or crystallized out, or process
pre-coat and dry residues.
Filtration with continuous
flow, or with compressed
gas
Highly flexible range of applications:
•• merkur Type EF:
•• merkur Type EFA:
Laboratory filter
Press filter with large filling volume for solid
matter separation in batch operation
•• merkur Type EFD: Press filter with small filling volume for
clearing and fine filtration of large quantities
of liquid
Removal of solid material
with the filter opened
The right investment for every field of use: We will be happy to
supply you with designs optimized to your process.
Displacement or
suspension washing
merkur EF 6
merkur EFA 60
6
merkur EF 22
Removal of solid
matter in the form of a
suspension, via a riser
liquitec
•• Design and construction comply with GMP
guidelines and FDA regulations.
•• Materials such as Cr-Ni-Mo steel, hastelloy,
titanium, monel, enamel are used.
•• Long service life. High level of safety for your
personnel and reliable product quality.
•• Various process stages e.g. extracting, filte-
ring, washing out, dissolving and dying can be
combined in one piece of equipment.
•• Saves space and interfaces, enables higher
utilization of your investment.
•• Additional equipment such as fittings, valves,
agitators, mobile chassis, measuring probes,
gassing pipes and riser, CIP/SIP systems, control and regulating systems are also available.
merkur EFA 160 with quick-locking
Sizes
EF 6 to EFA 200
Filter Area
20 cm2 to 3,1 m2
Usable Volume
0,3 l to 3.200 l
Filter base complies with GMP and FDA guidelines
merkur EFA 100 with cake ring
7
4. terra Filter Dryer
A process filter combining several processing stages
The terra filter dryer is a press filter for non-continuous operation, which can be sterilized, and is ideally suited for the
combination of several processing steps in one system.
Applications: Designed for easily filterable suspensions with a
high solid matter content. Additional processing steps include:
extraction, washing out, blowing out, steaming, vacuum or
hot gas drying, dissolving and sublimation, solids discharge.
This allows for the combination of multiple processing stages
in a minimum of space.
•• Sealed filter system with height-adjustable agitator for
washing, spreading, drying and removal of the filter cake
•• Assured high-quality and performance for gentle product
processing ●
●
•• May be extended with measuring, control and regulating
systems, circulation heating or cooling, reactor vessel, heat
exchanger, vacuum and compressed air equipment
•• A complete solution from a single source
•• The degree of automation ranges from manual operation to
computer supported operation with monitoring and process
control, variable levels of operational convenience, with the
highest levels of safety
•• Processing of toxic or oxygen-sensitive substances is possible
8
•• Fulfils the highest demands in terms of product safety
terra EFR 140 with quick locking
Suspension or displacement
washing or extraction
Solids side discharge
Solids center discharge
liquitec
Many designs are available, for adaptation into
different processes:
•• Filter equipment with heating and cooling ja-
ckets on the upper and lower areas of the filter
•• Heated agitator to improve drying performance
•• Drying of the filter cake under a vacuum or with
hot air or inert gas
•• Solids discharge from the side of the cylindrical
vessel frame, or centrally from the base area of
the vessel
•• Agitator with fluid or gas-lubricated double
mechanical seal
•• Metallic sealing discharge valve
Extraction filter terra 125 for the production
of pharmaceutical active ingredients
•• Sterile operation and discharge
•• Discharge via glove-box
Optimum adaptation to your requirements due
to process-orientated design.
A lowerable and extendable base unit enables the
filter elements, filter cloths or metal composite
screen to be exchanged outside the equipment.
Design and construction comply with GMP
guidelines and FDA regulations. Materials such as
hastelloy, alloy 69, titanium, stabilized titaniumpalladium, Cr-Ni-Mo steel, enamel and modified
PTFE are used. Long sevice life and high machine
availability.
terra agitator
Sizes
EFR 20 to EFR 180
Filter Area
0,03 m2 to 2,5 m2
Usable Volume
10 l to 2.300 l
Solid Volume
5 l to 1.000 l
terra base unit
9
5. wega Filter Dryer
Combines various processes in one system
The wega filter dryer is a more advanced press filter with an agitator and
the ability to be swung into various working positions. The filter, which is
designed as a vacuum dryer with a vessel and filter plate (which can be
heated or cooled), may be used for the following applications:
•• reaction, precipitation and crystallization
•• filtration and washing
•• drying and discharge
Advantages of the wega-filter dryer:
•• Eminently suitable for the production of sterile pharmaceuticals in
GMP-compliant batch production
•• Short drying times and uniform product quality due to intensive mixing
and properly dimensioned heating surfaces, including additional improvement of drying performance due to the heated agitator
•• No transport of the product between the various stages of production
•• Sealed systems for environmentally-friendly and safe operation
•• CIP and SIP in a sealed system
•• Due to the sealed system design, there is no danger to personnel from
toxic substances or solvents
Reaction, Precipitation,
and Crystallization
10
Filtration and
Washing
Drying
Discharge
liquitec
Construction variations
The filter dryers are constructed with two basic
designs, their names are derived from their main
fields of application:
•• Chemical:
A simple and robust functional design, which
offers many systemic advantages yet remains
a low-cost solution suitable for lower-quality
products.
•• Pressure and vacuum vessel supported on a
•• Pharma:
2-column frame
It is immediately apparent that with this further
development, even the finest details are tailored
to the production of substances of the highest
purity.
•• Pivoting movement via a self-arresting spiral
drive
•• Fixed piping between the vessel and the hose-
reel for the feed and drain pipes
These basic designs are available in various models, depending on the process and the size of the
apparatus.
•• Static vacuum connection on the shaft bushing
•• Separate control panel with built-in hydraulic
unit
•• Vessel can be heated or cooled
Sizes
EFT 60 to EFT 250
Filter Area
0,27 m2 to 4,70 m2
Usable Volume
225 l to 9.200 l
•• Inlets and outlets with base-mounted valve
Solid Volume
13,5 l to 2.830 l
•• Base unit can be lowered and extended
•• Conduction coil for uniform temperature distri-
bution
•• Mixing-tool sealing with double mechanical seal
Camera on
Filter Dryer
Image of Filter Dryer for Automation
Magnification of pod support with
camera
11
6. orion Multi-sheet Filter
Flexible plate filter with
simple handling
orion Multi-sheet filters are frame filters with
square filter elements in a vertical configuration,
with a choice of 13, 25 or 40 mm filter turbid
frame widths. Hydraulic lock for compressing
the filter package, double-action cylinder with
automatic pressure control, pneumatic drive and
control.
pilot
Applications: Separation of filter aids and solids;
clarification and fine filtration, especially of products containing oils or solvents. Wide range of
applications with high quality assurance.
The orion CDG has a gas-tight mobile vessel
and is therefore a sealed system.
orion CD
Environmentally friendly technology
Protection for personnel and environment
against toxic substances, solvent vapors or high
temperatures.
No emissions of hazardous substances
(Technical Regulations for Air Purity).
orion CDG
with heating jacket
Filtration diagram
Transfer chamber
Final filtration
Pre-filtration
Filtrate
Filtrate
Unfiltrated
Turbid plate
Turbid plate
Filter layer
12
Filtrate plate
Filtrate plate
Filter layer
Unfiltrated
liquitec
Design and construction comply with GMP guidelines and FDA regulations. Use of Cr-Ni-Mo steels and hastelloy ensures long service life and
high level of machine availability.
•• orion Type CD, seal-free filter system with internal eyelets
•• orion Type CDG, gasket-free, gas-tight sealed filter system
orion S stainless steel filter plates
•• orion Type S, clean system, drip-free, with surrounding O-ring,
hermetically sealed, easy to clean
The right filter for every application; special designs on request:
•• Filter packages made from stainless steel, PP, PVDF
•• Heated/cooled filter plate design
orion S PP filter plates
in membrane filter press
•• Double filtration with a transfer chamber e.g. kieselguhr and sterile
filtration or clarifying and sterile filtration
Adaptability and performance, even for special applications; various filter
elements available. The ideal filter element for every application.
orion S filter plates
with squeezing membranes
orion CDG with touch protection
orion CDG
Standard-dimensions/
Filter plate
dimensions
pilot
20 x 20 cm
orion CD
40 x 40 cm / 60 x 60 cm
orion CDG
40 x 40 cm / 60 x 60 cm
orion S
40 x 40 cm / 60 x 60 cm / 80 x 80 cm
100 x 100 cm / 120 x 120 cm
13
7. radium Horizontal Plate Filter
A sealed system for maximum safety
radium Horizontal plate filters are sheet filters with a filter package consisting of round,
stacked filter elements in a sealed pressure vessel.
Applications: Loss-free filtration and separation of solid materials with subsequent washing
process. Also suitable for absorption and extraction processes. High efficiency for perfect
results.
Two different flow directions are available:
•• radium Type A with outward flow direction
The high flow speed of the unfiltered material is maintained until it arrives at the filter
element. There is no settling, even with solids which easily form sediment.
•• radium Type B with inward flow direction
It is possible to build very light filter elements, which are easy to handle, even with large
diameters.
Design and construction comply with GMP guidelines and FDA regulations. Materials used:
•• Type A: Cr-Ni-Mo steel, hastelloy, and lined vessels; filter elements made from Cr-Ni-Mo
steel, PP, PVDF and hastelloy
•• Type B: Made entirely from Cr-Ni-Mo steel. Long service life with the highest possible
availability
Horizontal plate filter radium A
outward filtering direction
14
Horizontal plate filter radium B
inward filtering direction
liquitec
•• Sealed, pressure resistant system
•• Safe processing of toxic, inflammable and
corrosive liquids
•• Perfect cleaning and sterile processing
•• Uniform product quality and safety
•• Flow-optimized construction
•• Robust, consistent filter cake
radium RZ 60 A
Construction Types:
•• Mechanical or hydraulic pressing of the
filter package
•• With heating or cooling jacket
•• Hydro-pneumatic lift for vessel head-plate
and the filter package
Adaptable in application and use. Easily dismantled
filter elements. Fast replacement of filter package by
use of reserve package. Simple handling saves time.
Sizes / Types
Filter Area
RZ 60 B
0,75 – 12,0 m
10,0 – 175,0 l
RZ 60 A
1,75 – 8,0 m
11 – 105,0 l
radium RZ 60 A6GH 21 CW 5,25 m2
RZ 80 B
3,0 – 23,5 m2
40,0 – 425,0 l
radium RZ 60 A open
Filter Cake Volume
2
2
Open radium filter
package
15
8. disc Pre-Coat and Dry-Residue Filter
disc filters are characterized by:
•• Filtration in sealed systems that can be automated
•• As surface or pre-coat filters
•• Pre-coat filter with wet removal
•• Residue filters with dry removal
•• Sealed system for environmentally friendly and safe operation
•• Uniform structure of filter cake
•• Driven from above, with external bearing
•• Filtration of residual volume. No loss of product filtrate
•• Cascade washing of the filter cake with minimum amount
of washing fluid
•• Filter cake drying with sealed inert gas circulation
Pre-coat filter
•• All filter media available
The series is characterised by the following features:
Sizes
Filter Area
0,15 m2 to 45,00 m2
Filter Plate
Diameters
400, 600, 800, 1.000
and 1.200 mm
Cake Volume
30 l to 2.800 l
Residue filter
16
liquitec
Drive
Filter package
Seal/Bearing
1 Structure of filter cake
Filter package
2 Filtration
Seal/Bearing
Scraper
3 Filtration of residual volume
4 Filter cake washing
and drying
Filtering vessel
5 Spin-drying and
discharge of the filter cake
17
9.Worth knowing
9.1 Implementation of ATEX Directives
Naturally, our filters and plant can be supplied to conform to the 94/9 EEC Directive. For safety
reasons, this directive specifies that also mechanical components shall be designed in such a
way that any source of ignition will be avoided (EN13463). We will be pleased to advise you
on how to establish the necessary procedures.
•• Determination of explosion hazards in operation, and
assessment of the Directives
•• Determination of the relevant material data for Ex purposes
•• Definition and representation of the organizational and
technical procedures
•• In addition to electrical devices, the mechanical components
of more complex plant and equipment must undergo a risk
analysis (EN14121-1) as laid down in the Directive.
•• Preparing explosion-protection documents – explosion-
protection concepts are integrated into the operating
instructions
18
liquitec
9.2 Materials and surface finish
We only use stainless steel and nickel-based materials, e.g.
hastelloy. The standard material is DIN 1.4435 (AISI 316 L).
Manufacturing stage
9.3Qualifications
Our machinery is often employed in validated plant. The
support of process validation by DQ-/IQ-/OQ-documentation
is therefore a routine matter for us.
Our qualifications are your security:
••
••
••
••
••
••
cGMP, GAMP
FDA
EN ISO 9001:2000
ISO 3834
21 CFR Part 11
Pressure Equipment Directive
97/23/EG
•• AD 2000-leaflet
••
••
••
••
HP0/HP100R
ÖNORM M7812
SCC-2004
WHG §8
ATEX Directive
94/9EG
FAT with Radium RZ60A HC 1,75 m2
This also includes acceptance of our machines in the course
of a FAT (factory acceptance test) at our works, or by third
parties, and the SAT (site acceptance test).
Low maintenance designs and reliable products are our guarantee for high-quality and safe functionality.
SAT with terra EFR 180 (Exhaust precipitator)
19
liquitec
liquitec ag
Industrie Neuhof 54
CH-3422 Kirchberg
Switzerland
T+41 (0)55 450 83 00
F+41 (0)55 450 83 01
[email protected]
www.liquitec.ch