ASAHI KASEI ULTRAFILTRATION MEMBRANE MODULE

TM
Microza OLT-6036H

OPERATING INSTRUCTIONS

Caution
 To ensure safe and proper use of the UF modules, read carefully and adhere to all of
the safety instructions in these Operating Instructions.
 Maintain this manual in a convenient location for consultation.
 PREFACE

The UF module and the module system may be subject to the Export Control
Regulation of Japan. If it is the case, the Export license is required as the formal
application for the export.
Asahi Kasei Chemicals Corporation (hereinafter "Asahi Kasei") inspects every
Microza UF module, and ships only the modules that meet Asahi Kasei's
specifications. However, even though adhering to operating parameter as outlined
in this manual, there remains possibility of membrane failure resulting in a breach,
or leakage, between the feed and permeate sides of the membrane. It is therefore
strongly recommended that the user of Microza provide adequate detection
equipment and embody quality control protocols and procedures to avoid damage
caused by membrane failures. Please ensure that appropriate procedures are
enacted to avoid contact with chemicals and leaking fluids resulting from module
housing failure. Asahi Kasei shall not be held liable for consequential damages or
losses caused by such noted membrane failure or for non-adherence of the above
noted recommendations. Asahi Kasei shall provide replacement module free of
charge if you find any defects against its shipment standards and notify thereof in
writing within six (6) month after the delivery date, under Section 526 of Japanese
Commercial Code.

1
 CONTENTS

Page

１．SAFETY INSTRUCTIONS ------------------------------------------------------------ 3

２．APPLICATION OF MODULE -------------------------------------------------------- 7

３．MODULE PRECAUTIONS ----------------------------------------------------------- 8

４．SPECIFICATIONS -------------------------------------------------------------------- 16

５．SHIPPING INSPECTIONS --------------------------------------------------------- 18

６．FUNDAMENTAL CHARACTERISTICS ----------------------------------------- 19

７．HOW TO FIX MODULE & PIPING ----------------------------------------------- 24

８．STANDARD OPERATING PARAMETERS ------------------------------------ 29

９．INSTRUCTIONS FOR MODULE USE ------------------------------------------ 31

１０．DRAWINGS OF MODULE AND PARTS ------------------------------------ 38

2
1. SAFETY INSTRUCTIONS

Adhere to the notes in these instructions when using the OLT-6036HA ultrafiltration
module (hereinafter “UF module”) to ensure correct and safe operation.
Asahi Kasei shall not be held liable for injuries, losses, or consequential damages
caused by non-adherence to these instructions.

1-1. Safety Symbol

The safety notes in these instructions and the warning labels attached to the module
are classified as follows:

Warning

Incorrect handling or operation of the UF module by not adhering to the

'warning' may cause serious, and possibly, fatal injury.

Caution

Incorrect handling or operation of the UF module by not adhering to the

'caution' may cause injury to personnel and/or damage and loss of equipment.

3
1-2. Safety Symbol Legend

There are three types of signals in these instructions:

WARNING or CAUTION.

NO or DO NOT.

NOTICE.

4
1-3. Safety Guidelines

Warning

Wear protectors when cutting the module for disposal as flying

fragments may cause injury.

When handling hazardous chemicals, always wear protectors such

as safety goggles and rubber gloves. If the solution comes in contact
with eyes or skin, immediately rinse thoroughly with water. Then
seek professional medical attention as soon as possible as there
may be serious injury to eyes and skin.

Do not use the module for liquids containing organic solvents as it

may cause cracks in the module housing. Steam or hot water may
blast out from such cracks during sterilization by steam or during
high-temperature operation, which may result in burns. (Refer to
Sections 3-1 and 3-2.)

Temperature of module and pipe is elevated when the UF system is

disinfected with hot water. Hot water may leak or spout out from
modules and pipes. Following care should be taken to prevent burns
and injuries.

1. Cover all modules and parts in the UF unit to protect workers

from possible splashing hot water. Insulate thermally all pipes
and parts of the unit to which workers may contact by chance.
2. Check all seal parts of pipeline prior to hot water operation.

Avoid shocks of temperature and/or pressure or repeated

up-and-down of them, even if they are within allowed service
conditions in the specification.

5
 Caution

Module contains preservative solution, formaldehyde 0.37%. Ventilate

the environment for draining out and wear protectors to prevent the
solution from touching eyes and hands.

Do not allow the module to come in contact with organic solvents, or

solvent vapors, including cleaning agents which contain organic
solvents, or with paints, or labels or tapes with adhesive backings.
Contact with organic solvents may cause cracking of plastic housings.

The weight of a module is about 35kg, when filled with water fully. Due
to the high weight of modules, they should be handled by two or more
workers.

Operate UF module within allowed specification. The operation may

damage the module. (Refer to Section 4.)

Ensure that adequate measures are in place to avoid damage to

peripheral units and/or environmental contamination from exposure to
leaking or splashing liquid.

6
2. APPLICATION OF MODULE

Use OLT-6036H as a final filter for ultrapure water in fields such as the semiconductor
industry. Do not use them for other applications.

Consult Asahi Kasei:

- If an application is not specifically noted in these Instructions.
- If there is a change in the application or in the system operation after the modules
(or system) are installed.

Asahi Kasei shall not be held liable for consequential damages or losses caused by
such noted membrane failure or for non-adherence of the above noted
recommendations.

These instructions include some typical applications and operating parameters.

Should the application differ due to variant feeds and/or operating parameters, please
first ensure the suitability of the module prior to use.

7
3. MODULE PRECAUTIONS

Carefully adhere to the Operating Instructions for proper and safe use of the module.

3-1. Notes on Solvents and Medical Agents

Alarming Label
To draw attention to solvents, Asahi Kasei affixes the following warning label to
polysulfone resin module housings.

8
3-2. Chemical Resistance of Module Housing
Note:
Don't come to contact with following solvents and/or chemicals or vapors of them to
prevent stress cracking of module housing:

Classification Typical Examples

Fatty series organic halogen Methylene chloride, trichloroethylene, Chloroform,
carbon hydride Tetrachloroethylene
Aromatic series organic Chlorobenzyl
halogen carbon hydride
Fatty series amine, Amides Dimethylformamide (DMF), Dimethylacetamide (DMAC)
Cyclic amine, Aromatic series N methyl-2-Pyrolidone (NMP), Pyridine
amine
Nitriles Acetonitrile
Cyclic ketone Cyclohexanone
Thinners Thinners
Esters Ethyl acetate, Butyl acetate
Ethers Isopropyl ether, Ethyl ether
Ketones Acetone, Methyl ethyl ketone (MEK)
Aromatic series carbon hydride Benzol, Toluene, Xylene
Alcohols Methanol, Ethanol
Fatty series carbon hydride Hexane, Heptane, DOP, Kerosene, Gasoline, Edible oil
Strong acids, Strong bases Concentrated nitric acid, Concentrated sulfuric acid, Chromic
acid, Concentrated ammonia, Ethyl amine

Other Notices
 Do not contact module with rubber sheet that contains ester plasticizer or with
soft PVC hose. Trace plasticizer or solvent may cause crack on module
housing
 Do not wipe off module with solvent wet cloth, or paste PVC tape or gum tape.
Do not mark on the module housing with a felt pen.
 Wash module with water and wipe it with dry cloth to remove dust/stain on the
module.

Examples of Past Accidents

 Paint stuck to a module and the section with the paint cracked.
 An adhesive used to fix a heat insulator to a module caused module cracks.
 Soft PVC sheet to fix module with U-bolts, as a cushion, caused module crack
(migration of plasticizer).

9
3-3. Preservative Solution.

The module is filled with 0.37% formaldehyde solution (preservative solution) to

prevent proliferation of bacteria and to keep UF membrane wet. Thoroughly wash off
the preservative with ultrapure water before using the module. Refer to the following
notices for use.

- Some modules shipped overseas are filled with an aqueous preservative solution of
65% glycerine and 2% ethanol. This solution prevents membrane freezing and
microorganism growth. Consult Asahi Kasei for handling these modules.

Caution
Formaldehyde solution (0.37%) is used as a preservative
solution. This preservative solution may cause an
inflammation when entering eyes. Always wear protectors,
such as safety goggles and rubber gloves, to prevent skin
contact and eye contact.

3-4. General

System Cleaning before Operation

Thoroughly clean inside the piping before operation. Foreign matter, such as metal
shards in the tank or in pipe lines, may seriously damage the membranes. Oil spill and
detergent also become causes of membrane fouling.

Locating the System

Protect the modules from direct sunlight and ultraviolet light as they may degrade the
UF membrane and module housing.

Module Mounting
Follow the label instruction on the module, "Feed Inlet" and "Concentrate Outlet", for
mounting on the module rack.

10
Module Mounting
The weight of a module is about 35kg, when filled with water fully. Module support
only by pipes on the rack may damage module and/or pipes (refer to Paragraph 7-1 for
a countermeasure). Module fixing with a U-bolt or a U-band may cause of case
damage. Refer to the next paragraphs "Thermal Expansion of Module" and "Module
Fixing Method and Piping" shown below in this manual.

Thermal Expansion of Module

Module extends its length by about 4 mm, when its temperature changes from 20 oC
to 90 oC (linear expansion coefficient: 5.5 ×10-5/ oC). Think over countermeasures for
the expansion in the design of module rack and piping. Firm supporting of module to
pipe or rack and firm fixing of it with U-bands, etc. may cause module break by
concentration of expansion stress to it.

Module Fixing Method and Piping

 Use two (2) filtrate nozzles to draw out filtrate from module. Filtrate pipe should
be designed, so as there remains no air bubble in it. It is recommended to place
a filtrate header at a position higher than modules.
 The module should be placed in an upright position on the rack with the feed
side at the bottom and concentrate side at the top. At least feed nozzle and
concentrate nozzle of the module should be at upright position when the
module is placed horizontally by an unavoidable reason. Follow to the label
indication of feed side and concentrate side nozzles of the module.
 Pay attention for avoiding unnecessary stress on the module in course of
designing of module rack and piping. No thermal stress should be given, for
example, in the course of hot water disinfection by expansion absorption
mechanisms. Use dummy modules (sold separately on request) to assemble a
module rack.
 Note that the diameter of the dummy module (165mmφ) is different from that of
the actual module (172mmφ).
 The pressure resistance of dummy module is max. 200 kPa. If dummy modules
are used for cleaning, make sure that this pressure is not exceeded.

11
3-5. Notices on UF Unit Operation

Prohibition of abrupt startup and sharp fluctuation of pressure

If a large amount of water is fed into the module and the system is started sharply
while air is remaining in the module or the piping, the module housing or membrane
may be damaged by water hammer phenomenon. Operate with filtrate flow rate 2m3/hr
at first and increase it up to the desired level after the air in the modules has been vent
out. Don't give thermal or pressure shock or repeated up-and-down to the Unit even if
they are within available limits.

Prohibition of Flushing
Flushing is not effective to remove accumulated foreign matter on the feed side of the
membrane, in the case of "Outside to Inside Filtration mode" type module.

Prohibition of Dead-End Operation

No DEAD-END operation allowed. DEAD-END operation may damage UF membrane and
module case.

Dead-end Filtration
Dead-end filtration (100% recovery of feed water as product) may cause quick fouling
of UF membrane by particulates and/or bacteria and the membrane may lose filtration
ability. If operation is performed in dead-end mode or in a mode close to this mode,
refer to Section 9-4 "Recovery Rate" (P32).

Prohibition of Thermal Shock

Adhere to instructions in this manual in the case of hot water disinfection. Thermal
shock, too quick rising up or falling down of feed water temperature, may damage UF
membrane and module case. Refer to the figures shown below.
◆ Rising speed: < 5°C /min.
◆ Falling down speed: < 5°C /min.

12
Hot DI Water Operation
Temperature of module and pipe is elevated when the UF system is disinfected with
hot water. Hot water may leak or spout out from modules and pipes. Following care
should be taken to prevent burns and injuries:
 Check leak from seals prior to Hot DI water operation.
 Cover all modules and parts in the UF unit to protect workers from possible
splashing hot water. Insulate thermally all pipes and parts of the unit to which
workers may contact by chance.
 Avoid shocking the UF unit thermally and hydraulically, especially during Hot DI
water operation.

Warning

There are possibilities of scalding by hot water. Cover all

dangerous parts and/or wear protectors.

13
3-6. STORAGE & TRANSPORTATION

Temporary Suspension of Processing and Module Storage

Fill ultrapure water and seal the module, when the suspension term is shorter than
three (3) days. Longer suspension may induce proliferation of bacteria, increase of
particle count and need a longer rising up time of specific resistance. Storage without
water in the module may dry UF membrane and the membrane loses its performance
as UF membrane.

Long-Term Suspension and Module Storage

Fill 0.37% formaldehyde solution for suspension/storage longer than three (3) days.
Keep modules in a cool and dry place, away from direct sunlight. Rinse modules
thoroughly, till no formaldehyde is detected for reuse. Consult Asahi Kasei for storage
periods exceeding one (1) year.

Protect from Freezing

Ensure that the membrane is not allowed to freeze. Freezing can damage the
modules and lose the performance of UF membrane.

Keep Wet
When suspending operation or storing the modules, ensure that the modules are filled
with clean water to prevent membrane drying, which may result in the loss of UF
membrane properties and productivity (capacity). Don't leave modules without water
especially when they are going to be mounted or dismounted from the module rack.
Drain out water that is used for Hot DI water operation, after it comes to normal
temperature. Contact with air, while the temperature of UF membrane is still high, dries
the membrane very quickly and damages it.

Avoid UV Light and High Temperature Exposure

Do not expose modules to direct sunlight, other UV light sources, or high
temperatures for extended periods as the module housing and UF membrane may be
degraded.

Avoid Mechanical Impact

Modules must not be subjected to sudden impact, mechanical shock, or vibration as it
may result in damaged membranes, even if there is no damage on the housing.

14
Avoid Transporting the System with Modules Installed
Remove the modules from the UF system for transportation. Transportation induced
vibration, mechanical shock, or impact may damage the membranes. Use of dummy
modules is recommended for transportation.

3-7. Other Notices

Protection of Module Filtrate Side from Contaminations

The filtrate side of the module is free from particles when the module is shipped from
Asahi Kasei. Be careful not to spoil the clean part.

Notice on Use of Hydrogen Peroxide

UF membrane is easily damaged by hydrogen peroxide. Use only dilute and room
temperature hydrogen peroxide.

Notice on Selection of Piping Materials

Select those materials with lowest extractable.

3-8. Module Disposal

Modules are to be disposed of in accordance with applicable local ordinances and

adhering to applicable regulatory requirements.

Warning

Wear protectors when cutting the module for disposal as flying

fragments could cause injury.

15
4. SPECIFICATIONS

Module specifications are given in Table 4-1.

The module is manufactured in a clean environment and is filled with 0.37%
formaldehyde solution (preservative solution) after disinfection to prevent proliferation
of bacteria and to keep UF membrane wet. Particle-free ultrapure water without viable
cells can easily be obtained if the preservative solution is replaced with ultrapure water
continuously.

Table 4-1 Module Specifications

Hollow fiber membrane size 0.6mmφ (ID)

Specifications Effective membrane area 34m2
Module diameter 172mm *1
Module length 1,177mm
Nominal molecular weight 6,000
Performance cutoff
Permeate flow rate 16m3/hr or more (25°C, 100 kPa) *2
Max. trans-membrane 300kPa (25°C)
pressure
Operating Max. feed water-side 900kPa (25°C)
Parameter pressure
*3
Max. permeate-side 900kPa (25°C)
pressure
Max. temperature used 80°C (but up to 90°C during hot water
sanitization)
pH range 1 - 14
Hollow fiber Polysulphone series
Module housing Polysulphone series
Materials
Potting material Epoxy resin
Gasket F-rubber
Preservative 0.37% formaldehyde solution *4
Solution

*1: Note that the diameter of a dummy module is 165mmφ and that of the
actual module is 172mmφ.
*2: Note that this figure is not the design flux but the initial filtration rate
achieved when pure water is filtrated at 25°C.
*3: Refer to Table 9-6 for the in-depth relationship between water temperatures
and filtration fluxes.
*4: Some modules shipped overseas are filled with an aqueous preservative
solution of 65% glycerine and 2% ethanol.

16
*1: Transmembrane pressure = Pi-Pf1
Permeate
濾過水 Ｐ f2
Transmembrane pressure is defined as "Pi-Pf1"
*2: Feed water-side pressure = Pi
*3: Permeate-side pressure = Pf1
Ｐo

Concentrate
濃縮水

Ｐi

Feed供給水
Water
Ｐ f1

Warning

Operate UF module within allowed specification. The operation may

damage the module.

◆ Consult Asahi Kasei if you wish to use the OLT-6036S for a higher maximum
feed pressure desired.

◆ Consult Asahi Kasei if you wish to use the OLT-6036V for a higher pressure
desired in a hot ultrapure water line.

17
5. SHIPPING INSPECTIONS

Asahi Kasei ships all modules after inspections by its own shipping standard.

Inspection items are as follows:

1. Cut-off molecular weight

2. Permeate Flux Inspection

3. Dimension Inspection

4. External Appearance Inspection

5. Integrity Testing

6. Module Leak

7. Particle Counts in Filtrate

8. Specific Resistivity of Filtrate

18
6. FUNDAMENTAL CHARACTERISTICS

6-1. Average Filtration Pressure and Filtrate Flow Rate

An example of relationship between average filtration pressure and filtrate flow rate is
given in Figure 6-1.

Permeate
濾過水 Ｐ f2

15.0
／Ｈｒ・２５℃）

Ｐo
at 25°C)

濃縮水
Concentrate
Flux (m3/hr

10.0
3
濾過水量（ｍ

Ｐi
Permeate

5.0
供給水
Feed Water
Ｐ f1

0.0
0.0 0.5 1.0

Filtration Pressure (100kPa)

濾過圧力（１００ｋＰａ）

Test Condition
(Pi  Po) Pf1  Pf2
Pressure 
Filtration 濾過圧力 
2 2
◆ Feed water: Ultrapure water; particle count less than 50pcs./ml, larger
than 0.1μm
◆ Filtrate recovery: 98% of feed water at 25°C

Fig. 6-1 Filtration Pressure and Permeate Flux

19
6-2. Feed Flow Rate and Pressure Drop

An example of relationship between feed flow rate and pressure drop is shown in Figure
6-2.

濾過水
Permeate Ｐf2

0.15
（１００ｋＰa）
Pi-Po (100kPa)

Ｐo

0.10 濃縮水
Loss Ｐｉ－Ｐo

Concentrate
圧力損失

Ｐi
Pressure

0.05

供給水
Feed Water
Ｐf1

0.00
0.0 5.0 10.0 15.0

3
Feed Flow Rate (m3 ／Ｈｒ）
モジュール供給水量（ｍ /hr)

Test Condition

 Module: As shown above, a module is placed in an upright position and

feed water is fed to bottom feed nozzle.
 Feed water: Ultrapure water; particle count less than 50pcs./ml, larger
than 0.1μm
 Pressure drop = (Pi - Po) (100kPa)
 Filtrate recovery: 98% of feed water at 25°C

Fig. 6-2 Feed Water Volumes and Pressure Losses

20
6-3. Recoverability of Permeate Nonconductivity after Startup

This module is filled with 0.37% formaldehyde solution and sealed. The following
graph shows data regarding a rinse process. This data represents only one example of
rinsing in our system, so that permeate nonconductivity does not necessarily recover at
all sites in the same way as indicated here.
Some modules shipped overseas are filled with an aqueous preservative solution of
65% glycerine and 2% ethanol. Consult Asahi Kasei for data on rinsing these modules.

Recoverability of Permeate Nonconductivity

Figure 6-3-1 shows an example of changes in the recoverability of permeate
nonconductivity. The time required to recover permeate nonconductivity is shortened
as the volume of feed water increases. Set the module on the unit and then rinse the
module by feeding ultrapure water of 18 megohms-cm (25°C) or more until the
predetermined nonconductivity is reached.

19.0

Specific Resistivity of Feed Water

供給水の比抵抗レベル
x cm at 25°C)
(MΩ ・ｃｍ・２５℃）

18.0
比抵抗 （ＭΩ

17.0
Specific Resistance

16.0

15.0
0.0 1.0 2.0 3.0 4.0 5.0

Filtration Time (hrs)

濾過時間（時間）

Test Condition
◆ Filtrate flow rate: 10.0 m3/hr per module
◆ Water recovery rate: 98%
◆ Specific resistivity of feed water: 18.17 MEG-cm (25°C)
◆ Conductivity meter: TOA-DKK-made AQ-11

Fig. 6-3-1 Data on Recoverability of Permeate Nonconductivity after Startup

21
 Particle Data

Figure 6-3-2 shows data on particle removal.

微粒子の除去データを図６－３－２に示します。

10.00

0.05μ m
Count (pcs./ml)

1.00
微粒子数（個/mL）

0.10μ m

0.10
Particle

0.01

0.00
0 6 12 18 24 30 36 42 48

Rinsing Time (hrs)

リンス時間（hrs）

Test Condition

◆ Filtrate flow rate: 10 m3/hr per module (25±1°C)

◆ Particle counter: PMS-made Ultra DI-50

Figure 6-3-2 UF permeate particle counts exhibited after system startup

22
TOC Data

Figure 6-3-3 shows TOC exhibited during the early stages of rinse process.

5.0

4.0
ＴＯＣ （ppb）

3.0 ⊿TOC ppb

2.0

1.0

0.0
0.0 12.0 24.0 36.0 48.0

Rinsing Time (hrs)

リンス時間（hrs）

Test Condition

◆ Filtrate flow rate: 10 m3/hr per module (28 - 30°C)

◆ Water recovery rate: 98%
◆ Feed water quality: 1-2ppb of TOC
◆ TOC meter: Anatel-made A-1000

Figure 6-3-3 UF permeate TOC exhibited after system startup

23
7. HOW TO FIX MODULE & PIPING

7-1. How to Fix Module on a Rack

 The weight of a module is about 35kg, when filled with water fully. Module support,
only by piping, is overload for module case and pipes. Adoption of special support
is recommendable. References are given in Figure 7-1 and 7-2.

 Avoid fixing the module housing too tightly with U-bolts or suchlike as it may strain
module pipe sections. The fixing should be light enough to prevent horizontal
swings.

 The module should be placed in an upright position on the rack with the feed side
at the bottom and concentrate side at the top. Feed nozzle and concentrate
nozzle are designated clearly by labels on the module. No reverse is allowed.

 A stand should support the bottom cap nut of the module as shown in Figure 7-1.
Fixing apparatus to keep module free from toppling is such as a band holding
module loosely and lightly. Dimensions in the Figure 7-1 are standard ones.

 Connection pipes to module are of elbow type as shown in Figure 7-1. This piping
method allows all module connection parts to be free from stress concentration.
No supports be used for elbows but headers.

 Connection part of the filtrate nozzle of the module is union socket of 2.5S size.
Use custom made sanitary cramp for the connection. The screwing torque of the
cramp should be kept within 1.5 - 2.5N-m. It is recommended to be skilled to the
torque by training with a torque wrench.

 Pipe elongates and shrinks thermally. Allowance for the expansion should be
taken into consideration at module rack designing and piping.

Caution

Due to the high weight of the module, take a lower back problem
preventive measure such as handling by two or more workers.

24
 Caution

Fix the module with a U-band or chain to the module rack when
installing modules. If the module falls down, it can cause injuries or
damages to the module housing.

Caution

Do not over tighten such U-band clamps or chains. Do not tighten

U-band clamps with a tool but with hands. When chains are used,
ensure that they are slack. Over tightening a U-band clamp or a
chain may damage the module housing.
If the module contacts an angle such as that of a metal part when
secured, protect the module with cushioning.

25
 PVDF PIPE
SIZE 50 FILTRATE

SCREWING TORQUE HEADER

SUPPORT
CONCENTRATE

PVDF IR90 ELBOW

O.D. 63

FASTEN LIGHTLY

FEED

MODULE STAND

SCREWING TORQUE
FILTRATE HEADER

OLT-6036H SUPPORT

Fig. 7-1 Module Supporting Method

26
7-2. Example of Module Stand

Figure 7-2 shows an example of module stand. The figure and dimensions are only for
reference. Use dummy module to fabricate and construct the stand. Note that the diameter
of a dummy module (165mmφ) is different from that of the actual module (172mmφ).

Fig. 7-2 Module Stand (Example)

27
7-3. Piping Design of Module Rack

The module has two filtrate nozzles at both ends of it. For piping installation, refer to
the piping design examples below. For Example 2, it is recommendable to put filtrate
headers higher than modules to avoid air bubbles remaining in the filtrate pipeline.
濾過水

濃縮水

Permeate Concentrate

例１ 1
Example

Feed
供給水
濾過水

濃縮水

Permeate Concentrate

例２ 2
Example

Feed
供給水

Fig.7-3 Piping Design of Rack

28
 7-4. Example of Module Rack Structure

A perspective drawing of module rack is shown below as an example.

Permeate

Concentrate

Feed

Permeate

Fig.7-4 Example of Rack Perspective

29
8. STANDARD OPERATING PARAMETERS

8-1. Recommended Operating Parameters

Recommendable operating parameters are given in the next table.

Table 8-1 Recommended Operating Parameters

Filtration mode Outside-in constant flow filtration *1
Recovery rate of 90 - 99%
filtrate
Filtration Around 100 kPa and up gradually
Pressure
(1) Particle count: <100pcs./ml, >0.1μm
Feed water ditto: < 20pcs./ml, >0.2μm
quality (2) Viable cell: <0.1cfu/ml
requirement (3) No membrane-clogging elution from IE resin, tank material,
pipe material, etc.
Hot water (1) About one hour at a temperature of 90°C
sterilization (2) Concentrate flow rate: Max. 300L/hr/module or less
requirement (3) Filtrate flow rate: 10 m3/hr or less per module
Concentrate Concentrate flow rate: Max. 1.0m3/hr/module or less
conditions
*1: Outside-in constant flow filtration is the standard filtration mode. Note that
operation with a large flux change may degrade the performance of UF
membrane or damage it.

8-2. Feed Water Quality Requirements

Feed water that contains large amount of particles and/or microorganisms cause
decrease of membrane performance. Generally, water prepared by processes as
shown below is recommendable as feed water. Location of raw water intake or raw
water quality may also affect the performance of UF.

<Process flow diagrams of ultrapure water makeup plant>

Raw water  Pretreatment  Primary DI system  Sub-system

(Examples) (Example)
1) 2B3T +RO＋MB＋VDG UVOX＋AP＋CP＋UV＋UF
2) RO+2B3T＋MB＋VDG+RO
3) RO＋RO+ VDG+MBP
4) RO＋EDI＋CP

30
8-3. Recommendable Ultrapure Water Makeup Processes

 As mentioned in the previous paragraph, it is recommendable to use RO unit in

the primary DI system to stabilize and improve water quality.

 To reuse concentrate water of UF unit, the concentrate should be returned to

feed side of the previous RO unit. It is recommended that the particle count of the
feed water be less than 100pcs./ml (>0.1μm) and the viable cell count be less
than 0.1cfu/ml as standards. Even if these values are adhered to, other factors
may degrade the filtration performance.

 Degasification unit in the primary makeup process prevents the adsorption of gas
onto UF membrane, decrease of filtration performance, and accelerated
deterioration of membrane. Adoption of a degasification unit (such as VDG) is
recommendable.

 Eluted substances from ion exchange resin may affect the filtration performance
of UF membrane. The following notices should be taken into consideration.
1. Select the lowest elution resin available.
2. Rinse the resin thoroughly before use.
3. Remove free chlorine in feed to the resin unit. Free chlorine decomposes
resins and resulting eluted substances blocks UF membrane.

 Pay attention to elution from tank and piping materials. Eluted substances may
clog UF membrane. Periodical cleaning of machines and equipments that locate
at previous stages of the water purification line is recommendable.

 Periodical hot water sanitization is recommended. Hot water sanitization also

cleans the UF membrane and is very effective in preventing the degradation of
the membrane performance. Refer to the section "Hot Water Sanitization"
described below.

Warning

Don't touch the hot parts of the UF unit, which could result
in burns.

Note: Those recommendations above are not guarantees or conditions of

guarantees.
Note: Designers and/or water engineering companies of UF units are requested to
carefully read and follow this manual prior to designing and engineering.

31
9. INSTRUCTIONS FOR MODULE USE

9-1. Rinsing Method

Mount dummy modules to the UF unit and rinse thoroughly the whole stages of the
water makeup line, including previous stages and the UF unit, before mounting the real
UF modules. The pressure resistance of dummy module is max. 200 kPa.
The module contains 0.37% formaldehyde solution as preservative solution. Supply
ultrapure water (>18 MEG-cm at 25°C) and rinse the UF unit until filtrate quality
reaches a desired level. Don't soil the filtrate side (clean side) of the module during
mounting work. Figure 6-3-1 (page 21) shows an example of changes in the
recoverability of permeate nonconductivity.
Some modules shipped overseas are filled with an aqueous preservative solution of
65% glycerine and 2% ethanol. Consult Asahi Kasei for data on rinsing these modules.

Caution

The module may contain formaldehyde 0.37%

preservative solution. Ventilate the environment for
draining out and wear protectors to prevent the solution
from touching eyes and hands.

9-2. Filtration Mode

The filtration mode of OLT-6036HA module is "Outside-In Constant Flow Filtration"

32
9-3. Average Filtration Pressure

Average filtration pressure (Ave. P) is defined by the formula.

(Pi  Po) Pf1  Pf2 Ｐ f2
Ave. P 
濾過圧力  濾過水
Filtrate
2 2

 Max. feed pressure (Pi) is 1200 kPa (25°C).

Ｐo
 Max. transmembrane pressure is 300 kPa (25°C)

* Maximum transmembrane pressure is defined as 濃縮水

Concentrate
"Pi-Pf1"

 Decide design capacity of module considering feed

Ｐi
water quality and other restrictive conditions.
供給水
Feed water
Ｐ f1

9-4. Recovery Rate

90 - 99% of feed volume is recovered as UF filtrate, generally. Remaining 1 - 10% is

discharged from the UF unit as UF concentrate.

Note on Dead-end Filtration

Dead-end filtration (100% recovery of feed water as product) may cause an air
buildup in the upper part of the module. This could lead to membrane drying and
prevent normal filtration performance. Dead-end filtration may also cause quick fouling
of UF membrane by particulates and/or bacteria and the membrane may lose filtration
ability. Pay attention to following items if recovery rate comes closer to 100%.
 To confirm and follow feed water quality periodically
 Rising operation of recovery rate should be very slow. Spend several months.

33
9-5. Maximum Service Temperature

The maximum service temperature of the module is 80°C. Use the module at
temperatures below 80°C unless otherwise used for hot water sanitization, described
below. Such operation may cause module damage.

Warning

Don't operate UF module outside of allowed specification. The

operation may damage the module.

9-6 Feed Water Temperatures and Allowable Operating Pressures

Feed water temperature and operating pressure should be applied as specified in the
following table. Operation under a higher pressure than specified may cause module
damage.

Table 9-6 Feed Water Temperatures and Allowable Operating Pressures

UF feed water Max. Max. feed Max. permeate-side
temperature trans-membrane water-side pressure pressure
(°C) pressure (kPa) (kPa)
(kPa)
- <30 300 900 900

30 - <50 300 600 600

50 - <70 200 500 500

70 - <80 150 400 400

80 - 90 100 350 350

34
 Warning

There are possibilities of scalding by hot water. Cover all

dangerous parts and/or wear protectors. Also take
measures such as providing covers around modules and
units to prevent accidents caused by hot pipes or hot
water (40°C or more) from pipe connections.

35
9-7. Hot Water Sanitization

Two examples of hot water sanitization are shown below.

Hot Water Sanitization Flow 1

A hot water tank is provided, and hot water is fed to the UF membrane unit from the
hot water tank. Water from the use point is then returned to the hot water tank. (The
dashed lines in the figure show hot water lines.)

◆ Temperature raising method 1

Raise the temperature of the UF unit to 90°C, taking at least 15 minutes. After
hot water sanitization, also take at least 15 minutes to bring the temperature
back to normal.

◆ Temperature raising method 2

If a facility restriction does not allow gradual raising of water temperature, raise it
in two steps. When the temperature of hot tank water reaches 50 to 60°C, feed
the hot water to the UF modules for 10 or more minutes to raise the module
temperature to a constant temperature of 50 to 60°C. Keep feeding hot water to
the modules to raise the temperature of the hot tank water to 90°C. Decrease
the temperature also in two steps.

濃縮水
Concentrate

一 ポ ユ
Ｕ
Primary pure water

次 Ｕ リ ー
Polisher

Use point

純 ス
　 ッ 　 Per-
濾過水
tank

水 Ｖ シ meate ポ
タ Ｆ イ
ャ
ン ー ン
ク ト

Hot
熱Water
水

Hot water
蒸気またはヒーター
Steam or Heater 熱水タンク
tank

Fig. 9-7-1 Hot Water Sanitization Flow (1)

36
Hot Water Sanitization Flow 2
A heat exchanger is installed in the ultrapure water line before the UF modules and
hot water is fed to the UF modules and use point. (The dashed lines in the figure show
hot water lines.)

◆ Temperature raising method

Raise the temperature of the UF unit to 90°C, taking at least 15 minutes. After
hot water sanitization, also take at least 15 minutes to bring the temperature
back to normal.

Permeate
濾過水
Concentrate
濃縮水

Per-
濾過水
一 ポ meate ユ
Primary pure water

Heat exchanger

次 熱
Ｕ Ｕ ー
Polisher
リ

Use point
純 交 ス
　 ッ 　
tank

水 換 ポ
Ｖ シ
タ 器 Ｆ イ
ャ
ン ー ン
ク ト
Hot熱
Water
水
蒸気
Steam 熱水
Hot
Water

Fig. 9-7-2 Hot Water Sanitization Flow (2)

37
Notes on Hot DI Water Operation
Note the following for hot water sanitization:

 It is recommended that hot water of 90°C be run through the sections up to the
end of the use point piping for one to two hours.
 If a cleaning effect on the UF module and piping is intended, about one-hour
operation with hot water of 90°C is recommended. In this case, discharge 100 to
300 liters of concentrate an hour per module. (The concentrate in module must
be discharged constantly from the concentrate-side port during hot water
sanitization to prevent the buildup of air in the upper part of the module. Such air
buildup could lead to membrane drying.)
 Take at least 15 minutes when raising the water temperature to 90°C to feed hot
water to the UF modules. Also take 15 or more minutes when bringing the water
temperature back to normal.
 Use of a sensor for high temperatures is recommended as hot water may pose a
problem for a conductivity sensor.
 Automation of hot water sanitization is recommended, as the operation is likely
to be performed frequently.
 Note that, if hot water is discharged from the UF unit right after hot water
sanitization while the water is still hot, the UF membrane may dry quickly through
contact with air and loose its performance as UF membrane.

Warning

There are possibilities of scalding by hot water. Cover all

dangerous parts and/or wear protectors. Also take
measures such as providing covers around modules and
units to prevent accidents caused by hot pipes or hot
water (40°C or more) from pipe connections.

38
10. DRAWINGS OF MODULE AND PARTS

10-1. Module

Module in Shipping Package (Dwg. No.: AUM-OT60H-01)

Two sanitary gaskets for filtrate sanitary nozzles are packed in the container.

Module Connection Assembly (Dwg. No.: AUM-OT60H-02, AUM-OT60H-03)

Two filtrate nozzles are used as outlets of filtrate at all times.

10-2. Parts List (Standard Parts)

Parts Name Qty. Materials Parts No.

Feed Cap nut 2 GR-PPE 0450600
&Conc. O-ring: 63.8Φ x 3.5 2 F-rubber 0150611
Standard side Blind plate: 85Φ 2 PP 0150618
Parts 3-piece clamp: 2.5S 2 SUS-304 0150613
Filtrate
Sanitary gasket: 2.5S 2 F-rubber 0150612
side
Blind plate: 77.5Φ 2 PP 0150617
Union socket (feed & conc. 2 PVDF 0450602
Feed side) 0450601
&Conc. 2-piece retainer ring 2 GR-PPE 0450600
PVDF
side Cap nut 2 GR-PPE 0150611
Parts
O-ring: 63.8Φ x 3.5 2 F-rubber
(Sold by
Union socket (permeate side) 2 PVDF 0450603
request) Filtrate
Sanitary gasket: 2.5S 2 F-rubber 0150612
side
3-piece clamp: 2.5S 2 SUS-304 0150613
Union socket (feed & conc. 2 C-PVC 0450604
C-PVC
Feed side) 0450601
Parts for
&Conc. 2-piece retainer ring 2 GR-PPE 0450600
Normal
side Cap nut 2 GR-PPE 0150611
Temperat
O-ring: 63.8Φ x 3.5 2 F-rubber
ure
Union socket (permeate side) 2 C-PVC 0450605
(Sold by Filtrate
Sanitary gasket: 2.5S 2 F-rubber 0150612
request) side
3-piece clamp: 2.5S 2 SUS-304 0150613
Dummy module - ABS and 0450609
others
*GR-PPE: Glass fiber-reinforced modified polyphenylene ether resin
*F-rubber: Fluorocarbon rubber

39
 Contact Asahi Kasei:

◆ If the specified filtration rate is not achieved

◆ A change of the originally intended application
◆ For module storage requirements exceeding one (1) year
◆ Requirement for more detailed information on UF system design
◆ Requirement for additional product parameters or information on product use

ASAHI KASEI CHEMICALS CORPORATION

MICROZA & WATER PROCESSING DIVISION

Jinbocho-Mitsui Building 1-105, Kanda Jinbocho, Chiyoda-ku, Tokyo

101-8101, Japan

Phone: +81-3-3296-3227

Fax: +81-3-3296-3449

Revised in April, 2012

40