Professional Documents
Culture Documents
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Water Purification System for a
Laboratory Facility
Millipore Corporation
Bioscience Division
Christopher Yarima
Mike Kelly
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Outline
Contaminants in Water
Pure Water Applications and Quality Standards
Water Purification Technologies
Key Water Purification System Design Steps
Systems
Questions
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Water Chemistry – Contaminants
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Ground & Surface Water
Surface Water
- Lower in dissolved ions
- Higher in organic materials
- Higher in particulates
- Higher in biological material
Ground Water
- Higher in dissolved ions
- Lower in organic
materials
- Lower in particulates
- Lower in biological
Material
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Contaminants in Potable Water
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Water Standards
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Standards and Common Terms
Ultrapure/Reagent Grade
Critical Applications
“Ultrapure” Water for HPLC,GC, HPLC ,AA , ICP-MS, for
buffers and culture media for mammalian cell
Type 1 culture & IVF, reagents for molecular biology...
Pure/Analytical Grade
Standard Applications
Buffers, pH solutions,culture media
Type II preparation ,clinical analysers and
“Pure” weatherometers feed.
Pure/Laboratory Grade
General Applications
Glassware rinsing, heating baths,
Type III humidifiers and autoclaves filling
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Laboratory Water Purity Specifications
Consolidated Guidelines
* Overview of USP28 and EP 4th edition, (refer to detailed specifications for exact norms).
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Purification Technologies
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Purification Technologies
Filtration – Depth and Screen Filters
Activated Carbon and chlorine removal
Mineral scale control – Softening and Sequestering
Distillation
Reverse Osmosis
Deionization
Electrodeionization
Ultraviolet light
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Purification Technologies
Filtration Summary
Depth Filters
Random Structure
Nominal retention rating
Works by entrapment within “depths” of filter
media
High “dirt” holding capacity
Screen/Membrane Filters
Uniform Structure
Absolute retention rating
Works largely by surface sieving
Low dirt holding capacity
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Activated Carbon
Granules or beads of carbon
activated to create a highly porous
structure with very high surface area
Activation can be heat or chemical
Pore sizes typically <100 to 2000 Å
Surface area typically 500 to >2000
m2/gram
Removal of organics by adsorption
Removal of chlorine by adsorption-
reduction
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Mineral Scale Control
Calcium and carbonate ions are common in tap water supplies
Scale forms when concentration exceeds solubility limits and CaCO3
precipitates as a solid
Higher concentrations increase risk of scale formation
Higher pH and higher temperature increase risk of scale formation
Important in domestic water systems and purification technologies
CO3= CO3=
Ca++
CO3= CO3=
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Scale Control – Ion-exchange Softening
"Hard water"
Cation
Ca++ + 2 Cl- Exchange Resin
Mg++ + 2 Cl-
R Na Na R
R Na Na R
R Ca R
R Mg R
4 Na+ + 4 Cl-
"Soft water"
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Scale Control
Ion-exchange Softener Regeneration
Regenerated resin
R Na Na R Na+ Cl-
R Na Na R
R Ca R
conc. NaCl
Mg++ + 2 CL- R Mg R
Ca++ + 2 Cl-
EXCESS Na+ Cl-
Exhausted resin
Softeners are regenerated using a concentrated “brine” flush
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Scale Control – Chemical Sequestering
Chemical sequestering “weakly binds” calcium ion preventing
calcium and carbonate ions from forming scale
Liquid and solid chemical options available
Solid polyphosphate shown as example illustration
Ca++
CO3= _ CO3=
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Polyphosphate chain
Double Distillation Principal
Benefits
Removes wide class of
Recondense contaminants
by cooling vapor Cooling water
jacket Bacteria / pyrogen-free
Low capital cost
Limitations
High maintenance
High operating cost
Osmotic
Pressure
Water
Plus
Contaminants
Pure
Water
Water
Plus
Contaminants Pure
Water
Semi-Permeable
Reject Reverse Osmosis
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Membrane
Reverse Osmosis Summary
Benefits Limitations
All types of contaminants removed: Not enough contaminants removed for
ions, organics - pyrogens, viruses, Type II water.
bacteria, particulates & colloids.
RO membrane sensitivity to plugging
Low operating costs due to low energy (particulates), fouling (organic,colloids),
needs. piercing (particle, chemical attack) and
Minimum maintenance (no strong acid scaling (CaCO3) in the long run if not
or bases cleaning) properly protected.
Good control of operating parameters. Need of right pressure (5 bars) & right pH
Ideal protection for ion-exchange resin for proper ion rejection.
polisher: a large ionic part already Flow fluctuation with pressure and
removed (↑ resin lifetime), particulates,
temperature.
organics, colloids also eliminated (no
fouling). Membrane sensitivity to back pressure
Preservative rinsing needed
Need optimized reject
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Ion Exchange
Cation Exchange Resin
Ion (-)
Particulate
H2O
Colloid (-)
Organics
Benefits Limitations
Effective at removing ions Limited or no removal of particles, colloids, organics
Resistivity 1-10 MΩ.cm with a single pass or microorganisms
through the resin bed. Capacity related to flow rate and water ionic content
Resistivity 18 MΩ.cm with proper pretreatment Regeneration needed using strong acid and base
Easy to use: Simply open the tap and get water Prone to organic fouling
Low capital cost Multiple regenerations can result in resin breakdown
and water contamination
Risk of organic contamination from previous uses
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Electrodeionization (EDI, CDI, ELIX, CIX)
RO Feed Water Continuous deionization technique
Ion Exchange Resin
where mixed bed ion-exchange
resins, ion-exchange membranes and
a small DC electric current
+ A C A C - continuously remove ions from water
(commercialize by Millipore in mid 80’s)
Na+ Cl- OH- Conductive
H+ Cl- Na+ Carbon
Beads
Performance enhancements:
Cl-- Na+
Ion-exchange added to waste
OH- channels improve ion transfer and
H+ Cl- Na+ removal.
Na+ Cl-
Conductive beads aded to cathode
Waste electrode channel reduces risk of
Product
scale and use of a softener
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Contaminant Removal Efficiency
Distillation
Reverse Osmosis
Ultrapure Ion Exchange
Electrodeionization
Ultraviolet light
Carbon
Ultrafiltration
Microporous Filtration http://aqua-pro.ae
2311BD10
Water Purification System Design
Multi-Step Purification Process
RO systems
Both
RO + EDI systems
Progard Pack Reverse Elix Technology UV Lamp
Pretreatment Osmosis Electrodeionization Production of
pack Remove up to Consistent water with low
RO cartridge 99% of feed production levels of
protection water of high resistivity Bacteria
contaminants and low TOC water
Product
1 2 3 4 Water
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Major phases in a project
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Major phases in a project
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Design Process
Key Steps
Dishwasher
Direct Feed
monitoring
2
UV
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Design Process: Step 1
1
Dishwasher
Ultrapure
General
Polishing
Glassware
How much water? for HPLC
Rinsing
When is it needed?
Where is it needed?
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1
Defining the pure water requirements and specifications
What purity level?
What labs and locations need purified water?
What kind of work will be carried out in each lab, at each location?
General rinsing/washing to sensitive trace analysis,…?
Are there instruments that will need pure water?
Glassware washers, steam sterilizers, autoclaves…..?
Are there any “maximum” purity level requirements?
What water quality is needed for each location?
Ionic, Organic, and Microbiological Quality?
Are there alert and action levels? Dishwasher
Direct Feed
Are there standard specifications to follow?
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Definition of the needs 1
Questions to select the right configuration and design
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Defining the pure water requirements and specifications
1
What purity level?
How much water? When? Where?
Additional questions:
Does the equipment need to be validated?
At all locations?
Who will do the maintenance?
Is a service/maintenance contact required?
Are the water quality requirements similar between locations?
How many researchers/scientists will work in each lab?
Dishwasher
Where can the equipment be located (space)? Direct Feed
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Step 2: Designing the Distribution Loop 2
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Distribution Loop Layout Options: 2
Gravity Feed
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Distribution Loop Layout Options: 2
Single Loop and make-up system Central Location
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Distribution Loop Layout Options: 2
Single Loop and Duplex-central make-up system
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Distribution Loop Layout Options: 2
Multiple Loop and make-up systems
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Distribution Loop Layout Options: 2
Multiple Loop and make-up systems and POU systems
“Satellite” Units
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Design Considerations; Avoid Dead legs
2
“6D rule” CFR212 regulations of 1976
Good Engineering practice requires
minimizing the length of dead legs and
there are many good instrument and valve
designs available to do so.
“6D rule”
Ø 0.59”
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Design Considerations; Flow Velocity
2
Design system for 3 to 5 f/s (~1 to 1.5 m/s) to:
Maintain turbulent flow
Minimize biofilm on internal walls
Balance between velocity and pressure drop
Higher velocity results in too high a pressure drop
– Requiring a larger pump and risk of increased water temperature
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Define Loop Purification and Monitoring
Equipment
2
Loop purification equipment to maintain water quality
– UV lamp
» Bacteria control
» TOC Reduction
– Filtration
» Membranes for Bacteria and particle control
» Ultra-filtration for Pyrogen removal
– Deionization – Ion removal
Loop Water Purity Monitoring
– Resistivity
– TOC
– Bacteria
– Temperature
– Sanitant Monitors (Ozone)
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Loop Monitoring
2
Resistivity http://aqua-pro.ae
Loop Bacteria Sampling
2
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Determine the Distribution Pump
Requirements
2
Pump selection is based on flow rate and pressure requirements
Flow rate required defined in step 1
Pressure requirement
Total Pressure requirement can be estimated by adding:
piping pressure loss
+
loop equipment pressure loss
+
pressure due to elevation changes
+
pressure required at furthest point of use (25 psi typical)
Select a pump that delivers the required flow rate and pressure
Reduce pressure loss by increasing pipe diameter, (keeping balance
with flow required and target velocity)
For added reliability a duplex pumping system can be used
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Distribution Systems
Water Flow Dynamics; Pressure drop
2
Determining pressure drop through fittings:
Fittings; (elbows, tees, unions, etc…..)
Flow through fittings creates turbulence and adds to
pressure drop
“Equivalent pipe length” method most common
Express each fitting as a length of pipe
1 foot
Example:
2 ft + 1 ft + (1) 90o elbow
90o elbow = 2 equivalent feet of pipe
2 + 1 + 2 eq-ft = 5 feet total length
90o
2 feet elbow
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Distribution Systems
Water Flow Dynamics; Pressure drop
2
Determining pressure drop through additional loop equipment
Refer to manufacturers specifications
UV lamps: Typically 2 to 3 psi
Filters and housings:
Pressure loss data
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Step 3 - Design the Makeup Purification 3
System and Storage Tank
Size the storage tank to meet peak demands during the day
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Makeup System Sizing and Quality
3
Match to the quality requirement (defined in step 1)
RO/EDI or RO/DI system for Type 2 pure water applications
Size the makeup system to match the quantity required per day
(defined in step 1)
Plans for future expansion?
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Sizing Makeup System and Tank
3
Sizing the makeup system is done in
conjunction with the storage tank
Sizing Examples:
Company A needs water to clean vessels in the first two hours of
the day shift. They need a total of 1200 Gallons in two hours.
1500 Gallon Tank with 100 gph make-up rate
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Determine the pretreatment needed for
the makeup water system
3
Determine feed flow rate base on the make-up system water
recovery rate
Feed Flow Rate = RO Product / RO recovery rate
Complete feed water analysis
conductivity, chlorine, fouling index, pH, hardness, alkalinity……..
Select pretreatment options based on feed water analysis and
manufacturers recommendations
Multimedia Sand – Particulate contamination
Carbon Filters – Chlorine and some organic removal
Softeners – Hard water (Mg++ or Ca++ contamination)
Cartridge Filters – Particulate and carbon options
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Design Process Step 4 4
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Outline
Contaminants in Water
Pure Water Applications and Quality Standards
Water Purification Technologies
Key Water Purification System Design Steps
Systems
Questions ???
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Water Purification System for a
Laboratory Facility
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