Ceramic Ultrafiltration with Ozone for WFI Production
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for producing Water for Injection (WFI) are energy-intensive due to distillation requirements and fail to effectively disinfect and maintain the integrity of ultrafiltration systems against microorganisms.
Innovation Solution
A process involving pre-treatment with an ion exchanger, followed by reverse osmosis, electrodeionization, and ultrafiltration using a ceramic membrane, with ozone application for disinfection, and UV irradiation to remove ozone before subsequent stages, ensuring the system's sterility and ion reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If distillation process is used to produce WFI, then water purity is improved, but energy consumption increases
Solution Approach 1:
The water purification process is divided into multiple sequential stages: reverse osmosis for initial separation, electrodeionization for ion removal, and ultrafiltration for final purification. This segmentation allows each stage to specialize in removing specific impurities, achieving high purity without requiring energy-intensive distillation.
Solution Approach 2:
The patent replaces the thermal-mechanical distillation process with a combination of membrane-based separation (reverse osmosis and ultrafiltration) and electrochemical processes (electrodeionization). This substitution eliminates the need for high-temperature heating and phase change, significantly reducing energy consumption while maintaining water purity.
2Manufacturing precision
If conventional ultrafiltration membrane is used, then water purification is improved, but microorganism contamination risk increases
Solution Approach 1:
The patent introduces ozone (a strong oxidant) into the ultrafiltration system to continuously disinfect the water and kill microorganisms on the membrane surface. The ozone oxidizes and destroys microbial cell walls and structures, providing effective disinfection without compromising the ultrafiltration membrane's integrity or the water's purity.
Solution Approach 2:
The patent implements continuous ozone treatment throughout the ultrafiltration process, maintaining constant disinfection pressure. This continuous action ensures that microorganisms are constantly killed and prevented from accumulating on the membrane, eliminating the need for periodic cleaning and maintaining consistent water quality.
3Object-affected harmful factors
If ozone is applied for disinfection in ultrafiltration, then microorganism elimination is improved, but membrane damage risk increases
Solution Approach 1:
The patent carefully controls the ozone concentration, contact time, and pH levels in the ultrafiltration system. By optimizing these parameters, the system achieves effective microorganism elimination while preventing excessive oxidation that could damage the membrane. The controlled conditions ensure ozone acts as a disinfectant rather than a membrane-degrading agent.
4Manufacturing precision
If multiple purification stages are implemented, then water purity is improved, but device complexity increases
Solution Approach 1:
The patent designs each purification stage to serve multiple functions: reverse osmosis removes both ions and suspended particles, electrodeionization targets specific ions, and ultrafiltration eliminates microorganisms while maintaining water clarity. This multi-functionality at each stage reduces the need for additional separate systems, managing overall process complexity while achieving high purity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach eliminates the need for costly distillation, effectively reduces ion content, and maintains system sterility by continuously disinfecting the ultrafiltration module and storage areas, enabling the production of high-purity WFI while preventing microorganism accumulation.
Implementation Method 1
The feed water is first subjected to reverse osmosis. Prior to reverse osmosis, the feed water undergoes pretreatment, for example, softening by an ion exchanger.
Implementation Method 2
The feed water is first subjected to reverse osmosis.
Implementation Method 3
After at least one reverse osmosis stage, the water is subjected to electrodeionization
Implementation Method 4
the water is subjected to at least one ultrafiltration stage. According to the invention, the semipermeable membrane used for ultrafiltration is a ceramic membrane.
Implementation Method 5
The module where ultrafiltration takes place is continuously exposed to ozone. This disinfects and kills any microorganisms that may be present.
Implementation Method 6
UV irradiation to remove ozone before subsequent stages
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a process for producing pharmaceutically usable water (31), in particular water for injection (WFI). In this process, drinking water quality water, hereinafter referred to as feed water (30), is subjected to at least one reverse osmosis (10) and at least one ultrafiltration (20) to treat the feed water (30). The membrane used for the ultrafiltration (20) is a ceramic membrane (21), and the module in which the ultrafiltration (20) takes place is continuously exposed to ozone. The invention proposes that, after the at least one reverse osmosis (10), the water is subjected to electrodeionization (11).Furthermore, the invention relates to a device for carrying out the previously described method for producing pharmaceutically usable waters (31), wherein the invention provides that at least one reverse osmosis device (10) and at least one ultrafiltration device (20) as well as an electrodeionization device (11) are provided and that the membrane of the ultrafiltration device (20) is a ceramic membrane (21) and the ultrafiltration device (20) is exposed to ozone (Fig. 1).