In situ monitoring techniques for concentration polarization and fouling phenomena in membrane filtration

Engineered multi-scale roughness of carbon nanofiller-embedded 3D printed spacers for membrane distillation

Membrane distillation (MD) transfers heat and mass simultaneously through a hydrophobic membrane. Hence, it is sensitive to both concentration and temperature polarisation (CP and TP) effects. In this study, we fabricated feed spacers to improve MD efficiency by alleviating the polarisation effects. First, a 3D printed spacer design was optimised to show superior performance amongst the others tested. Then, to further enhance spacer performance, we incorporated highly thermally stable carbon nanofillers, including carbon nanotubes (CNT) and graphene, in the fabrication of filaments for 3D printing. All the fabricated spacers had a degree of engineered multi-scale roughness, which was relatively high compared to that of the polylactic acid (PLA) spacer (control). The use of nanomaterial-incorporated spacers increased the mean permeate flux significantly compared to the PLA spacer (27.1 L/m²h (LMH)): a 43% and 75% increase when using the 1% graphene-incorporated spacer (38.9 LMH) and 2% CNT incorporated spacer (47.5 LMH), respectively. This could be attributed to the locally enhanced turbulence owing to the multi-scale roughness formed on the spacer, which further increased the vaporisation rate through the membrane. Interestingly, only the CNT-embedded spacer markedly reduced the ion permeation through the membrane, which may be due to the effective reduction of CP. This further decreased with increasing CNT concentration, confirming that the CNT spacer can simultaneously reduce the CP and TP effects in the MD process. Finally, we successfully proved that the multi-scale roughness of the spacer surface induces micromixing near the membrane walls, which can improve the MD performance via computational fluid dynamics.

Monitoring residual fouling after cleaning of multi-fiber membrane modules fiber-by-fiber using non-invasive MRI monitoring

In this study non-invasive low field magnetic resonance imaging (MRI) technology was used to monitor fouling induced changes in fiber-by-fiber hydrodynamics inside a multi-fiber hollow fiber membrane module containing 401 fibers. Using structural and velocity images the fouling evolution of these membrane modules were shown to exhibit distinct trends in fiber-by-fiber volumetric flow, with increasing fouling causing a decrease in the number of flow active fibers. This study shows that the fouling rate is not evenly distributed over the parallel fibers, which results in a broadening of the fiber to fiber flowrate distribution. During cleaning, this distribution is initially broadened further, as relatively clean fibers are cleaned more rapidly compared to clogged fibers. By tracking the volumetric flow rate of individual fibers inside the modules during the fouling-cleaning cycle it was possible to observe a fouling memory-like effect with residual fouling occurring preferentially at the outer edge of the fiber bundle during repeated fouling-cleaning cycle. These results demonstrate the ability of MRI velocity imaging to quantitatively monitor these effects which are important when testing the effectiveness of cleaning protocols due to the long term effect that residual fouling and memory-like effect may have on the operation of membrane modules.

Filtration with Multiple Species of Particles

Membrane filtration of feed containing multiple species of particles is a common process in the industrial setting. In this work, we propose a model for filtration of a suspension containing multiple particle species (concrete examples of our model are shown in two and three species), each with different affinities for the material of the porous filter membrane. Using the pore shape within the membrane as a design objective, we formulate a number of optimization problems pertaining to effective separation of desired and undesired particles in the special case of two-particle species and we present results showing how properties such as feed composition affect the optimal filter design. In addition, we propose a novel multi-stage filtration strategy, which provides a significant mass yield improvement for the desired particles, and, surprisingly, higher purity of the product as well.

Influence of the Zeolite ZSM-22 Precursor on a UF-PES Selective Substrate Layer for Salts Rejection

Fabrication of the ZSM-22/Polyethersulfone (ZSM-22/PES) membranes as selective salt filters represent a growing membrane technological area in separation with the potential of high economic reward based on its low energy requirements. The incorporation of ZSM-22 zeolite material as additives into the PES polymer matrix has the prospective advantage of combining both the zeolite and polymer features while overcoming the limitations associated with both materials. This work investigated the influence of the nature of the silica precursor on ZSM-22 zeolite hydrothermally synthesised using colloidal (C60) and fumed (C60) silica to Si/Al of 60. The successful synthesis of the highly crystalline zeolitic materials was confirmed through XRD, FTIR, and SEM with EDX. The ZSM-22 additives were directly dispersed into a PES polymeric matrix to form a casting solution for the preparation of the ZSM-22/PES selective substrate layers via a phase inversion method for salts rejection. The polymeric PES was selected as an organic network in which the content of the ZSM-22 zeolite (ranging between 0 and 1.0 wt.%), was obtained and characterised by XRD, FTIR, and SEM analysis, as well as water contact angle (WCA) measurement and dead-end filtration cell. The phase inversion preparation method has induced the resulting ZSM-22/PES NF substrates anisotropy, as attributed to a high water flux to the above 700 L·m−2·h−1; high selectivity and rejection of salts to above 80% is revealed by the obtained results. The materials also exhibited improved antifouling behavior to above 70% flux recovery ratios. As such, the nature of the silica precursor influences ZSM-22 zeolite synthesis as a potential additive in the PES polymer matrix and led to the enhanced performance of the pure PES ultrafiltration membrane.

Membrane Fouling Phenomena in Microfluidic Systems: From Technical Challenges to Scientific Opportunities

The almost ubiquitous, though undesired, deposition and accumulation of suspended/dissolved matter on solid surfaces, known as fouling, represents a crucial issue strongly affecting the efficiency and sustainability of micro-scale reactors. Fouling becomes even more detrimental for all the applications that require the use of membrane separation units. As a matter of fact, membrane technology is a key route towards process intensification, having the potential to replace conventional separation procedures, with significant energy savings and reduced environmental impact, in a broad range of applications, from water purification to food and pharmaceutical industries. Despite all the research efforts so far, fouling still represents an unsolved problem. The complex interplay of physical and chemical mechanisms governing its evolution is indeed yet to be fully unraveled and the role played by foulants' properties or operating conditions is an area of active research where microfluidics can play a fundamental role. The aim of this review is to explore fouling through microfluidic systems, assessing the fundamental interactions involved and how microfluidics enables the comprehension of the mechanisms characterizing the process. The main mathematical models describing the fouling stages will also be reviewed and their limitations discussed. Finally, the principal dynamic investigation techniques in which microfluidics represents a key tool will be discussed, analyzing their employment to study fouling.

Spatiotemporal Measurement of Osmotic Pressures by FRET Imaging

Osmotic pressures (OPs) play essential roles in biological processes and numerous technological applications. However, the measurement of OP in situ with spatiotemporal resolution has not been achieved so far. Herein, we introduce a novel kind of OP sensor based on liposomes loaded with water-soluble fluorescent dyes exhibiting resonance energy transfer (FRET). The liposomes experience volume changes in response to OP due to water outflux. The FRET efficiency depends on the average distance between the entrapped dyes and thus provides a direct measure of the OP surrounding each liposome. The sensors exhibit high sensitivity to OP in the biologically relevant range of 0-0.3 MPa in aqueous solutions of salt, small organic molecules, and macromolecules. With the help of FRET microscopy, we demonstrate the feasibility of spatiotemporal OP imaging, which can be a promising new tool to investigate phenomena involving OPs and their dynamics in biology and technology.

Microfluidics Used as a Tool to Understand and Optimize Membrane Filtration Processes

Membrane filtration processes are best known for their application in the water, oil, and gas sectors, but also in food production they play an eminent role. Filtration processes are known to suffer from a decrease in efficiency in time due to e.g., particle deposition, also known as fouling and pore blocking. Although these processes are not very well understood at a small scale, smart engineering approaches have been used to keep membrane processes running. Microfluidic devices have been increasingly applied to study membrane filtration processes and accommodate observation and understanding of the filtration process at different scales, from nanometer to millimeter and more. In combination with microscopes and high-speed imaging, microfluidic devices allow real time observation of filtration processes. In this review we will give a general introduction on microfluidic devices used to study membrane filtration behavior, followed by a discussion of how microfluidic devices can be used to understand current challenges. We will then discuss how increased knowledge on fundamental aspects of membrane filtration can help optimize existing processes, before wrapping up with an outlook on future prospects on the use of microfluidics within the field of membrane separation.

Cross-Flow Microfiltration of Glycerol Fermentation Broths with Citrobacter freundii

This paper reports the study of the cross-flow microfiltration (MF) of glycerol fermentation broths with Citrobacter freundii bacteria. A single channel tubular ceramic membrane with a nominal pore size of 0.14 µm was used. It has been demonstrated that the MF ceramic membrane has been successfully applied to bacteria cell removal and to effectively eliminate colloidal particles from glycerol fermentation broths. However, due to fouling, the significant reduction of the MF performance has been demonstrated. In order to investigate the impact of transmembrane pressure (TMP) and feed flow rate (Q) on MF performance, 24 experiments have been performed. The highest steady state permeate flux (138.97 dm3/m2h) was achieved for 0.12 MPa and 1000 dm3/h. Fouling analysis has been studied based on the resistance-in series model. It has been found that the percentage of irreversible fouling resistance during the MF increases with increasing TMP and Q. The permeate flux regeneration has been achieved by membrane cleaning with 3 wt % NaOH and 3 wt % H3PO4 at 45 °C. The results of this study are expected to be useful in industrially employing the MF process as the first step of glycerol fermentation broth purification.

Quantifying Concentration Polarization - Raman Microspectroscopy for In-Situ Measurement in a Flat Sheet Cross-flow Nanofiltration Membrane Unit

In this work, the concentration polarization layer (CPL) of sulphate in a cross-flow membrane system was measured in-situ using Raman microspectroscopy (RM). The focus of this work is to introduce RM as a new tool for the study of mass transfer inside membrane channels in reverse osmosis (RO) and nanofiltration (NF) generally. Specifically, this work demonstrates how to use RM for locally resolved measurement of sulphate concentration in a cross-flow flat-sheet NF membrane flow cell with channel dimensions similar to commonly applied RO/NF spiral wound modules (channel height about 0.7 mm). Concentration polarization profiles of an aqueous magnesium sulphate solution of 10 g_sulphate·L⁻¹ were obtained at operating pressure of 10 bar and cross-flow velocities of 0.04 and 0.2 m·s⁻¹. The ability of RM to provide accurate concentration profiles is discussed thoroughly. Optical effects due to refraction present one of the main challenges of the method by substantially affecting signal intensity and depth resolution. The concentration profiles obtained in this concept study are consistent with theory and show reduced CPL thickness and membrane wall concentration with increasing cross-flow velocity. The severity of CP was quantified to reach almost double the bulk concentration at the lower velocity.

Roles of surfactants in pressure-driven membrane separation processes: a review

Surfactants widely exist in various kinds of wastewaters which could be treated by pressure-driven membrane separation (PDMS) techniques. Due to the special characteristics of surfactants, they may affect the performance of membrane filtration. Over the last two decades, there are a number of studies on treating wastewaters containing surfactants by PDMS. The current paper gives a review of the roles of surfactants in PDMS processes. The effects of surfactants on membrane performance were discussed via two aspects: influence of surfactants on membrane fouling and enhanced removal of pollutants by surfactants. The characteristics of surfactants in solution and at solid-liquid interface were summarized. Surfactants in membrane filtration processes cause membrane fouling mainly through adsorption, concentration polarization, pore blocking, and cake formation, and fouling degree may be influenced by various factors (feed water composition, membrane properties, and operation conditions). Furthermore, surfactants may also have a positive effect on membrane performance. Enhanced removal of various kinds of pollutants by PDMS in the presence of surfactants has been summarized, and the removal mechanism has been revealed. Based on the current reports, further studies on membrane fouling caused by surfactants and enhanced removal of pollutants by surfactant-aided membrane filtration were also proposed.

Investigating fouling at the pore-scale using a microfluidic membrane mimic filtration system

The work investigates fouling in a microfluidic membrane mimic (MMM) filtration system for foulants such as polystyrene particles and large polymeric molecules. Our MMM device consists of a staggered arrangement of pillars which enables real-time visualization and analysis of pore-scale phenomena. Different fouling scenarios are investigated by conducting constant-pressure experiments. Fouling experiments are performed with three different types of foulants: polystyrene particle solution (colloidal fouling), polyacrylamide polymer solution (organic fouling) and a mixture of these two solutions (combined fouling). Four major categories of microscopic fouling are observed: cake filtration (upstream), pore blocking (inside the pores), colloidal aggregation (downstream) and colloidal streamer fouling (downstream). Our microfluidic experiments show that downstream colloidal aggregation and streamer fouling have a significant effect on overall membrane fouling which were not studied before.

In Situ Visualization of Concentration Polarization during Membrane Ultrafiltration Using Microscopic Laser-Induced Fluorescence

A novel noninvasive technique-microscopic laser-induced fluorescence (micro-LIF)-has been applied to achieve in situ visualization of concentration polarization (CP) of nanoparticles during cross-flow ultrafiltration at high resolutions. The reversible, highly dynamic nature of CP and its sensitive response to the filtration conditions were investigated and validated by direct visualization of the CP layer and the well depicted concentration profile near the membrane surface. Using micro-LIF, the formation of a CP layer during filtration and its back-diffusion after the filtration ceased can be directly observed. The dynamic variation of the CP layer with the cross-flow velocity and transmembrane pressure (TMP) change has also been demonstrated. The results showed that CP reached the steady state approximately 1 min after the filtration condition change. A higher cross-flow velocity and/or a lower TMP decrease the CP concentration and thickness. Further quantitative analysis of the filtration test results using the film theory model helps to obtain the particle concentration at the membrane surface and the thickness of the CP layer (30-50 μm). Accordingly, the nature of CP dynamics was characterized and the deficiency of the traditional CP model was explored.

Electrofiltration improves dead-end filtration of hyaluronic acid and presents an alternative downstream processing step that overcomes technological challenges of conventional methods

Hyaluronic acid (HA) dispersion obtained from the bacteria Streptococcus equi was concentrated by electrofiltration. In the conventional downstream processing of HA, extraction and precipitation lead to increase in environmental issues, structural changes, and time and energy related costs. Using electrofiltration as an alternative technology delivers solutions to these limitations. Experiments were conducted in order to test the applicability of electrofiltration to downstream processing of the negatively charged HA. The structural changes and molecular weight distributions, often a consequence of the employed separation method, were tested by analysis of the initial dispersions and final products. In comparison to the conventional filtration, concentration factors were increased up to almost four times without any detectable structural change in the final product.

Time-resolved monitoring of biofouling development on a flat sheet membrane using optical coherence tomography

Biofouling on a membrane leads to significant performance decrease in filtration processes. In this study, an optical coherence tomography (OCT) was used to perform a time-resolved analysis of dynamic biofouling development on a submerged membrane under continuous operation. A real-time change in the biofouling morphology was calculated through the image analysis of OCT scans. Three videos were generated through the acquisition of serial static images. This is the first study that displays the dynamic biofouling formation process as a video. The acquisition of OCT cross-sectional scans of the biofouling allowed to evaluate the time-lapsed evolution for three different time periods (early stage, double layers and long-term). Firstly, at the early filtration stage, membrane coverage and average biofouling layer thickness were found to be linearly correlated with the permeate flux pattern. Secondly, after 3 d of operation, an anomalous morphology was observed, constituted by a double-layered biofouling structure: denser on the bottom and looser on the top. In a long-term operation, the biofouling structure underwent a dynamic evolution over time, resulting in a multi-layered structure. The biofouling formation information was closely associated with filtration performance (i.e. flux) indicating the suitability of OCT as real-time and in-situ biofouling monitoring technique.

Effect of vertically aligned carbon nanotube density on the water flux and salt rejection in desalination membranes

In this paper, vertically aligned carbon nanotube (VACNT) membranes of different densities are developed and their performances are investigated. VACNT arrays of densities 5 × 10⁹, 10¹⁰, 5 × 10¹⁰ and 10¹¹ tubes cm⁻², are initially grown on 1 cm × 1 cm silicon substrates using chemical vapour deposition. A VACNT membrane is realised by attaching a 300 μm-thick 1 cm × 1 cm VACNT array on silicon to a 4″ glass substrate, applying polydimethylsiloxane (PDMS) through spin coating to fill the gaps between the VACNTs, and using a microtome to slice the VACNT–PDMS composite into 25-μm-thick membranes. Experimental results show that the permeability of the developed VACNT membranes increases with the density of the VACNTs, while the salt rejection is almost independent of the VACNT density. The best measured permeance is attained with a VACNT membrane having a CNT density of 10¹¹ tubes cm⁻² is 1203 LMH at 1 bar.

Microfluidic colloid filtration

Filtration of natural and colloidal matter is an essential process in today’s water treatment processes. The colloidal matter is retained with the help of micro- and nanoporous synthetic membranes. Colloids are retained in a “cake layer” – often coined fouling layer. Membrane fouling is the most substantial problem in membrane filtration: colloidal and natural matter build-up leads to an increasing resistance and thus decreasing water transport rate through the membrane. Theoretical models exist to describe macroscopically the hydrodynamic resistance of such transport and rejection phenomena; however, visualization of the various phenomena occurring during colloid retention is extremely demanding. Here we present a microfluidics based methodology to follow filter cake build up as well as transport phenomena occuring inside of the fouling layer. The microfluidic colloidal filtration methodology enables the study of complex colloidal jamming, crystallization and melting processes as well as translocation at the single particle level.

Dynamics of colloid accumulation under flow over porous obstacles

The accumulation of colloidal particles to build dense structures from dilute suspensions may follow distinct routes. The mechanical, structural and geometrical properties of these structures depend on local hydrodynamics and colloidal interactions. Using model suspensions flowing into microfabricated porous obstacles, we investigate this interplay by tuning both the flow pattern and the ionic strength. We observe the formation of a large diversity of shapes, and demonstrate that growing structures in turn influence the local velocity pattern, favouring particle deposition either locally or over a wide front. We also show that these structures are labile, stabilised by the flow pushing on them, in low ionic strength conditions, or cohesive, in a gel-like state, at higher ionic strength. The interplay between aggregate cohesion and erosion thus selects preferential growth modes and therefore dictates the final shape of the structure.

Novel approach to characterizing the growth of a fouling layer during membrane filtration via optical coherence tomography

Fouling control is one of the critical issues in membrane filtration and plays a very important role in water/wastewater treatment. Better understanding of the underlying fouling mechanisms entails novel characterization techniques that can realize a real-time noninvasive observation and provide high resolution images recording the formation of a fouling layer. This work presents a characterization method based on optical coherence tomography (OCT), which is able to detect the internal structures and motions by analyzing the interference signals. An OCT system was incorporated with a laboratory-scale membrane filtration system, and the growth of the fouling layer was observed by using the structural imaging. Taking advantage of the Doppler effects, the OCT-based characterization also provided the velocity profiles of the fluid field, which are of great value in analyzing the formation of the cake layer. The characterization results clearly reveal for the first time the evolution of the morphology of the cake layer under different microhydrodynamic environments. This study demonstrates that OCT-based characterization is a powerful tool for investigating the dynamic processes during membrane fouling.