Overcoming the drawbacks of microsieves with micromeshes for in situ product recovery

Float-Cast Microsieves with Elliptical Pores

Polymeric microsieves bearing elliptical pores were successfully prepared via float-casting: a dispersion comprising nonvolatile acrylate monomers and ellipsoidal polystyrene particles was spread onto a water surface. The resulting self-organized monolayer was laterally compressed, and the monomer was photopolymerized, giving rise to a membrane comprising ellipsoidal particles laterally embedded in a 0.5 μm thin polymer membrane. The particles were dissolved, leaving behind elliptical pores. These pores had an average length of the major axis of 0.87 ± 0.1 μm and of the minor axis of 0.42 ± 0.07 μm and an aspect ratio of approximately 2. The microsieve bearing these submicrometric elliptical pores was transferred to a hierarchical structure made out of microsieves bearing circular pores of 6 μm diameter on top of a microsieve with 70 μm diameter pores. The resulting hierarchically structured microsieve had a porosity of 0.13. At a pressure difference of typically 103 Pa (Reynolds number aprox. 0.002), the volumetric permeance for water was Pe = V ˙ /A/Δp = 0.5·10-6 m/s/Pa, the product viscosity·permeance is η·V ˙ /A/Δp = 0.5·10-9 m. This value is lower than the corresponding values of microsieves with circular pores of similar diameter produced by the same technique. The beneficial effects of higher permeance per pore caused by the elliptical shape are countered by lower porosity caused by less efficient packing of the ellipsoidal particles.

Modeling tangential flow filtration using reverse asymmetric membranes for bioreactor harvesting

Tangential flow filtration (TFF) has many advantages for bioreactor harvesting, as the permeate could be introduced directly to the subsequent capture step. However, membrane fouling has limited its widespread use. This is particularly problematic given the high cell densities encountered today. Here, a reverse asymmetric membrane, where the more open surface faces the feed stream and the tighter barrier layer faces the permeate stream, has been investigated. The open surface contains pores up to 40 μm in diameter while the tighter barrier layer has an average pore size of 0.4 μm. Filtration of yeast suspensions has been conducted under a range of conditions. The yeast cells are trapped in the open pore structure. The membrane stabilizes an internal porous cake that acts like a depth filter. This stabilized cake layer can remove particulate matter that would foul the barrier layer if it faced the feed stream. As filtration continues, a surface cake layer forms on the membrane surface. A resistance in series model has been developed to describe the permeate flux during TFF. The model contains three fitted parameters which can easily be determined from constant pressure normal flow filtration experiments and total recycle constant flux TFF experiments. The model can be used to estimate the capacity of the filter for a given feed stream. Our results suggest that using a reverse asymmetric membrane could avoid severe flux decline associated with fouling of the barrier layer during bioreactor harvesting.

Optimizing Flux Capacity of Dead-end Filtration Membranes by Controlling Flow with Pulse Width Modulated Periodic Backflush

Standard dead-end sample filtration is used to improve sample purity, but is limited as particle build-up fouls the filter, leading to reduced recovery. The fouling layer can be periodically cleared with backflush algorithms applied through a customized fluidic actuator using variable duty cycles, significantly improving particulate recovery percentage. We show a Pulse Width Modulation (PWM) process can periodically backflush the filter membrane to repeatedly interrupt cake formation and reintegrate the fouling layer into the sample, improving net permeate flux per unit volume of sample by partially restoring filter flux capacity. PWM flow for 2.19 um (targeted) and 7.32 um (untargeted) polystyrene microbeads produced 18-fold higher permeate concentration, higher recovery up to 68.5%, and an 8-fold enrichment increase, compared to a uniform flow. As the duty cycle approaches 50%, the recovery percentage monotonically increases after a critical threshold. Further, we developed and validated a mathematical model to determine that fast, small-volume backflush pulses near 50% duty cycle yield higher recovery by decreasing fouling associated with the cake layer. Optimized PWM flow was then used to purify custom particles for immune activation, achieving 3-fold higher recovery percentage and providing a new route to improve purification yields for diagnostic and cellular applications.

Printing Reinforcing Structures onto Microsieves That Are Floating on a Water Surface

This article describes the preparation of hierarchically structured microsieves via a suitable combination of float-casting and inkjet-printing: A mixture of hydrophobized silica particles of 600 nm ± 20 nm diameter, a suitable non-water-soluble nonvolatile acrylic monomer, a nonvolatile photoinitiator, and volatile organic solvents is applied to a water surface. This mixture spontaneously spreads on the water surface; the volatile solvents evaporate and leave behind a layer of the monomer/initiator mixture comprising a monolayer of particles, each particle protruding out of the monomer layer at the top and bottom surface. Photopolymerization of the monomer converts this mixed layer into a solid composite membrane floating on the water surface. Onto this membrane, while still floating on the water surface, a hierarchical reinforcing structure based on a photocurable ink is inkjet-printed and solidified. In contrast to the nonreinforced membrane, the reinforced membrane can easily be lifted off the water surface without suffering damage. Subsequently, the silica particles are removed, and thus, the reinforced composite membrane is converted into a reinforced microsieve of 350 nm ± 50 nm thickness bearing uniform through pores of 465 nm ± 50 nm diameter. This reinforced microsieve is mounted into a filtration unit and used to filter model dispersions: its permeance for water at low Reynolds numbers is in accordance with established theories on the permeance of microsieves and significantly above the permeance of conventional filtration media; it retains particles exceeding the pore size, while letting particles smaller than the pore size pass.

Hierarchical Porous Polybenzimidazole Microsieves: An Efficient Architecture for Anhydrous Proton Transport via Polyionic Liquids

Liquid-induced phase-separation micromolding (LIPSμM) has been successfully used for manufacturing hierarchical porous polybenzimidazole (HPBI) microsieves (42-46% porosity, 30-40 μm thick) with a specific pore architecture (pattern of macropores: ∼9 μm in size, perforated, dispersed in a porous matrix with a 50-100 nm pore size). Using these microsieves, proton-exchange membranes were fabricated by the infiltration of a 1H-3-vinylimidazolium bis(trifluoromethanesulfonyl)imide liquid and divinylbenzene (as a cross-linker), followed by in situ UV polymerization. Our approach relies on the separation of the ion conducting function from the structural support function. Thus, the polymeric ionic liquid (PIL) moiety plays the role of a proton conductor, whereas the HPBI microsieve ensures the mechanical resistance of the system. The influence of the porous support architecture on both proton transport performance and mechanical strength has been specifically investigated by means of comparison with straight macroporous (36% porosity) and randomly nanoporous (68% porosity) PBI counterparts. The most attractive results were obtained with the poly[1-(3H-imidazolium)ethylene]bis(trifluoromethanesulfonyl)imide PIL cross-linked with 1% divinylbenzene supported on HPBI membranes with a 21-μm-thick skin layer, achieving conductivity values up to 85 mS cm^-1 at 200 °C under anhydrous conditions and in the absence of mineral acids.

A membrane stirrer for product recovery and substrate feeding

During fermentation processes, in situ product recovery (ISPR) using submerged membranes allows a continuous operation mode with effective product removal. Continuous recovery reduces product inhibition and organisms in the reactor are not exposed to changing reaction conditions. For an effective in situ product removal, submerged membrane systems should have a sufficient large membrane area and an anti-fouling concept integrated in a compact device for the limited space in a lab-scale bioreactor. We present a new membrane stirrer with integrated filtration membranes on the impeller blades as well as an integrated gassing concept in an all-in-one device. The stirrer is fabricated by rapid prototyping and is equipped with a commercial micromesh membrane. Filtration performance is tested using a yeast cell suspension with different stirring speeds and aeration fluxes. We reduce membrane fouling by backflushing through the membrane with the product stream.