A mini-module with built-in spacers for high-throughput ultrafiltration

TL;DR

This study introduces a novel built-in 3D spacer structure in ultrafiltration modules, designed via in-silico methods, which enhances permeate flux by up to 30% compared to traditional spacers, verified through simulations and experiments.

Contribution

The paper presents a new integrated 3D spacer design for ultrafiltration modules, optimized through digital twin simulations and validated experimentally, reducing manufacturing complexity and improving flux performance.

Findings

Built-in 3D sinusoidal spacer outperforms conventional mesh spacers by 30%.

Flow characteristics inside the module are optimized with the new design.

Experimental verification confirms simulation results.

Abstract

Ultrafiltration membrane modules suffer from a permeate flow decrease arising during filtration and caused by concentration polarization and fouling in, e.g., fermentation broth purification. Such performance losses are frequently mitigated by manipulating the hydrodynamic conditions at the membrane-fluid interface using, e.g., mesh spacers acting as static mixers. This additional element increases manufacturing complexity while improving mass transport in general, yet accepting their known disadvantages such as less transport in dead zones. However, the shape of such spacers is limited to the design of commercially available spacer geometries. Here, we present a methodology to design an industrially relevant mini-module with an optimized built-in 3D spacer structure in a flat-sheet ultrafiltration membrane module to eliminate the spacer as a separate part. Therefore, the built-in structures have been conceptually implemented through an in-silico design in compliance with the specifications for an injection molding process. Ten built-in structures were investigated in a digital twin of the mini-module by 3D-CFD simulations to select two options, which were then compared to the empty feed channel regarding mass transfer. Subsequently, the simulated flux increase was experimentally verified during bovine serum albumin (BSA) filtration. The new built-in sinusoidal corrugation outperforms conventional mesh spacer inlays by up to 30% higher permeation rates. The origin of these improvements is correlated to the flow characteristics inside the mini-module as visualized online and in-situ by low-field and high-field magnetic resonance imaging velocimetry (flow-MRI) during pure water permeation.