CN108697973A - 多叶膜组件及其制造方法 - Google Patents

多叶膜组件及其制造方法 Download PDF

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Publication number
CN108697973A
CN108697973A CN201680068559.5A CN201680068559A CN108697973A CN 108697973 A CN108697973 A CN 108697973A CN 201680068559 A CN201680068559 A CN 201680068559A CN 108697973 A CN108697973 A CN 108697973A
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China
Prior art keywords
film
partition
leaf
membrane module
leafy
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Pending
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CN201680068559.5A
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English (en)
Inventor
约翰·赫伦
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Magic Technologies Ltd
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Magic Technologies Ltd
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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Engineering & Computer Science (AREA)
  • Analytical Chemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Mechanical Engineering (AREA)
  • Water Supply & Treatment (AREA)
  • Textile Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Nanotechnology (AREA)
  • Separation Using Semi-Permeable Membranes (AREA)

Abstract

本发明的实施例涉及一种用于过滤产物流体流(例如，食品产品或废水)的多叶膜组件的制造方法及这样的多叶膜组件。在实施例中，公开了一种多叶膜组件。该多叶膜组件包括渗透流体流管和膜片，该渗透流体流管界定了用于渗透的渗透流体流通道，该膜片围绕渗透流体流管螺旋缠绕。膜片包括两个或更多膜叶。两个或更多膜叶中的每个膜叶包括进料隔片和渗透结构，该进料隔片包括形成在其中的至少一个开口，该开口至少部分地界定进料通道，产物流体流通过该进料通道，该渗透结构界定渗透流体流通道。两个或更多膜叶中的每个膜叶中的渗透结构包括至少一个膜和至少一个多孔渗透隔片。

Description

多叶膜组件及其制造方法
相关申请的交叉引用
本申请要求在2015年9月24日提交第62/232,062好美国临时申请的优先权，并通过引用将其公开的内容全文并入本文。
背景技术
用于给食物或废水(比如垃圾渗滤液)脱水的膜组件常常被污垢所限制。一个控制污垢的方法是在膜组件的膜表面的切向上以较高速度送流体，并且清除膜组件的进料通道内的全部阻塞物。没有在进料通道上接触膜的隔片的膜组件被称为“开放通道”膜组件。典型地，开放通道膜组件具有管状或者板框式设计，反之标准的经济型螺旋缠绕膜设计包括进料隔片。
已经开发出具有开放进料通道的螺旋缠绕膜组件。例如，已经开发出“私下出售的”家用的开放通道式低压反渗透膜组件，但是这种膜组件很难承受较大的横流速度。也已经开发出另外一种用于生产用于对高污染流体进行脱水的开放水道膜组件的方法，这种膜组件可以经受相对较高的横流速度并且可以成功地浓缩高污染流体。然而，这种生产这样的开放通道膜组件的方法非常繁琐并且受限于每个单元的单个膜膜叶。
因此，螺旋缠绕膜组件的用户和生产者继续寻求对其的改进。
发明内容
在此公布的实施例涉及用于过滤/分离产物流体流(例如食品产品或废水)的螺旋缠绕多叶模组的制造方法和这样的多叶膜组件。在实施例中，公开了一种多叶膜组件的制造方法。提供包括两个或更多膜叶的膜片。两个或更多膜叶中的每个膜叶都包括进料隔片和渗透结构，该进料隔片具有至少一个可移除部分，该渗透结构包括至少一个膜和至少一个渗透隔片。当渗透结构中的粘合剂是至少部分地未固化时，将膜片围绕渗透流体流管螺旋缠绕。当膜片围绕渗透流体流管螺旋缠绕时，允许粘合剂至少部分地固化。在粘合剂至少部分地固化后，将膜片至少部分地从该渗透流体流管上解绕。当膜片至少部分地解绕时，从两个或更多膜叶中的每个膜叶的进料隔片上移除至少一个可移除部分以在进料隔片中形成至少一个开口，该开口至少部分地界定产物流体流通道。在移除至少一个可移除部分后，具有至少一个开口的膜片围绕渗透流体流管螺旋缠绕以形成膜组件。
在实施例中，公开了一种多叶膜组件。该多叶膜组件包括渗透流体流管和膜片，该渗透流体流管界定用于渗透的渗透流体流通道，该膜片围绕渗透流体流管螺旋缠绕。膜片包括两个或更多膜叶。两个或更多膜叶中的每个膜叶都包括进料隔片和渗透结构，该进料隔片包括形成在其中的至少一个开口，该开口至少部分地界定进料通道，产物流体流通过该进料通道，该渗透结构界定渗透流体流通道。两个或更多膜叶中的每个膜叶中的渗透结构包括至少一个膜和至少一个多孔渗透隔片。
任何公开的实施例中的特征可以互相组合使用而不受限制。此外，在参考了以下详细描述和附图后，本发明的其他特征和优势将对于本领域的普通技术人员是显而易见的。
附图说明
附图示出了本发明的若干实施例，其中，在附图中展示的不同视图或实施例中，相同的附图标记指的是相同的元素或特征。
图1是根据一个实施例的多叶膜组件的示意等距视图；
图2A是图1中的膜组件的放大的前视图；
图2B是图1中的膜组件的放大的前视图，并用不同的交叉影线示出了不同的膜叶；
图3是图1中的膜组件沿线3-3的部分横截面图；
图4是根据一个实施例的在安装到图1中的膜组件之前的波纹形进料隔片的等距视图；
图5是根据一个实施例的图4中的进料隔片在移除其可移除部分前的俯视图；
图6是根据一个实施例的图5中的进料隔片在移除其可移除部分后的俯视图；
图7是根据一个实施例的图1中的膜组件的制造方法的流程图；以及
图8是压降相对产物流体流的表面速度的图表，此图表将根据本发明的一个实施例的膜组件与传统膜组件相比较。
具体实施方式
在此所公布的实施例涉及用于过滤/分离产物流体流(例如食品产品或废水)的螺旋缠绕多叶模组及其制造方法。在此被公布的膜组件可被用于，例如，苹果汁澄清、废水处理、干酪乳清脱盐、饮用水生产、油水乳液分离、盐水脱盐，以及许多其他合适应用中的薄膜分离。
在此公开的膜组件包括具有两个或更多膜叶的膜片，每个膜叶都有进料隔片和渗透隔片/膜结构。此处公开的膜组件的膜片可比只使用一个膜叶的情况相对更短，但仍然能使膜组件具有至少相同或更高的分离效率。通过利用包括两个或更多膜叶的膜片，通过指定渗透隔片的渗透流体流到达渗透流管所行进的距离相对较小，这减小了渗透通道的压降。在某些应用中，这种被减小的压降能够增大净施加压力，并且从而增大膜通量。
图1和图2A-2B分别是根据一个实施例的螺旋缠绕多叶膜组100的等距示意图和放大前视图。参照图1和2A，膜组件100包括具有两个或更多膜叶104A和104B的膜片，膜叶104A和104B在此也被称为膜叶104。参照图2B，膜叶104A和104B沿膜组件100的径向相互交错。在图2B中，膜叶104A以向左的交叉影线示出，膜叶104B以向右的交叉影线示出。
再次参照图2A，膜叶104中的的每个膜叶都包括分层有渗透结构108的进料隔片106。渗透结构108包括夹在两个多孔渗透隔片112之间的加固层110，和至少一个膜113，膜113靠近这两个多孔渗透隔片112中径向最外侧者。例如，对于膜叶104A而言，膜113中径向最外侧的膜与膜叶104A相关联，同时膜113中径向最内侧的靠近膜叶104A的渗透结构108的膜与另一膜叶104B关联。换言之，膜叶104中的每个膜叶都包括自进料隔片106径向向外放置的膜113中的一个。
使用粘合剂115，例如合适的胶水(例如基于聚氨酯的胶水或其他合适的胶水)，将膜113仅沿其三个边粘合至多孔渗透隔片112。渗透结构108的膜113的靠近渗透流体流管114的一边没有通过粘合剂115粘合至下面的多孔渗透隔片112，使得存在一条通过多孔渗透隔片112至渗透流体流管114的自由流体路径，该流体路径并没有被粘合剂所阻挡。在图2中膜113相对渗透结构108的厚度比按比例绘制的膜113显得更厚。
如图2A所示，其中一个膜叶104的每个进料隔片106的靠近渗透流体流管114的终端被膜113连同膜叶104围住。例如，进料隔片106的终端可由相应的膜113环绕包裹。通过封闭每个进料隔片116的终端，可避免产物流体流124与渗透流体流126相互混合，和/或可避免产物流体流124被直接泵送到渗透流体流管114中。
其中包括膜叶104的膜片围绕渗透流体流管114螺旋缠绕，并由渗透流体流管114支撑。渗透流体流管114界定了用于对从中通过的流进行渗透的渗透流体流通道116。如下面将参照图7所示的制造方法将更详细讨论的，加固层110为渗透结构108提供了足够的硬度从而有助于膜片的螺旋缠绕，同时维持膜组件100的部件的预期布置。
保护壳117可以封闭螺旋缠绕的膜片的圆周来固定螺旋缠绕的膜片，密封膜组件102的圆周并且保护膜组件100中的部件，例如进料隔片106和渗透结构108。例如，保护壳117可以由玻璃纤维、收缩缠绕在膜片上的塑料、其他适合的复合材料或其他适合的材料构成。
值得注意的是，为便于说明，尽管在所示的实施例中仅展示了两个膜叶104，在此公开的膜组件中，膜叶的数量可在不同实施例中变化。例如，在其他的实施例中，膜片可包括至少三个膜叶104、至少四个膜叶104、至少五个膜叶104、至少六个膜叶104、至少七个膜叶104、至少八个膜叶104、至少九个膜叶104、至少十个膜叶104、至少十一个膜叶104、十五个或更多膜叶104、或甚至二十个或更多膜叶104。
参照图3，图3是图1中的膜组件100沿线3-3的局部横截面图，每个进料隔片106都包括形成在其中的两个或更多开口118，开口118部分地限定了供产物流体流124从中流过的进料通道。相应的进料隔片106的每个开口118与邻近的渗透结构108流体连通，使得产物流体流124中的一部分产物流体能够经邻近的渗透结构108的膜113扩散，并且允许渗透经过邻近的渗透结构108的多孔渗透隔片112到达渗透流体流管114。需要注意的是，尽管在图3中所示的实施例的进料隔片106包括两个开口，在其他的实施例中，在此公布的进料隔片可包括仅仅一个开口或者三个或者更多开口。
进料隔片106可由波纹形隔片材料构成。例如，图4是根据一个实施例的在安装到膜组件100之前的波纹形进料隔片106的等距视图。然而，在其他实施例中，进料隔片106可由聚合网而非波纹形材料构成。
如下面将参照图7所示的制造方法更详细地讨论的，如图5的俯视图所示，进料隔片106上的开口118可通过有选择地移除可移除部分120形成。在一个实施例中，可移除部分120可暂时地通过一个或更多胶带123、其他适合的粘合剂，或穿孔125，固定至进料隔片106。图6是根据一个实施例的图5中的进料隔片106在移除可移除部分120从而形成开口118后的俯视图。
膜叶104的进料隔片106的厚度和材料可在不同的实施例中变化。例如，进料隔片106可由聚乙烯、聚丙烯、聚苯乙烯、聚酯、其他任何适合的材料或它们的组合构成，并且可处于波纹结构或者网的形式。进料隔片106的厚度，举例来说，可为大约0.020英寸到大约0.20英寸，比如大约0.45英寸到大约0.1英寸。
膜叶104的渗透结构108的厚度和材料可在不同的实施例中变化。例如，渗透结构108的加固层110可由塑料薄膜材料构成。用于加固层110的塑料薄膜材料可由聚氯乙烯(“PVC”)、氯化聚氯乙烯(“C-PVC”)、聚丙烯、聚乙烯、聚苯乙烯、腈纶、不锈钢、铜、铜合金、锡、锡合金、铝、铝合金，或它们的组合构成。例如，加固层110可以是，食品用途的聚乙烯、非食品用途的PVC、或高温用途的C-PVC。加固层110的厚度可以是，例如，大约0.010英寸到0.080英寸，比如大约0.020英寸到大约0.050英寸。
供渗透流体流126流经以到达渗透流体流管114的渗透结构108的多孔渗透隔片112可由聚合材料(比如聚酯、环氧涂层聚酯或其他塑料)制成的网构成。多孔渗透隔片112的厚度可以是，比如，大约0.0050英寸到大约0.10英寸，比如大约0.010英寸到大约0.030英寸。
膜叶104的渗透结构108的膜113的厚度和材料可在不同的实施例中变化。例如，膜113可由多层结构构成，该多层结构包括由致密纤维素泡沫支撑的纤维素层，该致密纤维素泡沫内嵌有净厚度在大约0.001英寸到大约0.005英寸的平织涤纶。膜113的厚度可以是，例如，大约0.0030英寸到大约0.010英寸，比如大约0.0045英寸到大约0.0060英寸或大约0.0050英寸到大约0.0060英寸。
在具体的实施例中，进料隔片106可由厚度大约为0.085英寸的聚苯乙烯构成，加固层110可由厚度大约为0.030英寸的聚苯乙烯构成，多孔渗透隔片112可由厚度大约为0.020英寸的环氧涂层聚酯构成，并且膜113可由厚度大约为0.0060英寸的三乙酸纤维素(“CTA”)构成。
参照图1，在工作中，产物流体流124由泵(未图示)抽出，经过波纹结构或多孔网的开口流入膜组件100的进料隔片106中。产物流体流124流经进料隔片106和进料隔片106中由开口118(图3)界定的进料通道。例如，产物流体流124可包括苹果汁、废水、用于饮用水生产的洗涤水、油水乳状液、用于脱盐的盐水、或其他适合的需要分离的流体。当产物流体流124流经进料隔片106，一部分产物流体流124在压力下通过邻近的渗透结构108的邻近的膜113扩散，并且有选择地从产物流体流124中过滤/分离选择性化学物质来生成渗透流体流126。渗透流体流126沿穿过邻近的渗透结构108的多孔渗透隔片112的螺旋路径流动，并且沿着多孔渗透隔片112的剩余长度流动以穿过形成在渗透流体流管114外部的开口119(图2A-2B)，渗透流体流管114与渗透流体流通道116流体连通。如此，当产物流体流124进入其中一个相对另一个进料隔片106径向向内的进料隔片106时，渗透流体流126行进相对较短的距离到达渗透流体流管114。渗透流体流126流经渗透流体流管144中的开口119，并流经和流出渗透流体流管114的渗透流体流通道116。从膜组件100流出的产物流体流124具有更高浓度的被过滤/分离化学物质，并且被称为浓缩流体流128。根据需要，浓缩流体流128可作为产物流体流124进入膜组件100进行再循环，以便进一步过滤或分离。此外，在一些实施例中，可将多个膜组件100流体地串联起来。
相对于仅使用一个膜叶104的情况，膜组件100可由较短的膜片构成。例如，膜片的长度可为大约20英寸到大约40英寸，比如大约30英寸。另外，通过使用两个或更多膜叶104，渗透流体流126到达渗透流体流管114行进相对较短的距离，这样减少了压降。
图7是根据一个实施例的图1中的膜组件100的制造方法700的流程图。制造方法700包括步骤702、704、706、708、710和712，这些以下将进行详细讨论。
步骤702包括提供包括两个或更多膜叶104的膜片，两个或更多膜叶104中的每个膜叶都包括具有至少一个可移除部分120的进料隔片106和渗透结构108。步骤704包括当渗透结构108中的粘合剂115是至少部分地未固化时，将膜片围绕渗透流体流管114螺旋缠绕。步骤706包括当膜片围绕渗透流体流管114螺旋缠绕时，允许粘合剂115至少部分地固化。
步骤708包括在粘合剂至少部分地固化后，将膜片至少部分地从渗透流体流管114上解绕。步骤710包括当膜片至少部分地解绕时，从两个或更多膜叶104中的每个膜叶的进料隔片106上移除可移除部分120来形成两个或更多开口118，每个开口118都至少部分地界定了产物流体流通道。步骤712包括在拆下至少一个可移除部分后，将具有两个或更多开口118的膜片围绕渗透流体流管114螺旋缠绕。
在一个实施例中，方法700还包括在螺旋缠绕的膜片外部形成保护壳117。例如，保护壳可由缠绕在螺旋缠绕的膜片的圆周上的玻璃纤维、收缩缠绕在螺旋缠绕的膜片的圆周上的塑料，或者其他适合的技术来构成。
在一个实施例中，从两个或更多膜叶104中的每个膜叶的进料隔片106上移除至少一个可移除部分120的步骤710包括破坏两个或更多膜叶104中的每个膜叶的进料隔片106上的穿孔125(图5)，使得至少一个可移除部分120可被移除。在其他实施例中，当采用胶带123(图5)来固定可移除部分时，从两个或更多膜叶中的每个膜叶的进料隔片106上移除至少一个可移除部分120的步骤710包括移除两个或更多膜叶104中的每个膜叶的进料隔片106上的胶带123，随后移除至少一个可移除部分122。无论使用的是穿孔还是粘合剂，当膜片至少部分地解绕时，通过操作人员插入他们的手并且手动移除至少一个可移除部分120，可从两个或更多膜叶104中的每个膜叶的进料隔片106上移除至少一个可移除部分120，从而在其中形成两个或更多开口118，通过一个操作者将他们的手伸入并手动拆下至少一个可移除部分120。渗透结构108的加固层110为渗透结构108提供了足够的硬度，从而有助于围绕渗透流体流管114螺旋地重绕膜片，使得渗透结构108不会从通过移除至少一个可移除部分120而形成的开口118中伸出。
图8是压降相对产物流体流的表面速度的图表，该图表将根据本发明的一个实施例的膜组件与传统膜组件进行比较。工作实例1为进料隔片不具有开口(例如，图3和6所示的开口)的传统膜组件，工作实例2为根据本发明的一个实施例的膜组件，该膜组件类似于膜组件100，具有带有两个大的开口的进料隔片。工作实例1与工作实例2进行比较测试。
工作实例1和2的膜组件都包括0.0060英寸的嵌入-支撑CTA的膜、0.020环氧涂层聚酯的渗透隔片和0.085英寸波纹形聚苯乙烯的进料隔片。工作实例1中的膜组件具有大约28.000英寸的膜叶长度、大约29.000英寸的进料隔片长度、3个膜叶和大约3.01m2的膜面积。工作实例2中的膜组件具有大约28.875英寸的膜叶长度、大约31.750英寸的进料隔片长度、2个膜叶和大约2.24m2的膜面积。
通过在25℃下泵送测试水溶液作为分别进入工作实例1和2的膜组件的进料隔片的产物流体，评估工作实例1和2的膜组件的压降。如图8中所示，工作实例2中的膜组件的开口提供了相对较低的压降，该压降大约为工作实例1的膜组件的压降的大约20％到大约30％。这种相对较低的压降减小了用于将产物流体流泵送到膜组件中的泵送能量。
虽然本文已经公开了各个方面和实施例，但是其他方面和实施例是显而易见的。本文中所公开的各个方面和实施例是为了说明的目的，而非意图限制。

Claims (22)

1.一种制造多叶膜组件的方法，所述方法包括：
提供包括两个或更多膜叶的膜片，所述两个或更多膜叶中的每个膜叶都包括进料隔片和渗透结构，所述进料隔片具有至少一个可移除部分，所述渗透结构包括至少一个膜和至少一个渗透隔片；
当所述渗透结构中的粘合剂是至少部分地未固化时，将所述膜片围绕渗透流体流管螺旋缠绕；
当所述膜片围绕所述渗透流体流管螺旋缠绕时，允许所述粘合剂至少部分地固化；
在所述粘合剂至少部分地固化后，将所述膜片至少部分地从所述渗透流体流管上解绕；
当所述膜片至少部分地解绕时，从所述两个或更多膜叶中的每个膜叶的所述进料隔片上移除所述至少一个可移除部分以在所述进料隔片中形成至少一个开口，所述开口至少部分地界定产物流体流通道；以及
在移除所述至少一个可移除部分后，具有所述至少一个开口的所述膜片围绕所述渗透流体流管螺旋缠绕。
2.根据权利要求1所述的方法，还包括在具有两个或更多开口的螺旋缠绕的膜片外部形成保护壳。
3.根据权利要求2所述的方法，其特征在于，所述保护壳包括玻璃纤维。
4.根据权利要求1所述的方法，其特征在于，所述两个或更多膜叶中的每个膜叶的所述进料隔片包括波纹形隔片材料。
5.根据权利要求1所述的方法，其特征在于，所述两个或更多膜叶中的每个膜叶的进料隔片包括塑料网。
6.根据权利要求1所述的方法，其特征在于，所述两个或更多膜叶中的每个膜叶的所述进料隔片的所述至少一个可移除部分包括界定所述可移除部分的周边的穿孔。
7.根据权利要求6所述的方法，其特征在于，从所述两个或更多膜叶中的每个膜叶的所述进料隔片上移除所述至少一个可移除部分包括破坏所述两个或更多膜叶中的每个膜叶的所述进料隔片中的所述穿孔。
8.根据权利要求1所述的方法，其特征在于从所述两个或更多膜叶中的每个膜叶的所述进料隔片上移除所述可移除部分包括移除将所述至少一个可移除部分固定至所述两个或更多膜叶中的每个膜叶的所述进料隔片的粘合剂。
9.根据权利要求1所述的方法，其特征在于，所述两个或更多膜叶中的每个膜叶的所述进料隔片展示出大约0.020英寸到大约0.20英寸的厚度。
10.根据权利要求9所述的方法，其特征在于，所述厚度为大约0.045英寸到0.10英寸。
11.根据权利要求1所述的方法，其特征在于，所述至少一个渗透隔片包括两个或更多渗透隔片，其中，所述两个或更多膜叶中的每个膜叶的所述渗透结构包括夹在两个多孔渗透隔片之间的加固层，所述至少一个膜从所述两个多孔渗透隔片径向向外放置。
12.根据权利要求11所述的方法，其特征在于，所述加固层展示出大约0.020英寸到大约0.050英寸的厚度。
13.一种多叶膜组件，包括：
渗透流体流管，其界定用于渗透的渗透流体流通道；以及
膜片，其围绕所述渗透流体流管螺旋缠绕，所述膜片包括两个或更多膜叶，所述两个或更多膜叶中的每个膜叶都包括：
进料隔片，其包括形成在其中的至少一个开口，所述至少一个开口至少部分地界定进料通道，产物流体流通过所述进料通道；
渗透结构，其界定渗透流体流通道，所述渗透结构包括至少一个膜和至少一个多孔渗透隔片。
14.根据权利要求13所述的多叶膜组件，还包括形成在所述膜片外部的保护壳。
15.根据权利要求14所述的多叶膜组件，其特征在于，所述壳包括玻璃纤维。
16.根据权利要求13所述的多叶膜组件，其特征在于，所述两个或更多膜叶中的每个膜叶的所述进料隔片包括波纹形隔片材料。
17.根据权利要求13所述的多叶膜组件，其特征在于，所述两个或更多膜叶中的每个膜叶的所述进料隔片包括塑料网。
18.根据权利要求13所述的多叶膜组件，其特征在于，所述两个或更多膜叶中的每个膜叶的所述进料隔片展示出大约0.020英寸到大约0.20英寸的厚度。
19.根据权利要求18所述的多叶膜组件，其特征在于，所述厚度为大约0.045英寸到大约0.10英寸。
20.根据权利要求13所述的多叶膜组件，其特征在于，所述至少一个多孔渗透隔片包括两个多孔渗透隔片，其中，所述渗透结构包括夹在两个多孔渗透隔片之间的加固层，并且，所述至少一个膜从所述两个多孔渗透隔片径向向外放置。
21.根据权利要求13所述的多叶膜组件，其特征在于，所述加固层展示出大约0.030英寸到大约0.050英寸的厚度。
22.根据权利要求13所述的多叶膜组件，其特征在于，所述两个或更多膜叶包括至少五个膜叶。
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