WO2017027626A2 - Ceramic membrane module with recessed membrane and related methods - Google Patents

Ceramic membrane module with recessed membrane and related methods Download PDF

Info

Publication number
WO2017027626A2
WO2017027626A2 PCT/US2016/046408 US2016046408W WO2017027626A2 WO 2017027626 A2 WO2017027626 A2 WO 2017027626A2 US 2016046408 W US2016046408 W US 2016046408W WO 2017027626 A2 WO2017027626 A2 WO 2017027626A2
Authority
WO
WIPO (PCT)
Prior art keywords
membrane
housing
end cap
recited
recessed
Prior art date
Application number
PCT/US2016/046408
Other languages
French (fr)
Other versions
WO2017027626A8 (en
WO2017027626A3 (en
Inventor
Paul OSMUNDSON
Original Assignee
Nanostone Water Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Nanostone Water Inc. filed Critical Nanostone Water Inc.
Priority to CN201680057825.4A priority Critical patent/CN108348860A/en
Publication of WO2017027626A2 publication Critical patent/WO2017027626A2/en
Publication of WO2017027626A3 publication Critical patent/WO2017027626A3/en
Publication of WO2017027626A8 publication Critical patent/WO2017027626A8/en

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D71/00—Semi-permeable membranes for separation processes or apparatus characterised by the material; Manufacturing processes specially adapted therefor
    • B01D71/02—Inorganic material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D63/00—Apparatus in general for separation processes using semi-permeable membranes
    • B01D63/06—Tubular membrane modules
    • B01D63/066—Tubular membrane modules with a porous block having membrane coated passages
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D65/00—Accessories or auxiliary operations, in general, for separation processes or apparatus using semi-permeable membranes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2313/00—Details relating to membrane modules or apparatus
    • B01D2313/04—Specific sealing means
    • B01D2313/041—Gaskets or O-rings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2313/00—Details relating to membrane modules or apparatus
    • B01D2313/08—Flow guidance means within the module or the apparatus
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2313/00—Details relating to membrane modules or apparatus
    • B01D2313/20—Specific housing
    • B01D2313/201—Closed housing, vessels or containers

Definitions

  • a ceramic membrane module with recessed membrane and related methods is provided.
  • Membranes are commonly used to remove such contaminants.
  • Membrane elements are typically made of plastics or ceramics, both of which are frequently placed inside a pressure vessel to contain the pressurized fluid to be treated.
  • the element and pressure vessel combination are referred to as membrane modules or modules.
  • Such pressure vessels also provide separate ports to allow a feed to enter the module, filtrate to exit after being processed through the membrane, and a retentate for removal of the filtered material.
  • Ceramic membranes are commonly used as a multilayer structure with a relatively high permeability support, and a thinner separation layer which enables the separation by passing some components (typically water and small solutes) while retaining others.
  • a number of channels are typically present in the support, each with a coating.
  • feed enters these channels before passing through the membrane into the support structure.
  • a face end seal layer is used to prevent transport through the ends.
  • Commonly used materials for face end seals include epoxies, polyurethanes, and glass.
  • this face end seal is particularly sensitive to mechanical damage due to both the material properties of the face end seal, and the fact that housings which have been used to date leave the face end seal at the end of the housing preventing it from serving as shielding. What is needed is a module design allowing the housing to protect, shield, and/or create an impingement zone or buffer space around the face end seal improving the durability and integrity of the membrane.
  • a ceramic membrane module system for treating liquid water includes a housing having an exterior portion and an inner portion, the housing extending from a first housing end to a second housing end, the housing having an inner feed radius Rhsg.
  • the system further includes a membrane module including at least one membrane disposed within the housing, the membrane extending from a first membrane end to a second membrane end, the at least one membrane having capillaries extending from the first membrane end to the second membrane end, the at least one membrane having an end seal face at each end.
  • the system further includes at least one end cap disposed near at least one of the first or second membrane ends, a mixing zone disposed between the membrane and the end cap, where the end cap having an outlet defined by an inner radius Rendcap.
  • the at least one membrane is recessed within the housing such that
  • ⁇ is measured from the outlet of the end cap to the end seal face of the membrane, the outlet is fluidly coupled with the mixing zone, and the mixing zone is fluidly coupled with interior portion of the capillaries.
  • Rendcap is the smallest outlet of the end cap.
  • potting material is disposed within the membrane module directly adjacent to the end seal face of the at least one membrane.
  • the end cap is a dome end cap.
  • the housing includes one or more side ports fluidly coupled with an exterior portion of the membrane between two potted ends of the membrane module.
  • a ceramic membrane module system for treating liquid water includes a housing having an exterior portion and an inner portion, the housing extending from a first housing end to a second housing end, the housing having an inner feed radius, a membrane module including at least one membrane disposed within the housing, the membrane extending from a first membrane end to a second membrane end, the at least one membrane having capillaries extending from the first membrane end to the second membrane end, the at least one membrane having an end seal face at each end; the membrane, at least one end cap disposed near at least one of the first or second membrane ends, a mixing zone disposed between the membrane and the end cap, and the end cap having an outlet defined by an inner radius Rendcap- The membrane recessed within the housing such that
  • ⁇ is measured from the outlet of the end cap to the end seal face of the membrane, the outlet is fluidly coupled with the mixing zone, and the mixing zone is fluidly coupled with interior portion of the capillaries.
  • Rendcap is the smallest outlet of the end cap.
  • potting material is disposed directly adjacent to the end seal face of the membrane.
  • the end cap is a dome end cap.
  • the housing includes one or more side ports fluidly coupled with an exterior portion of the membrane between two potted ends of the membrane module.
  • the membrane recessed within the housing such that
  • the membrane is recessed within the housing such that
  • a method for forming a ceramic membrane module system for treating liquid water includes providing a housing having a membrane therein, the membrane having capillaries therein, the membrane recessed from an end portion of the housing, where the membrane is recessed within the housing such that when liquid water enters the inner portion of the housing the liquid water enters prior to entering the membrane, sealing the end portion of the housing with the removable gasket, disposing potting material into the housing at a recessed position from an end of the housing, wherein disposing the potting occurs without plugging the capillaries with the potting, removing the gasket from the housing.
  • one housing end a distance Recesshsg such that an approach angle is:
  • the method includes placing the housing in a vertical orientation prior to potting.
  • disposing potting material includes disposing potting material through a side port.
  • the method further includes disposing potting material at an opposite end of the housing.
  • a ceramic membrane module system for treating liquid water includes a housing having an exterior portion and an inner portion, the housing extending from a first housing end to a second housing end, the housing having an inner feed radius Rh Sg , a membrane module including at least one membrane disposed within the housing, the membrane extending from a first membrane end to a second membrane end, the at least one membrane having capillaries extending from the first membrane end to the second membrane end, the at least one membrane having an end seal face at each end, at least one membrane end recessed from at least one housing end a distance Recesshsg, at least one end cap disposed near at least one of the first or second membrane ends, a mixing zone disposed between the membrane and the end cap, the end cap having an outlet defined by an inner radius Rendcap, the at least one membrane recessed within the housing such that an approach angle is:
  • the outlet is fluidly coupled with the mixing zone, and the mixing zone is fluidly coupled with interior portion of the capillaries.
  • FIG. 1A is a block diagram of a conventional ceramic membrane.
  • FIG. IB is a block diagram of a ceramic membrane system according to one or more embodiments.
  • FIG. 1C is a block diagram of a conventional ceramic membrane.
  • FIG. ID is a block diagram of a conventional ceramic membrane.
  • FIG. IE is a block diagram of a ceramic membrane system according to one or more embodiments.
  • FIG. IF is a block diagram of a ceramic membrane system according to one or more embodiments.
  • FIG. 2A is a perspective view of a ceramic membrane system according to one or more embodiments.
  • FIG. 2B is a partially exploded perspective view of a ceramic membrane system according to one or more embodiments.
  • FIG. 3A is a cross-sectional view of a ceramic membrane system according to one or more embodiments.
  • FIG. 3B is a partially exploded side view of a ceramic membrane system according to one or more embodiments.
  • FIG. 4 illustrates a bottom view of a ceramic membrane system according to one or more embodiments.
  • FIG. 5 illustrates an end view of a ceramic membrane system according to one or more embodiments.
  • FIG. 6A illustrates a side view of a ceramic membrane system according to one or more embodiments.
  • FIG. 6B illustrates an end view of a ceramic membrane system according to one or more embodiments.
  • FIG. 6C illustrates a cross-sectional view taken along C-C of FIG. 6A.
  • FIG. 6D illustrates a cross-sectional view taken along D-D of FIG. 6C.
  • FIG. 6E illustrates an end view of a ceramic membrane system according to one or more embodiments.
  • FIG. 7A illustrates a side view of a ceramic membrane system according to one or more embodiments.
  • FIG. 7B illustrates an end view of a ceramic membrane system according to one or more embodiments.
  • FIG. 7C illustrates a cross-sectional view taken along C-C of FIG. 7A.
  • FIG. 7D illustrates a cross-sectional view taken along D-D of FIG. 7C.
  • FIG. 7E illustrates an end view of a ceramic membrane system according to one or more embodiments.
  • FIG. 8A illustrates a side view of a ceramic membrane system according to one or more embodiments.
  • FIG. 8B illustrates an end view of a ceramic membrane system according to one or more embodiments.
  • FIG. 8C illustrates a cross-sectional view taken along C-C of FIG. 8A.
  • FIG. 8D illustrates a cross-sectional view taken along D-D of FIG. 8C.
  • FIGs. 2 A, 2B, 3 A, 3B, 4, 5 A ceramic membrane system is shown in FIGs. 2 A, 2B, 3 A, 3B, 4, 5.
  • the system includes a housing, a ceramic membrane module, and an end cap.
  • the ceramic membrane module includes a ceramic monolith or potted segments making up a monolith that is set back from the ends of the housing.
  • the segments and or monolith of the ceramic membranes are aligned and affixed in from the ends of the housing and are potted in place in a manner that allow fluid to mix in a mixing zone 178 and evenly distribute flow over the face end of the capillary of the ceramic monolith or potted monolith.
  • the exit ends can be similarly prepared which then makes the housing more suitable for both cross flow and dead end flow applications of the filter.
  • a ceramic membrane module system 100 for treating liquid water is shown in FIGs. 6 - 8.
  • the system 100 includes a housing 120, where the housing 120 has a first housing end 122 and a second housing end 124, and is defined in part by an interior portion 127 and an exterior portion 128.
  • the housing 120 further has an inner feed diameter D.
  • the system further includes a membrane module 130 including at least one membrane 131.
  • the at least one membrane 131 is a ceramic membrane. Ceramic materials include, but are not limited to alumina, silicon carbide, and titania. In one or more embodiments, the ceramic materials are hydrophilic.
  • the at least one membrane extends from a first membrane end 132 to a second membrane end 134.
  • the membrane 131 has capillaries 136 (FIG. 5) therein, where the capillaries 136 extend from at least a first end 132 of the membrane 131 to the second end 134 of the membrane. In one or more embodiments, the capillaries 136 extend from the first end 132 to the second end 134 of the membrane.
  • the membrane 130 is recessed from at least one of the first or second housing ends 122, 124.
  • the housing includes side ports 126. These side ports provide an exit connection for purified fluids, and a means to clean the membrane surface by pressurizing the filtrate and causing the flow direction to temporarily reverse.
  • the port materials can be adjusted for the application and its temperature and chemical requirements, various metals allows and sealing pad systems or other housing materials as indicated earlier may be used for these ports.
  • At least one end cap 150 is disposed near at least one of the first or second membrane ends 132, 134.
  • the end cap has an outlet 152 defined by an inner radius Re cap.
  • the at least one membrane 131 is recessed within the housing as further discussed below.
  • the system as described herein affixes the ceramic membrane to the housing at a recess from the end of the housing, for example, a predetermined distance from either or both ends of the housing.
  • the distance of the ceramic membrane and potting from the end of the module housing provides for protection of the face end seal from accidental mechanical damage, while the distance from the end cap provides for mixing and uniform distribution of fluids to be processed.
  • FIGs. 1A - IF where FIGs. 1A, 1C, ID show conventional systems where damage can occur to the membrane given the proximity to the end of the housing.
  • FIGs. IB, IE, IF shows a recess that provides protection of the face end seal from accidental damage, and allows for mixing and uniform distribution fluids to be processed.
  • the housing contains the pressure
  • a variety of end cap designs can be used interchangeably and be made of various materials to optimize performance in a given installation. For instance, in applications where a high salinity stream is used a plastic end cap may be used to minimize corrosion, while in a high temperature application a metal end cap may be replaced.
  • the range of approach angles at which the ceramic is exposed is 180 degrees, as shown in FIG. 1A.
  • modules as described and shown herein have a decreased range of approach angles 110, preferably less than 140°, more preferably less than 120°, less than 100°, or even more preferably less than 90°, as shown in FIG. IB.
  • the angle from a corner of the potting (end seal face) to the opposite corner is the following:
  • TanO Recesshsg (m)/2Rh S g (m)
  • Recesshsg is the amount of recess 105 or a from the end of the housing (see FIG. IB, FIGs. 6 - 8), and Rh Sg is an inner feed radius of the housing (0.5 * D).
  • ⁇ is shown as 110 in FIG. IB, for example.
  • the recess distance is also an important in the uniformity of flow rates and pressures at the channel inlets and outlets. From a flow standpoint the optimal recess distance is a function of the inside of the housing diameter, the diameter of the feed or concentrate port and the flow rate. Fluid viscosity and temperature also have an impact on the optimal recess dimension.
  • Rendcap is inner radius of the feed or concentrate nozzle in inches.
  • Rendcap is a radius of a smallest outlet of the endcap, and ⁇ is the recess in inches, where ⁇ is measured from the outlet of the endcap to the face of the membrane, and Q is flow of the feed solution through the membrane in gallons per minute (GPM).
  • GPM gallons per minute
  • the ceramic membrane module system includes a housing, and a membrane disposed within the housing.
  • the feed solution to the membrane has a flow rate Q, and an end seal face.
  • the end seal face of the membrane is disposed toward an end portion of the housing.
  • An end cap is disposed at the end portion of the housing, where the end cap has an outlet defined by an inner radius Rendcap.
  • the membrane is recessed within the housing such that
  • ⁇ is measured from the outlet of the end cap to the end seal face of the membrane.
  • This module is commonly used in a vertical orientation, and can be supported by the edges of the base of the housing, while leaving the center region with clearance to remove the end cap and access the membrane.
  • the material used for the end cap can be chosen from a variety of materials.
  • Thermoset or thermoplastics may be used, and the may be used with or without reinforcement materials. These may include ABS, Acetal, PPE resin, Nylon, PEEK, PET, PPSU, CPVC, PVC, PP, PE, PVDF, PTFE, PEI, epoxies, urethanes, or other plastics.
  • These end caps may also be reinforced by the use of an external plate, preferably metal such as steel or aluminum.
  • the end cap may also be made of metals, which may optionally be coated or modified to improve stability to the fluids and cleaning agents used during use.
  • thrust snap rings can be used to hold the end cap in place internal to the vessel.
  • swing bolt/Victaulic type couplings, retaining bolts or pins, V- bands, union closures, or other similar closure styles can be used.
  • a method in an example of a method for preparing the ceramic membrane module system, includes disposing a removable gasket within a housing having a membrane therein, the membrane having capillaries therein, the membrane recessed from an end portion of the housing. The method further includes sealing the end portion of the housing with the removable gasket, disposing potting material into the housing at a recessed position from an end of the housing, wherein disposing the potting occurs without plugging the capillaries with the potting material. In addition, the method includes removing the gasket from the housing. The endcaps have the removable gaskets. The gasket keeps the potting in place during potting and curing, and then removed. Once the module is potted and cured, the gasket is removed.
  • the materials include, but are not limited to, thermoplastics, FRP including ABS, Acetal, Noryl, Nylon, PEEK, PET, Radel, Ultem, CPVC, PVC, PP, PE, PVDF, and PTFE.
  • Thermoplastics may also include reinforcement materials such as carbon fiber, glass or ceramic particles or fibers to improve thermal and mechanical stability.
  • Metals such as steel, stainless steel, aluminum, and titanium may also be used as a housing material. These metals may optionally be coated or modified to improve stability to the fluids and cleaning agents used during use.
  • the housing material includes fiber reinforced plastics (FRP), for instance glass fiber or carbon fibers reinforced with thermosets such as epoxy.
  • the housing includes side ports. These side ports provide an exit connection for purified fluids, and a means to clean the membrane surface by pressurizing the filtrate and causing the flow direction to temporarily reverse.
  • the port materials can be adjusted for the application and its temperature and chemical requirements, various metals allows and gasket systems or other housing materials as indicated earlier may be used for these ports.
  • Modules as described herein can be made by potting the ceramic plates within the housing.
  • the ceramic membrane is placed within the housing in a vertical orientation.
  • a support is used with a gasket material that seals the channels preventing the potting material from sealing the channels of the ceramic membrane.
  • the uncured potting material is added through the side port, through the opposite end, or through a hole in the sealing gasket so that the potting material completely seals the ceramic to the internal housing wall.
  • the depth of this potting material is chosen to maximize the mechanical integrity of the module, while minimizing the amount of potting material used. Preferred amounts give a depth of potting material between 0.1 and 20cm, preferably between 0.5 and 5cm, and more preferably between 1 and 3 cm.
  • the module can be inverted and the process repeated to pot the second end. In this instance the potting material may be applied through the side port or gasket.
  • a ceramic monolith 139 can be potted directly into the housing.
  • a segmented monolith can be either placed into the vessel with a series of spacers or a fixturing device, either of which end up being encapsulated in potting material.
  • the segments may be first potted into a prepot. In a prepot concept both ends of the ceramic are first potted together at both ends with a disc of potting material. Gaskets can be used to prevent potting material from entering the channels and a mold is used to prepare the disc shape which is slightly smaller than the internal diameter of the housing.
  • the surface of the vessel may be modified prior to potting. This may include cleaning, for instance with solvent, acids, or bases, mechanical roughening of the surface, for instance by sanding, or chemical modification for instance by functionalization or plasma or corona treatment.
  • a ceramic membrane module system for treating liquid water includes a housing having an exterior portion and an inner portion, the housing extends from a first housing end to a second housing end, the housing has an inner feed radius.
  • the system further includes a membrane module including at least one membrane disposed within the housing, where the membrane extends from a first membrane end to a second membrane end, and the at least one membrane has capillaries that extend from the first membrane end to the second membrane end.
  • the at least one membrane has an end seal face at each end.
  • At least one end cap is disposed near at least one of the first or second membrane ends, where the end cap has an outlet defined by an inner radius Rendcap.
  • the at least one membrane is recessed within the housing such that
  • Rendcap is the smallest outlet of the end cap.
  • potting material is disposed within the membrane module directly adjacent to the end seal face of the at least one membrane.
  • the end cap is a dome end cap.
  • a mixing zone disposed between the membrane and the end cap.
  • a ceramic membrane module system for treating liquid water includes a housing having an exterior portion and an inner portion, the housing extending from a first housing end to a second housing end, the housing having an inner feed radius.
  • the system includes a membrane module including at least one membrane disposed within the housing, the membrane extending from a first membrane end to a second membrane end, the at least one membrane having capillaries extending from the first membrane end to the second membrane end, the at least one membrane having an end seal face at each end.
  • At least one end cap is disposed near at least one of the first or second membrane ends, where the end cap has an outlet defined by an inner radius Rendcap.
  • a feed solution to the membrane has a flow rate Q.
  • the membrane is recessed within the housing such that
  • a is measured from the outlet of the end cap to the end seal face of the membrane.
  • Rendcap is the smallest outlet of the end cap.
  • potting material disposed directly adjacent to the end seal face of the membrane.
  • the end cap is a dome end cap.
  • a mixing zone is disposed between the membrane and the end cap.
  • the recess is defined as follows:
  • Examples include a 1" recess for a 25m 2 module with a 3" port, a 1.6" recess for a 25m 2 module with a 2" port.
  • a 2.6" recess for a 25m 2 module with a 3" port For example, a 3.9" recess for a 25m 2 module with a 2" port.
  • the recess is as follows:
  • a method for forming a ceramic membrane module system for treating liquid water comprises disposing an end cap with a removable gasket within a housing having a membrane therein, the membrane having capillaries therein.
  • the membrane is recessed from an end portion of the housing, where the membrane is recessed within the housing such that when liquid water enters the inner portion of the housing the liquid water enters prior to entering the membrane.
  • the method further includes sealing the end portion of the housing with the removable gasket, disposing potting material into the housing at a recessed position from an end of the housing, wherein disposing the potting occurs without plugging the capillaries with the potting, and removing the gasket from the housing.
  • the membrane during use, has a flow rate Q and an end seal face, the at least one end cap having an outlet defined by an inner radius R;
  • the method further includes placing the housing in a vertical orientation prior to potting.
  • disposing potting material includes disposing potting material through a side port. In one or more embodiments, disposing potting material includes disposing potting material through the sealing gasket.
  • the method further includes disposing potting material at an opposite end of the housing.
  • feed water enters the end cap via the outlet.
  • pressure applied to the feed results in water flow through the membrane and out the permeate side port.
  • pressure applied to the permeate results in water flowing through the membrane and out the end cap outlet.
  • the feed water enters the mixing zone via the end cap, and then enters an interior portion of the capillaries of the membrane.
  • the membrane filters the water, and the permeate exits out the side ports of the housing.
  • the concentrate exits the other end of the system via the capillaries.
  • Recessed membrane and potting allows a mixing zone for uniform entry into the feed side of the membrane.
  • the extension of the housing walls leads to a mechanical protection of the face end seal and ceramic membrane from damage.
  • the recessed potting allows a closure type that enables the use of a thrust snap ring closure type, a flat or domed inward end cap, a swing bolt type enclosure, a v-band type closure, and other grooved type closure methods. These are cost advantages over other types of closure thus reducing the housing cost and the product cost. These methods can be used in FRP, metallic and other plastic type housings and or endcaps.
  • the ceramic module described herein allows for less expensive endcaps and closure types such as inward domed or flat endcaps secured by thrust ring/ grooved closures, V-band swing bolts, screwed union or other similar methods.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Inorganic Chemistry (AREA)
  • Separation Using Semi-Permeable Membranes (AREA)

Abstract

A ceramic membrane module system for treating liquid water includes a housing having an inner feed radius Rhsg and a membrane module including at least one membrane disposed within the housing. The at least one membrane has an end seal face at each end. At least one end cap is disposed near at least one of the first or second membrane ends, where the end cap has an outlet defined by an inner radius Rendcap. The at least one membrane is recessed within the housing such that σ ≥ 0.1 * Rhsg 2 /Rendcap; and where σ is measured from the outlet of the end cap to the end seal face of the membrane.

Description

CERAMIC MEMBRANE MODULE WITH RECESSED MEMBRANE AND RELATED METHODS
Inventors
Paul Osmundson
CERAMIC MEMBRANE MODULE WITH RECESSED MEMBRANE AND RELATED METHODS
PRIORITY
This application claims priority to United States Provisional Application Number 62/203,253, filed 10 August 2015. The entire content of this United States Provisional Application is
incorporated herein by reference.
TECHNICAL FIELD
A ceramic membrane module with recessed membrane and related methods.
TECHNICAL BACKGROUND
Many waters contain contaminants that can present a hazard to people or the environment, or make further processing, such as evaporation or reverse osmosis more difficult. Membranes are commonly used to remove such contaminants. Membrane elements are typically made of plastics or ceramics, both of which are frequently placed inside a pressure vessel to contain the pressurized fluid to be treated. The element and pressure vessel combination are referred to as membrane modules or modules. Such pressure vessels also provide separate ports to allow a feed to enter the module, filtrate to exit after being processed through the membrane, and a retentate for removal of the filtered material.
Ceramic membranes are commonly used as a multilayer structure with a relatively high permeability support, and a thinner separation layer which enables the separation by passing some components (typically water and small solutes) while retaining others. In order to increase surface area a number of channels are typically present in the support, each with a coating. During use of the membrane, feed enters these channels before passing through the membrane into the support structure. To keep feed from passing directly into the support on either end, a face end seal layer is used to prevent transport through the ends. Commonly used materials for face end seals include epoxies, polyurethanes, and glass. In comparison to the other components in a ceramic housing this face end seal is particularly sensitive to mechanical damage due to both the material properties of the face end seal, and the fact that housings which have been used to date leave the face end seal at the end of the housing preventing it from serving as shielding. What is needed is a module design allowing the housing to protect, shield, and/or create an impingement zone or buffer space around the face end seal improving the durability and integrity of the membrane.
SUMMARY
In one or more embodiments, a ceramic membrane module system for treating liquid water includes a housing having an exterior portion and an inner portion, the housing extending from a first housing end to a second housing end, the housing having an inner feed radius Rhsg. The system further includes a membrane module including at least one membrane disposed within the housing, the membrane extending from a first membrane end to a second membrane end, the at least one membrane having capillaries extending from the first membrane end to the second membrane end, the at least one membrane having an end seal face at each end. The system further includes at least one end cap disposed near at least one of the first or second membrane ends, a mixing zone disposed between the membrane and the end cap, where the the end cap having an outlet defined by an inner radius Rendcap. The at least one membrane is recessed within the housing such that
σ > 0.1 * Rhsg2 /Rendcap; and
where σ is measured from the outlet of the end cap to the end seal face of the membrane, the outlet is fluidly coupled with the mixing zone, and the mixing zone is fluidly coupled with interior portion of the capillaries.
In one or more embodiments, Rendcap is the smallest outlet of the end cap.
In one or more embodiments, potting material is disposed within the membrane module directly adjacent to the end seal face of the at least one membrane.
In one or more embodiments, the end cap is a dome end cap.
In one or more embodiments, the housing includes one or more side ports fluidly coupled with an exterior portion of the membrane between two potted ends of the membrane module.
In one or more embodiments,
G > 0.2 * Rhsg2 /Rendcap.
In one or more embodiments,
σ > 0.25 * Rhsg2 /Rendcap. In one or more embodiments, a ceramic membrane module system for treating liquid water includes a housing having an exterior portion and an inner portion, the housing extending from a first housing end to a second housing end, the housing having an inner feed radius, a membrane module including at least one membrane disposed within the housing, the membrane extending from a first membrane end to a second membrane end, the at least one membrane having capillaries extending from the first membrane end to the second membrane end, the at least one membrane having an end seal face at each end; the membrane, at least one end cap disposed near at least one of the first or second membrane ends, a mixing zone disposed between the membrane and the end cap, and the end cap having an outlet defined by an inner radius Rendcap- The membrane recessed within the housing such that
σ > 4 x 10"5 * area Rendcap ; and
where σ is measured from the outlet of the end cap to the end seal face of the membrane, the outlet is fluidly coupled with the mixing zone, and the mixing zone is fluidly coupled with interior portion of the capillaries.
In one or more embodiments, Rendcap is the smallest outlet of the end cap.
In one or more embodiments, potting material is disposed directly adjacent to the end seal face of the membrane.
In one or more embodiments, the end cap is a dome end cap.
In one or more embodiments, the housing includes one or more side ports fluidly coupled with an exterior portion of the membrane between two potted ends of the membrane module.
In one or more embodiments, the membrane recessed within the housing such that
σ > 8 x 10"5 * area Rendcap
In one or more embodiments, the membrane is recessed within the housing such that
σ > 1 x 10"4 * area Rendcap.
In one or more embodiments, a method for forming a ceramic membrane module system for treating liquid water includes providing a housing having a membrane therein, the membrane having capillaries therein, the membrane recessed from an end portion of the housing, where the membrane is recessed within the housing such that when liquid water enters the inner portion of the housing the liquid water enters prior to entering the membrane, sealing the end portion of the housing with the removable gasket, disposing potting material into the housing at a recessed position from an end of the housing, wherein disposing the potting occurs without plugging the capillaries with the potting, removing the gasket from the housing.
In one or more embodiments, one housing end a distance Recesshsg such that an approach angle is:
Φ < 180 - 2arctan(Recesshsg /2RhSg),
where the housing having an inner feed radius Rhsg.
In one or more embodiment, the method includes placing the housing in a vertical orientation prior to potting.
In one or more embodiments, disposing potting material includes disposing potting material through a side port.
In one or more embodiments, the method further includes disposing potting material at an opposite end of the housing.
In one or more embodiments, a ceramic membrane module system for treating liquid water includes a housing having an exterior portion and an inner portion, the housing extending from a first housing end to a second housing end, the housing having an inner feed radius RhSg, a membrane module including at least one membrane disposed within the housing, the membrane extending from a first membrane end to a second membrane end, the at least one membrane having capillaries extending from the first membrane end to the second membrane end, the at least one membrane having an end seal face at each end, at least one membrane end recessed from at least one housing end a distance Recesshsg, at least one end cap disposed near at least one of the first or second membrane ends, a mixing zone disposed between the membrane and the end cap, the end cap having an outlet defined by an inner radius Rendcap, the at least one membrane recessed within the housing such that an approach angle is:
Φ < 180 - 2arctan(Recesshs /2RhSg) ; and
the outlet is fluidly coupled with the mixing zone, and the mixing zone is fluidly coupled with interior portion of the capillaries.
These and other embodiments, aspects, advantages, and features of the present invention will be set forth in part in the description which follows, and will become apparent to those skilled in the art by reference to the following description of the invention and referenced drawings or by practice of the invention. The aspects, advantages, and features of the invention are realized and attained by means of the instrumentalities, procedures, and combinations particularly pointed out in the appended claims and their equivalents.
BRIEF DESCRIPTION OF THE FIGURES FIG. 1A is a block diagram of a conventional ceramic membrane.
FIG. IB is a block diagram of a ceramic membrane system according to one or more embodiments.
FIG. 1C is a block diagram of a conventional ceramic membrane.
FIG. ID is a block diagram of a conventional ceramic membrane.
FIG. IE is a block diagram of a ceramic membrane system according to one or more embodiments.
FIG. IF is a block diagram of a ceramic membrane system according to one or more embodiments.
FIG. 2A is a perspective view of a ceramic membrane system according to one or more embodiments.
FIG. 2B is a partially exploded perspective view of a ceramic membrane system according to one or more embodiments.
FIG. 3A is a cross-sectional view of a ceramic membrane system according to one or more embodiments.
FIG. 3B is a partially exploded side view of a ceramic membrane system according to one or more embodiments.
FIG. 4 illustrates a bottom view of a ceramic membrane system according to one or more embodiments.
FIG. 5 illustrates an end view of a ceramic membrane system according to one or more embodiments.
FIG. 6A illustrates a side view of a ceramic membrane system according to one or more embodiments.
FIG. 6B illustrates an end view of a ceramic membrane system according to one or more embodiments.
FIG. 6C illustrates a cross-sectional view taken along C-C of FIG. 6A.
FIG. 6D illustrates a cross-sectional view taken along D-D of FIG. 6C. FIG. 6E illustrates an end view of a ceramic membrane system according to one or more embodiments.
FIG. 7A illustrates a side view of a ceramic membrane system according to one or more embodiments.
FIG. 7B illustrates an end view of a ceramic membrane system according to one or more embodiments.
FIG. 7C illustrates a cross-sectional view taken along C-C of FIG. 7A.
FIG. 7D illustrates a cross-sectional view taken along D-D of FIG. 7C.
FIG. 7E illustrates an end view of a ceramic membrane system according to one or more embodiments.
FIG. 8A illustrates a side view of a ceramic membrane system according to one or more embodiments.
FIG. 8B illustrates an end view of a ceramic membrane system according to one or more embodiments.
FIG. 8C illustrates a cross-sectional view taken along C-C of FIG. 8A.
FIG. 8D illustrates a cross-sectional view taken along D-D of FIG. 8C.
DETAILED DESCRIPTION
The following detailed description includes references to the accompanying drawings, which form a part of the detailed description. The drawings show, by way of illustration, specific embodiments in which the apparatus may be practiced. These embodiments, which are also referred to herein as "examples" or "options," are described in enough detail to enable those skilled in the art to practice the present embodiments. The embodiments may be combined, other embodiments may be utilized or structural or logical changes may be made without departing from the scope of the invention. The following detailed description is, therefore, not to be taken in a limiting sense and the scope of the invention is defined by the appended claims and their legal equivalents.
In this document, the terms "a" or "an" are used to include one or more than one, and the term "or" is used to refer to a nonexclusive "or" unless otherwise indicated. In addition, it is to be understood that the phraseology or terminology employed herein, and not otherwise defined, is for the purpose of description only and not of limitation. A ceramic membrane system is shown in FIGs. 2 A, 2B, 3 A, 3B, 4, 5. The system includes a housing, a ceramic membrane module, and an end cap. The ceramic membrane module includes a ceramic monolith or potted segments making up a monolith that is set back from the ends of the housing. The segments and or monolith of the ceramic membranes are aligned and affixed in from the ends of the housing and are potted in place in a manner that allow fluid to mix in a mixing zone 178 and evenly distribute flow over the face end of the capillary of the ceramic monolith or potted monolith. In one or more embodiments, the exit ends can be similarly prepared which then makes the housing more suitable for both cross flow and dead end flow applications of the filter.
In one or more embodiments, a ceramic membrane module system 100 for treating liquid water is shown in FIGs. 6 - 8. The system 100 includes a housing 120, where the housing 120 has a first housing end 122 and a second housing end 124, and is defined in part by an interior portion 127 and an exterior portion 128. The housing 120 further has an inner feed diameter D.
The system further includes a membrane module 130 including at least one membrane 131. The at least one membrane 131 is a ceramic membrane. Ceramic materials include, but are not limited to alumina, silicon carbide, and titania. In one or more embodiments, the ceramic materials are hydrophilic. The at least one membrane extends from a first membrane end 132 to a second membrane end 134. The membrane 131 has capillaries 136 (FIG. 5) therein, where the capillaries 136 extend from at least a first end 132 of the membrane 131 to the second end 134 of the membrane. In one or more embodiments, the capillaries 136 extend from the first end 132 to the second end 134 of the membrane. The membrane 130 is recessed from at least one of the first or second housing ends 122, 124.
In one or more embodiments, the housing includes side ports 126. These side ports provide an exit connection for purified fluids, and a means to clean the membrane surface by pressurizing the filtrate and causing the flow direction to temporarily reverse. The port materials can be adjusted for the application and its temperature and chemical requirements, various metals allows and sealing pad systems or other housing materials as indicated earlier may be used for these ports.
At least one end cap 150 is disposed near at least one of the first or second membrane ends 132, 134. The end cap has an outlet 152 defined by an inner radius Re cap. The at least one membrane 131 is recessed within the housing as further discussed below.
In one or more embodiments, the system as described herein, affixes the ceramic membrane to the housing at a recess from the end of the housing, for example, a predetermined distance from either or both ends of the housing. The distance of the ceramic membrane and potting from the end of the module housing provides for protection of the face end seal from accidental mechanical damage, while the distance from the end cap provides for mixing and uniform distribution of fluids to be processed. See for example FIGs. 1A - IF, where FIGs. 1A, 1C, ID show conventional systems where damage can occur to the membrane given the proximity to the end of the housing. In FIGs. IB, IE, IF shows a recess that provides protection of the face end seal from accidental damage, and allows for mixing and uniform distribution fluids to be processed. Since the housing contains the pressure, a variety of end cap designs can be used interchangeably and be made of various materials to optimize performance in a given installation. For instance, in applications where a high salinity stream is used a plastic end cap may be used to minimize corrosion, while in a high temperature application a metal end cap may be replaced.
To quantify the protection a given design can provide, it's useful to consider the range of approach angles at which the ceramic is exposed. For a conventional design with the ceramic membrane disposed at the end of the housing, the range of approach angles where the ceramic face end seal could be damaged is 180 degrees, as shown in FIG. 1A.
Recessing the ceramic membrane decreases the range of approaches which could cause damage, and thus the risk of damage to the membrane. A traditional module would have a range of approach angles 108 equal to 180° (FIG. 1 A). In one or more embodiments, modules as described and shown herein have a decreased range of approach angles 110, preferably less than 140°, more preferably less than 120°, less than 100°, or even more preferably less than 90°, as shown in FIG. IB.
In one or more embodiments, the angle from a corner of the potting (end seal face) to the opposite corner is the following:
TanO = Recesshsg (m)/2RhSg (m)
where Recesshsg is the amount of recess 105 or a from the end of the housing (see FIG. IB, FIGs. 6 - 8), and RhSg is an inner feed radius of the housing (0.5 * D).
The angle of approach would then be the following:
Φ < 18O - 20 (or)
Φ <180 - 2arctan(Recesshsg (m)/2RhSg(m))
where Φ is shown as 110 in FIG. IB, for example.
where Recesshsg and RhSg lead to an entry angle of less than
140 (would be 2.9" for an 8" housing); 120 (would be 4.6" for an 8" housing);
100 (would be 6.7" for an 8" housing); and
90 (would be 8" for an 8" housing). The recess distance is also an important in the uniformity of flow rates and pressures at the channel inlets and outlets. From a flow standpoint the optimal recess distance is a function of the inside of the housing diameter, the diameter of the feed or concentrate port and the flow rate. Fluid viscosity and temperature also have an impact on the optimal recess dimension. Higher flow rates require more recess distance, larger housing inside diameters require a deeper recess and smaller inlet and outlet ports require a deeper recess to provide optimal uniform flow to the ends of the membrane capillaries as well as egress flow during backwash purge and when used in cross flow the minimum distance should be such that the radius of the feed port on the inside of the end cap cross sectional area is equal to the circumference times the recess area. As the flow goes up it is important to increase recess dimension. Optimal ceramic module performance requires uniform flow to the feed channels in the membrane.
As shown in FIGs. 6 - 8, Rendcap is inner radius of the feed or concentrate nozzle in inches. In one or more embodiments, Rendcap is a radius of a smallest outlet of the endcap, and σ is the recess in inches, where σ is measured from the outlet of the endcap to the face of the membrane, and Q is flow of the feed solution through the membrane in gallons per minute (GPM). To determine the recess for the membrane relative to the housing, test data was developed. According to the test data, the minimum recess can be determined, as follows.
Figure imgf000011_0001
1.5 100 1.009149
1 100 1.509219
0.5 100 3.018439
2 200 1.509219
1.5 200 2.012292
1 200 3.018439
0.5 200 9.039877
In one or more embodiments the minimal recess distance for any flow and inlet radius can be calculated through the use of the following equation:
σ >Q/(66*Rendcap)
In an example of a system with a recessed membrane having a predetermined recess, the ceramic membrane module system includes a housing, and a membrane disposed within the housing. The feed solution to the membrane has a flow rate Q, and an end seal face. The end seal face of the membrane is disposed toward an end portion of the housing. An end cap is disposed at the end portion of the housing, where the end cap has an outlet defined by an inner radius Rendcap. The membrane is recessed within the housing such that
a >Q/(66*Rendcap),
where σ is measured from the outlet of the end cap to the end seal face of the membrane. This module is commonly used in a vertical orientation, and can be supported by the edges of the base of the housing, while leaving the center region with clearance to remove the end cap and access the membrane.
The material used for the end cap can be chosen from a variety of materials. Thermoset or thermoplastics may be used, and the may be used with or without reinforcement materials. These may include ABS, Acetal, PPE resin, Nylon, PEEK, PET, PPSU, CPVC, PVC, PP, PE, PVDF, PTFE, PEI, epoxies, urethanes, or other plastics. These end caps may also be reinforced by the use of an external plate, preferably metal such as steel or aluminum. The end cap may also be made of metals, which may optionally be coated or modified to improve stability to the fluids and cleaning agents used during use.
A variety of methods have been devised as a means to affix the end cap to the module. For instance thrust snap rings can be used to hold the end cap in place internal to the vessel. Alternately, swing bolt/Victaulic type couplings, retaining bolts or pins, V- bands, union closures, or other similar closure styles can be used.
In an example of a method for preparing the ceramic membrane module system, a method includes disposing a removable gasket within a housing having a membrane therein, the membrane having capillaries therein, the membrane recessed from an end portion of the housing. The method further includes sealing the end portion of the housing with the removable gasket, disposing potting material into the housing at a recessed position from an end of the housing, wherein disposing the potting occurs without plugging the capillaries with the potting material. In addition, the method includes removing the gasket from the housing. The endcaps have the removable gaskets. The gasket keeps the potting in place during potting and curing, and then removed. Once the module is potted and cured, the gasket is removed.
A variety of materials can be used for the housing. In one or more embodiments, the materials include, but are not limited to, thermoplastics, FRP including ABS, Acetal, Noryl, Nylon, PEEK, PET, Radel, Ultem, CPVC, PVC, PP, PE, PVDF, and PTFE. Thermoplastics may also include reinforcement materials such as carbon fiber, glass or ceramic particles or fibers to improve thermal and mechanical stability. Metals such as steel, stainless steel, aluminum, and titanium may also be used as a housing material. These metals may optionally be coated or modified to improve stability to the fluids and cleaning agents used during use. In one or more embodiments, the housing material includes fiber reinforced plastics (FRP), for instance glass fiber or carbon fibers reinforced with thermosets such as epoxy.
In one or more embodiments, the housing includes side ports. These side ports provide an exit connection for purified fluids, and a means to clean the membrane surface by pressurizing the filtrate and causing the flow direction to temporarily reverse. The port materials can be adjusted for the application and its temperature and chemical requirements, various metals allows and gasket systems or other housing materials as indicated earlier may be used for these ports.
Modules as described herein can be made by potting the ceramic plates within the housing.
To do this the ceramic membrane is placed within the housing in a vertical orientation. A support is used with a gasket material that seals the channels preventing the potting material from sealing the channels of the ceramic membrane. The uncured potting material is added through the side port, through the opposite end, or through a hole in the sealing gasket so that the potting material completely seals the ceramic to the internal housing wall. The depth of this potting material is chosen to maximize the mechanical integrity of the module, while minimizing the amount of potting material used. Preferred amounts give a depth of potting material between 0.1 and 20cm, preferably between 0.5 and 5cm, and more preferably between 1 and 3 cm. After the first side is potted, the module can be inverted and the process repeated to pot the second end. In this instance the potting material may be applied through the side port or gasket.
If a ceramic monolith 139 is used, as shown in FIGs. 8A - 8E, it can be potted directly into the housing. If a segmented monolith is to be used, it can be either placed into the vessel with a series of spacers or a fixturing device, either of which end up being encapsulated in potting material. Alternatively the segments may be first potted into a prepot. In a prepot concept both ends of the ceramic are first potted together at both ends with a disc of potting material. Gaskets can be used to prevent potting material from entering the channels and a mold is used to prepare the disc shape which is slightly smaller than the internal diameter of the housing.
To improve the adhesion of the potting material to the vessel, the surface of the vessel may be modified prior to potting. This may include cleaning, for instance with solvent, acids, or bases, mechanical roughening of the surface, for instance by sanding, or chemical modification for instance by functionalization or plasma or corona treatment.
In one or more embodiments, as shown in FIGs. 6 - 8, a ceramic membrane module system for treating liquid water includes a housing having an exterior portion and an inner portion, the housing extends from a first housing end to a second housing end, the housing has an inner feed radius. The system further includes a membrane module including at least one membrane disposed within the housing, where the membrane extends from a first membrane end to a second membrane end, and the at least one membrane has capillaries that extend from the first membrane end to the second membrane end. The at least one membrane has an end seal face at each end. At least one end cap is disposed near at least one of the first or second membrane ends, where the end cap has an outlet defined by an inner radius Rendcap. The at least one membrane is recessed within the housing such that
σ (m) > 0.1 (unitless) * RhS 2 (m2) /Rendcap (m) where σ is measured from the outlet of the end cap to the end seal face of the membrane, RhSg is the radius of the housing, and the membrane is recessed within the housing such that when liquid water enters the inner portion of the housing the liquid water enters prior to entering the membrane. In one or more embodiments, liquid water exits the membrane.
In one or more embodiments, Rendcap is the smallest outlet of the end cap.
In one or more embodiments, potting material is disposed within the membrane module directly adjacent to the end seal face of the at least one membrane.
In one or more embodiments, the end cap is a dome end cap.
In one or more embodiments, a mixing zone disposed between the membrane and the end cap.
In one or more embodiments, a ceramic membrane module system for treating liquid water, the system includes a housing having an exterior portion and an inner portion, the housing extending from a first housing end to a second housing end, the housing having an inner feed radius. The system includes a membrane module including at least one membrane disposed within the housing, the membrane extending from a first membrane end to a second membrane end, the at least one membrane having capillaries extending from the first membrane end to the second membrane end, the at least one membrane having an end seal face at each end. At least one end cap is disposed near at least one of the first or second membrane ends, where the end cap has an outlet defined by an inner radius Rendcap. A feed solution to the membrane has a flow rate Q. The membrane is recessed within the housing such that
σ >Q/(66*Rendcap); and
a is measured from the outlet of the end cap to the end seal face of the membrane.
In one or more embodiments, Rendcap is the smallest outlet of the end cap.
In one or more embodiments, potting material disposed directly adjacent to the end seal face of the membrane.
In one or more embodiments, the end cap is a dome end cap.
In one or more embodiments, a mixing zone is disposed between the membrane and the end cap. As discussed above, in one or more embodiments, the recess is defined as follows:
σ(Ιη) >Q(gpm)/(66gpm/in2)*Rendcap(in) It follows that:
σ (m) > Q(m3/h)/(23232(m/h) * Rendcap(m)
When the equation is solved for an example flow rate Q:
Q= 100gpm = 22.71m3/h
Q=Flux*Area
Area = filtration area
Filtration area = perimeter of the capillaries * length of capillaries * # of capillaries Flux = 22.71/25(m2) = 0.9084 (m3/m2/h)
Plug into recess σ equation:
σ (m) > 0.9084(m3/m2/h) *area(m2) / 23232(m/h) / Rendcap (m)
This can be further simplified as follows:
σ > 4 x 10"5 * area Rendcap
Examples include a 1" recess for a 25m2 module with a 3" port, a 1.6" recess for a 25m2 module with a 2" port.
In one more embodiments:
σ > 8 x 10"5 * area Rendcap
For example, there would be a 2" recess for a 25m2 module with a 3" port, a 3.1" recess for a 25m2 module with a 2" port.
In one or embodiments,
σ > 1 x 10"4 * area Rendcap
For example, a 2.6" recess for a 25m2 module with a 3" port, a 3.9" recess for a 25m2 module with a 2" port.
In one or more embodiments, the recess is as follows:
σ > 4 x 10"5 * area/Rendcap
σ > 4 x 10"5 * area * Rhsg 2/RhS 2 Rendcap
For example: area = 25m2 and Rhsg = 4" or 0.1016m
Bring area/RhSg2 into constant
σ > 4 x 10"5 * area* Rhsg 2 /Rnsg 2 /Rendcap
In one or more embodiments, O > 0.1 * Rhsg2 /Rendcap
For example, there would be 1" recess for a 8" housing with a 3" port, or a 1.6" recess for a 8"housing with a 2" port.
In one or more embodiments,
σ (m) > 0.2 * Rhsg2 /Rendcap
For example, there would be a 2" recess for a 8" housing with a 3" port, or a 3.2" recess for a 8" housing with a 2" port.
In one or more embodiments,
G > 0.25 * Rhsg2 Rendcap
For example, there would be a 2.7" recess for a 8" housing with a 3" port, or a 4" recess for a
8" housing with a 2" port.
In one or more embodiments, a method for forming a ceramic membrane module system for treating liquid water comprises disposing an end cap with a removable gasket within a housing having a membrane therein, the membrane having capillaries therein. The membrane is recessed from an end portion of the housing, where the membrane is recessed within the housing such that when liquid water enters the inner portion of the housing the liquid water enters prior to entering the membrane. The method further includes sealing the end portion of the housing with the removable gasket, disposing potting material into the housing at a recessed position from an end of the housing, wherein disposing the potting occurs without plugging the capillaries with the potting, and removing the gasket from the housing.
In one or more embodiments, during use, the membrane has a flow rate Q and an end seal face, the at least one end cap having an outlet defined by an inner radius R; and
the end cap recessed within the housing such that when the module system is in use, σ >Q/(66*R);
where σ is measured from the outlet of the end cap to the end seal face of the membrane. Any one of the equations discussed above can be substituted herein.
In one or more embodiments, the method further includes placing the housing in a vertical orientation prior to potting.
In one or more embodiments, disposing potting material includes disposing potting material through a side port. In one or more embodiments, disposing potting material includes disposing potting material through the sealing gasket.
In one or more embodiments, the method further includes disposing potting material at an opposite end of the housing.
During use of the system, feed water enters the end cap via the outlet. For example, pressure applied to the feed results in water flow through the membrane and out the permeate side port. In one or more embodiments, pressure applied to the permeate results in water flowing through the membrane and out the end cap outlet. The feed water enters the mixing zone via the end cap, and then enters an interior portion of the capillaries of the membrane. The membrane filters the water, and the permeate exits out the side ports of the housing. The concentrate exits the other end of the system via the capillaries.
Recessed membrane and potting allows a mixing zone for uniform entry into the feed side of the membrane. The extension of the housing walls leads to a mechanical protection of the face end seal and ceramic membrane from damage. The recessed potting allows a closure type that enables the use of a thrust snap ring closure type, a flat or domed inward end cap, a swing bolt type enclosure, a v-band type closure, and other grooved type closure methods. These are cost advantages over other types of closure thus reducing the housing cost and the product cost. These methods can be used in FRP, metallic and other plastic type housings and or endcaps. In addition, the ceramic module described herein allows for less expensive endcaps and closure types such as inward domed or flat endcaps secured by thrust ring/ grooved closures, V-band swing bolts, screwed union or other similar methods.
It is to be understood that the above description is intended to be illustrative, and not restrictive. Many other embodiments will be apparent to those of skill in the art upon reading and understanding the above description. It should be noted that embodiments discussed in different portions of the description or referred to in different drawings can be combined to form additional embodiments of the present application. The scope should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.

Claims

1. A ceramic membrane module system for treating liquid water, the system comprising:
a housing having an exterior portion and an inner portion, the housing extending from a first housing end to a second housing end, the housing having an inner feed radius RhSg;
a membrane module including at least one membrane disposed within the housing, the membrane extending from a first membrane end to a second membrane end, the at least one membrane having capillaries extending from the first membrane end to the second membrane end, the at least one membrane having an end seal face at each end;
at least one end cap disposed near at least one of the first or second membrane ends;
a mixing zone disposed between the membrane and the end cap;
the end cap having an outlet defined by an inner radius Rendcap;
the at least one membrane recessed within the housing such that
σ > 0.1 * Rhs 2 /Rendcap; and
where σ is measured from the outlet of the end cap to the end seal face of the membrane, the outlet is fluidly coupled with the mixing zone, and the mixing zone is fluidly coupled with interior portion of the capillaries.
2. The system as recited in claim 1, wherein Rendcap is the smallest outlet of the end cap.
3. The system as recited in claim 1, further comprising potting material disposed within the membrane module directly adjacent to the end seal face of the at least one membrane.
4. The system as recited in claim 1, wherein the end cap is a dome end cap.
5. The system as recited in claim 1, wherein the housing includes one or more side ports fluidly coupled with an exterior portion of the membrane between two potted ends of the membrane module.
6. The system as recited in claim 1, wherein
σ > 0.2 * Rhsg2 /Rendcap.
7. The system as recited in claim 1, wherein
σ > 0.25 * Rhsg2 /Rendcap.
8. A ceramic membrane module system for treating liquid water, the system comprising:
a housing having an exterior portion and an inner portion, the housing extending from a first housing end to a second housing end, the housing having an inner feed radius;
a membrane module including at least one membrane disposed within the housing, the membrane extending from a first membrane end to a second membrane end, the at least one membrane having capillaries extending from the first membrane end to the second membrane end, the at least one membrane having an end seal face at each end; the membrane ;
at least one end cap disposed near at least one of the first or second membrane ends;
a mixing zone disposed between the membrane and the end cap;
the end cap having an outlet defined by an inner radius Rendcap;
the membrane recessed within the housing such that
σ > 4 x 10"5 * area Rendcap ; and
where σ is measured from the outlet of the end cap to the end seal face of the membrane, the outlet is fluidly coupled with the mixing zone, and the mixing zone is fluidly coupled with interior portion of the capillaries.
9. The system as recited in claim 8, wherein Rendcap is the smallest outlet of the end cap.
10. The system as recited in any one of claims 8 - 9, further comprising potting material disposed directly adjacent to the end seal face of the membrane.
11. The system as recited in any one of claims 8 - 10, wherein the end cap is a dome end cap.
12. The system as recited in any one of claims 8 - 11, wherein the housing includes one or more side ports fluidly coupled with an exterior portion of the membrane between two potted ends of the membrane module.
13. The system as recited in any one of claims 8 - 12, wherein the membrane recessed within the housing such that
o > 8 x 10"5 * area Rendcap
14. The system as recited in any one of claims 8 - 13, wherein the membrane recessed within the housing such that
σ > 1 x 10"4 * area Rendcap
15. A method for forming a ceramic membrane module system for treating liquid water, the method comprising:
providing a housing having a membrane therein, the membrane having capillaries therein, the membrane recessed from an end portion of the housing, where the membrane is recessed within the housing such that the inner portion of the housing is fluidly connected to the membrane capillaries; sealing the end portion of the membrane capillaries with the removable gasket;
disposing potting material into the housing at a recessed position from an end of the housing, wherein disposing the potting occurs without plugging the capillaries with the potting, wherein disposing potting material includes disposing potting material through a side port of the housing; and placing the housing in a vertical orientation prior to potting.
16. The method as recited in claim 15, at least one membrane end recessed from at least one housing end a distance Recesshsg
such that an approach angle is:
Φ < 180 - 2arctan(Recesshsg /2RhSg),
where the housing having an inner feed radius RhSg;
17. The method as recited in claim 15, further comprising disposing potting material at an opposite end of the housing.
18. The method as recited in claim 15, further comprising modifying a surface of the housing prior to potting.
19. A ceramic membrane module system for treating liquid water, the system comprising:
a housing having an exterior portion and an inner portion, the housing extending from a first housing end to a second housing end, the housing having an inner feed radius RhSg;
a membrane module including at least one membrane disposed within the housing, the membrane extending from a first membrane end to a second membrane end, the at least one membrane having capillaries extending from the first membrane end to the second membrane end, the at least one membrane having an end seal face at each end;
at least one membrane end recessed from at least one housing end a distance Recesshsg ; at least one end cap disposed near at least one of the first or second membrane ends;
a mixing zone disposed between the membrane and the end cap;
the end cap having an outlet defined by an inner radius Rendcap;
the at least one membrane recessed within the housing such that an approach angle is:
Φ < 180 - 2arctan(Recesshsg /2RhSg) ; and
the outlet is fluidly coupled with the mixing zone, and the mixing zone is fluidly coupled with interior portion of the capillaries.
PCT/US2016/046408 2015-08-10 2016-08-10 Ceramic membrane module with recessed membrane and related methods WO2017027626A2 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
CN201680057825.4A CN108348860A (en) 2015-08-10 2016-08-10 Ceramic film component with recessed film and correlation technique

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US201562203253P 2015-08-10 2015-08-10
US62/203,253 2015-08-10

Publications (3)

Publication Number Publication Date
WO2017027626A2 true WO2017027626A2 (en) 2017-02-16
WO2017027626A3 WO2017027626A3 (en) 2017-05-04
WO2017027626A8 WO2017027626A8 (en) 2017-12-07

Family

ID=56740521

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2016/046408 WO2017027626A2 (en) 2015-08-10 2016-08-10 Ceramic membrane module with recessed membrane and related methods

Country Status (2)

Country Link
CN (1) CN108348860A (en)
WO (1) WO2017027626A2 (en)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2019141498A1 (en) * 2018-01-16 2019-07-25 Nanostone Water Inc. Membrane modules with limited defects and related methods

Family Cites Families (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
NL1013465C2 (en) * 1999-11-02 2001-05-03 Stork Friesland Bv Membrane filtration element with sleeve element and sleeve members.
DE10026344A1 (en) * 2000-04-01 2001-10-04 Membraflow Gmbh & Co Kg Filter Filter module
AU7578701A (en) * 2000-08-02 2002-02-18 Toray Industries, Inc. Hollow yarn membrane module, hollow yarn membrane module unit, and method of producing hollow yarn membrane modules
JP4195824B2 (en) * 2003-03-10 2008-12-17 メタウォーター株式会社 Filtration method
CL2008002533A1 (en) * 2007-10-20 2009-10-09 Porous Media Corp A filter assembly comprising a hollow casing open at least at one end at least one closure member that closes the at least one end, the removable closure member being, at least one tubular plate, one or plus holes or openings, an inlet bimpellent chamber formed in the hollow housing
US20090277826A1 (en) * 2008-05-08 2009-11-12 Pedersen Steven K Hollow fibre membrane module
EP2539052B1 (en) * 2010-02-22 2017-07-26 Nanostone Water GmbH Method for producing a membrane module and membrane module
JP5937569B2 (en) * 2011-03-22 2016-06-22 日本碍子株式会社 Separation membrane structure made of honeycomb-shaped ceramic
CA2834420A1 (en) * 2011-04-25 2012-11-01 Ngk Insulators, Ltd. Method for cleaning ceramic filter using reduced pressure
WO2013054794A1 (en) * 2011-10-11 2013-04-18 日本碍子株式会社 Ceramic filter
WO2014152264A1 (en) * 2013-03-15 2014-09-25 Celgard, Llc Membrane contactors and systems for membrane distillation or ammonia removal and related methods

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
None

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2019141498A1 (en) * 2018-01-16 2019-07-25 Nanostone Water Inc. Membrane modules with limited defects and related methods
CN111867706A (en) * 2018-01-16 2020-10-30 纳诺斯通水务公司 Diaphragm assembly with limited defects and related methods

Also Published As

Publication number Publication date
CN108348860A (en) 2018-07-31
WO2017027626A8 (en) 2017-12-07
WO2017027626A3 (en) 2017-05-04

Similar Documents

Publication Publication Date Title
KR102502797B1 (en) Flexible adjustable membrane cartridges for separation of fluids
US7160455B2 (en) Hollow fiber membrane module
US20020139741A1 (en) Integral gasketed filtration cassette article and method of making the same
US20240198290A1 (en) Ceramic Membrane Filtration Assembly with Multi Port Endcap and Related Methods
WO2004069391A1 (en) Hollow fiber membrane module and module arrangement group thereof
EP2796185A1 (en) Hollow fiber membrane module and casing tube used for same
US7635428B2 (en) Hollow fiber membrane submodule and module including the same
KR20170047249A (en) Hollow fiber membrane module and method for manufacturing hollow fiber membrane module
US20190054422A1 (en) Ceramic Membrane Module with Inflatable Assembly and Related Methods
US10758870B2 (en) Ceramic membrane module with external frame assembly and related methods
WO2017027626A2 (en) Ceramic membrane module with recessed membrane and related methods
US10744464B2 (en) Ceramic membrane module with drive plate and related methods
US7143900B2 (en) Separation device and method of making the same
EP3603775B1 (en) Fluid separating element and telescoping prevention plate
JPH09220446A (en) External pressure type hollow yarn membrane module
KR101414944B1 (en) Structure of hollow fiber membrane bundle arrangement in hollow fiber membrane module
KR101902458B1 (en) Hollowfiber Membrane Moldule
KR102717378B1 (en) Hollow fiber desert module and method for manufacturing hollow fiber desert module
CN216630351U (en) Hollow fiber membrane module
JP2024125762A (en) Hollow fiber membrane module
JP2023119191A (en) Hollow fiber membrane module and hollow fiber membrane module manufacturing method
KR20080103387A (en) Metal wire using membrane

Legal Events

Date Code Title Description
121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 16754087

Country of ref document: EP

Kind code of ref document: A2

NENP Non-entry into the national phase

Ref country code: DE

122 Ep: pct application non-entry in european phase

Ref document number: 16754087

Country of ref document: EP

Kind code of ref document: A2