WO2017070775A1 - Module de filtration de membrane à feuille plate empotée - Google Patents

Module de filtration de membrane à feuille plate empotée Download PDF

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Publication number
WO2017070775A1
WO2017070775A1 PCT/CA2016/051235 CA2016051235W WO2017070775A1 WO 2017070775 A1 WO2017070775 A1 WO 2017070775A1 CA 2016051235 W CA2016051235 W CA 2016051235W WO 2017070775 A1 WO2017070775 A1 WO 2017070775A1
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WO
WIPO (PCT)
Prior art keywords
filtration
membrane
sheets
permeate
potting material
Prior art date
Application number
PCT/CA2016/051235
Other languages
English (en)
Inventor
Ionel John TOMESCU
Alexandru TOMESCU
Original Assignee
Thetis Environmental 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
Priority claimed from US14/926,311 external-priority patent/US20160151743A1/en
Application filed by Thetis Environmental Inc. filed Critical Thetis Environmental Inc.
Publication of WO2017070775A1 publication Critical patent/WO2017070775A1/fr

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Classifications

    • 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
    • B01D63/08—Flat membrane modules
    • B01D63/081—Manufacturing thereof
    • 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
    • B01D63/08—Flat membrane modules
    • B01D63/089—Modules where the membrane is in the form of a bag, membrane cushion or pad
    • 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
    • B01D63/10—Spiral-wound membrane modules
    • B01D63/103—Details relating to membrane envelopes
    • 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
    • B01D65/003—Membrane bonding or sealing
    • 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
    • B01D2313/04—Specific sealing means
    • B01D2313/042—Adhesives or glues
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2313/00—Details relating to membrane modules or apparatus
    • B01D2313/12—Specific discharge elements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2313/00—Details relating to membrane modules or apparatus
    • B01D2313/14—Specific spacers
    • B01D2313/143—Specific spacers on the feed side

Definitions

  • This application relates to membrane modules and methods of making them.
  • Flat sheet membranes are typically made by casting liquid dope onto a substrate.
  • the substrate may be, for example, a woven or non-woven fabric. Pores are formed and the dope is cured into a solid membrane after casting.
  • the pore formation and curing mechanism may be, for example, interfacial polymerization or non-solvent induced phase separation.
  • the resulting flat sheet membrane may have pores in a range from reverse osmosis to microfiltration.
  • Flat sheet membranes are typically used to create spiral wound membrane modules, immersed modules with the membranes in large flat sheets attached to a frame, or in compressed stacks wherein the membranes are intermixed with alternating layers of feed carrier and permeate carrier sheets.
  • a stack is formed of membrane filter elements each having a stabilizing element positioned between outer membrane sheets. The stacked units are sequentially arranged in a housing. A flow medium flows in sequence through the stacked units.
  • Treating a Waste Stream describes an anaerobic reactor coupled with a membrane separation unit.
  • Mixed liquor is pumped from an intermediate portion of the reactor, where the concentration of solids is relatively low, to the membrane separation unit.
  • the mixed liquor is separated by the membrane unit into a permeate stream and a retentate stream.
  • the retentate stream is pumped back to the anaerobic reactor and mixed with the mixed liquor in the reactor.
  • Mixed liquor and relatively heavy solids are pumped from the bottom of the anaerobic reactor to a hydrocyclone.
  • a stream concentrated with heavier solids is sent from the hydrocyclone to a dewatering unit.
  • a lighter solids stream is sent from the hydrocyclone back to the anaerobic reactor.
  • the membrane separation unit uses cross flow tubular membrane modules.
  • a membrane feed pump forces mixed liquor and a recycled portion of the retentate under pressure through the insides of the membranes.
  • the filtration element includes multiple filtration sheets, which are assemblies of a) one or more flat sheet membranes, optionally forming an envelope and b) one or more inserts, one or more permeate carriers, or a combination of one or more inserts and one or more permeate carriers.
  • a filtration sheet may be sealed, optionally by in situ potting, in a housing, alternatively called a shell.
  • the membranes may be, for example, microfiltration (MF) or ultrafiltration (UF) membranes.
  • the filtration element may be used, for example, for water filtration including wastewater filtration.
  • a filtration sheet has an insert on the permeate side of a membrane, a permeate carrier (alternatively called a permeate spacer) on the permeate side of a membrane, or both.
  • the insert if any, is stiffer than a permeate carrier
  • an insert is optionally solid, or non-porous, with smooth surfaces or optionally with one or more surfaces that provide channels for permeate flow across the surface of a non-porous central part of the insert.
  • two membranes (which may be two parts of a single folded membrane) are attached to or around an insert, or to or around a permeate carrier, or to or around a combination of one or more inserts and one or more permeate carriers, to provide a filtration sheet having a sealed interior, or permeate side.
  • the outer, or feed, side of the filtration may be exposed to feed water channels within the filtration element.
  • Feed spacer material in the feed water channels is optional, but not used in the examples illustrated.
  • turbulence may be provided in the feed water channels without a feed spacer by way of feed cross flow, i.e. pumped re-circulated feed flow, in a manner similar to tubular membranes.
  • a filtration element typically has a plurality of filtration sheets.
  • the inserts, if any, and permeate carriers, if any, define part of a permeate side of a filtration sheet and, collectively, of a filtration element.
  • the inserts may include passages for taking permeate to edges of the filtration sheets, or passages for taking permeate to edges of the filtration sheets may be provided by permeate spacers, or both.
  • two membranes are bonded together to form an envelope around an insert and two permeate carriers.
  • no insert is used and a permeate carrier, bonded or not to the backing of the membranes, is introduced between the membranes.
  • the filtration sheets are potted in the filtration element, optionally at one or both ends of the filtration sheets.
  • potting material usually a thermosetting resin, separates the permeate side of the element from its feed side. Permeate is collected on a permeate side of the potting material.
  • permeate passages may be opened after potting, for example by cutting a notch through the potting material and the filtration sheets.
  • a filtration sheet is reinforced at an interface with potting material.
  • the reinforcement may be provided by an additional reinforcing or stiffening element, or integrally be allowing potting material into the filtration sheet.
  • a filtration sheet adapted for integral reinforcing includes a permeate tube.
  • the permeate tube is used to convey permeate collected on the permeate side of a filtration sheet through a potted region of the filtration sheet.
  • the permeate side of the filtration sheet may be filled with potting material in the potted region outside of the permeate tube.
  • the flat sheet membrane is oriented with a separation layer on the inside of a filtration sheet and a substrate on the outside of the filtration sheet.
  • a protective layer which may be in the form of an envelope, may be provided inside of the separation layer.
  • the filtration sheets are potted in a centrifuge.
  • the centrifuge may be arranged such that the potting material is applied to only part of the edge of a membrane.
  • generally rectangular filtration sheets are potted in a centrifuge spinning about a vertical axis with only enough potting material to cover corners of the membranes.
  • the elements may be used, for example, in a cross flow membrane process.
  • the feed side pressure is preferably below 2 bar, optionally below 1 bar.
  • the module may be used in a system and process as described in International Application No. PCT/CA2015/050412 filed on May 8, 2015, published as International Publication Number WO 2015/168801 A1 on November 12, 2015. BRIEF DESCRIPTION OF THE FIGURES
  • Figure 1A is a cross section of part of a first alternative filtration sheet that has bonded membranes without tape, an insert and permeate carriers.
  • Figure 1 B is a cross section of part of a second alternative filtration sheet that has bonded membranes with tape, an insert and permeate carriers.
  • Figure 1C is a cross section of part of a third alternative filtration sheet that has bonded membranes with tape, a permeate carrier and no insert.
  • Figure 1 D is a cross sections of part of a first alternative continuous filtration sheet having membranes bonded with a single strip of tape.
  • Figure 1 E is a cross section of part of a second alternative continuous filtration sheet having membranes bonded with two tape strips.
  • Figure 1 F is a plan view of a continuous filtration sheet according to Figure 1 D or Figure 1 E.
  • Figure 1G is a cross section of part of a fourth alternative filtration sheet that has a membrane facing inwards, a permeate carrier and additional layers of substrate material between the membranes and the permeate carrier.
  • Figure 1 H is a cross section of a fifth alternative filtration sheet having a membrane with its skin facing inwards and a flat taped seam.
  • Figure 11 is a cross section of a sixth alternative filtration sheet having a membrane with its skin facing outwards and folded taped seams.
  • Figure 11 is a cross section of a sixth alternative filtration sheet having a membrane with its skin facing inwards and folded taped seams.
  • Figure 2A is a cross section of part of an eighth alternative filtration sheet having membranes bonded to an insert.
  • Figure 2B is a cross section of part of a ninth alternative filtration sheet that has membranes bonded to an insert through permeate carriers.
  • Figure 3A is an isometric view of a filtration sheet according to Figure 2 with a cutout.
  • Figure 3B is an isometric view of a filtration sheet according to Figure 2 without a cutout.
  • Figure 4 is an isometric view of a bundle having filtration sheets according to
  • Figure 2 two end caps and a spacer ring.
  • Figure 5A is an isometric view of the end cap shown on the left side of the bundle assembly of Figure 4.
  • Figure 5B is an isometric view of the end cap shown on the right side of the bundle assembly of Figure 4.
  • Figure 6A is an isometric view of one half of the spacer ring of the bundle assembly of Figure 4 showing primarily the inside of the spacer ring.
  • Figure 6B is another isometric view of the half spacer ring of Figure 6A showing primarily the outside of the spacer ring.
  • Figure 7A is a longitudinal cross section of a filtration module having the bundle assembly of Figure 4 in a housing.
  • Figure 7B is an enlarged view of part B of Figure 7A.
  • Figure 8 is a schematic cross-sectional view of a filtration module as in Figure
  • Figure 9 is an enlargement of the bottom of Figure 7A showing details, in cross section, of part of the filtration module of Figure 7A including inserts used with a dynamic potting method.
  • Figure 10A is a cross sections of one end of an alternative filtration module showing inserts used with a static potting method.
  • Figure 10B is another cross section of the end of the alternative filtration module of Figure 10A, the section line in Figure 10B being perpendicular to the section line in Figure 10A.
  • Figure 10C is an isometric view of the sectioned end of the alternative filtration module shown in Figures 10A and 10B.
  • Figure 11 A is an isometric view of half of an alternative spacer ring.
  • Figure 11 B is an isometric view of two of the half spacer rings of Figure 11 A joined together to form a complete spacer ring.
  • Figure 12 shows, in cross section, a continuous filtration sheet as shown in
  • Figures 1 D, 1 E and 1 F bent around optional support rods having a round cross sectional shape and also showing examples of support rods of alternative shapes being a "U" shape and two variants of a "V" shape.
  • Figure 13A is a schematic drawing of a bundle of filtrations sheets being potted in a centrifuge with the filtration sheets oriented vertically.
  • Figure 13B is a schematic drawing of a bundle of filtrations sheets being potted in a centrifuge with the filtration sheets oriented horizontally.
  • Figure 14 is a cross section of part of a module made by potting as in Figure
  • Figure 15 is a cross section of another alternative filtration sheet having a permeate tube.
  • Figure 16A is an enlarged version of the right side of Figure 15.
  • Figure 16B is a variation of Figure 16A having an integral permeate tube.
  • Figure 17 is a vertical cut cross section of a module made with a filtration sheet as in Figure 15.
  • Figure 18 is a horizontal cut cross section of the module of Figure 17 along cut line A-A of Figure 17.
  • Figure 19 is an isometric view of a filtration sheet with a stiffening sheet.
  • Figure 20 is a cross section of the filtration sheet of Figure 19 cut along line A- A in Figure 19.
  • Figure 21 is a schematic drawing elevation view of part of a module made with filtration sheets as in Figure 19.
  • Figure 22 is a cross section of the module of Figure 21 cut along line A-A in
  • Figure 23 is a cross section of the module of Figure 21 cut along line B-B in
  • Figures 1A to 1J, 2A and 2B each represent a cross section of a filtration sheet (10), alternatively called a permeate sheet.
  • the filtration sheet (10) has one or more flat sheet membranes 14.
  • the filtration sheet (10) is configured such that, at least when the filtration sheet (10) is potted, a membrane 14 separates the inside, alternatively call the permeate side, of the filtration sheet (10), from the outside, alternatively called the feed side, of the filtration sheet (10).
  • the membrane or membranes (14) are typically formed into an envelope, which in this document refers to a structure having a fold or seal on at least two edges of a membrane (14) sheet.
  • the membrane (14) may have pores in the microfiltration or ultrafiltration range.
  • the membrane (14) may be a flat sheet membrane (14) made by any method or materials known in the art.
  • a membrane (14) may be made, for example, by casting one or more reactive solutions (commonly called "dope") onto a non-woven substrate.
  • liquid membrane dope is cast onto a substrate and then quenched, for example in a liquid bath, to solidify the dope and form pores in it.
  • the process can be according to a non-solvent induced phase separation (NIPS) or a thermally induced phase separation
  • the substrate may be a non-woven fabric as is typically used for forming flat sheet membranes.
  • the membrane (14) may be asymmetric, with a separation layer (alternatively called a skin) having pores sized to provide the desired level of filtration (for example microfiltration or ultrafiltration) on one side of the membrane material (i.e.
  • a more porous membrane material is embedded in the substrate and a less porous membrane material is cast over the more porous membrane material to form the skin.
  • the skin is preferably outside of the substrate but the remaining membrane material may be embedded in some or all of the thickness of the substrate.
  • the filtration sheet (10) also has one or more inserts (1 1), one or more permeate carriers (12) (alternatively called permeate spacers), or one or more inserts (11) and one or more permeate carriers (12).
  • Figures 1 A and 1 B show examples of filtration sheets (10) having an insert (11) and two permeate carriers (12).
  • Figure 1C shows a filtration sheet having a permeate carrier (12) used without an insert (1 1).
  • the membranes (14) are bonded to each other to form an envelope around the insert (1 1) or permeate carrier (12) or both.
  • An insert (11) is stiffer than a conventional permeate carrier (12).
  • the insert (1 1) may be made of a single piece of material, for example a
  • the insert (11) may optionally be non- porous.
  • the inserts (11) are solid, smooth surfaced, non-porous sheets of plastic, typically 0.3 to 3mm thick.
  • Assembly of the filtration sheet (10), in particular bonding of the membranes (14), can be done using welding with a seam tape.
  • This tape (30) can be of various widths, typically between three and ten millimeters, and will be added along one or more edges of the filtration sheet (10) between the flat sheet membranes (14).
  • the tape (30) is activated with the heat produced by various means like direct heat, RF, impulse, sonic welding or other means during the welding process.
  • the tape (30) may be made of different materials to suit the various technical requirements for welding, as well as various operational parameters such as: type of filtered fluid, chemical and physical characteristics of the filtered fluid and its contaminants, temperature, cleaning methods, etc.
  • the tape (30) can be applied to separate membrane sheets (14) as shown in Figure 1 B to provide a discrete filtration sheet (10), or with additional welds spanning between two edges to form a continuous filtration sheet (10) with a plurality of envelopes, each surrounding an insert (1 1) and permeate spacer (12), as shown in Figures 1 D, 1 E and 1 F.
  • the skin of the membranes (14) may face towards the inside or the outside of the filtration sheet (10). Having the membranes (14) face towards the inside of the filtration sheet (10) allows the filtration sheet (10) to be backwashed at a higher pressure without the membrane skin delaminating from the rest of the membrane (14).
  • the membranes (14) preferably have membrane material extending through most, for example at least 50% or at least 80% or at least 90%, of the thickness of the substrate to help prevent formation of a persistent fouling layer or biofilm in the substrate.
  • a protective layer optionally in the form of an envelope, is preferably provided between the membrane skin and a permeate carrier (12) or insert (11).
  • FIG. 2C shows an example of a filtration sheet (10) made with the skin of membranes (14) facing towards the inside (permeate side) of the filtration sheet (10).
  • Protective layers are provided by sheets of substrate fabric (44). These sheets may be made of the same substrate fabric used to make the membranes (14), or a similar material, but without membrane material cast onto or into them.
  • the edges of two membrane sheets (14) are joined together by a non-porous strip (46) bonded to the membrane sheets (14).
  • tape 30 as described in Figures 1A, 1 B or 1C could be used, but placed around the outsides of the membranes (14) rather than between them.
  • Figure 1 H shows another example of a filtration sheet (10) having a membrane (14) with its skin facing inwards.
  • an envelope is made by folding a membrane (14) twice and sealing the edges of the membrane (14) to each other.
  • the seal is made with a piece of tape 30 and a strip of membrane (14) with its skin facing outwards.
  • the substrate side of a membrane (14) contacts both sides of the tape
  • Figure 11 shows another example of a filtration sheet (10) having two membrane (14) sheets with their skins facing outwards. The edges of the membrane (14) are sealed to each other with strips of tape 30 and a bent strip of membrane (14) with its skin facing inwards.
  • Figure 1J shows another example of a filtration sheet (10) having a membrane (14) with its skin facing inwards.
  • an envelope is made with two sheets of membrane (14). The edges of the membrane (14) are sealed to each other with strips of tape 30 and a bent strip of membrane (14) with its skin facing outwards.
  • an additional layer or envelope of substrate fabric (44) could be added as shown in Figure 1G. In examples with a membrane (14) facing inwards, the flow of water is still from the outside of the filtration sheet (10) to the inside of the filtration sheet (10).
  • the membranes (14) can be bonded, for example by adhesive or welding, to an insert (11) as shown in Figures 2A and 2B.
  • the membranes (14) are bonded to one or more edges of the insert (11) and optionally at other places on the insert (1 1). In these examples, the membranes (14) are not bonded directly to each other.
  • Figure 2A shows one option in which membranes (14) extend beyond the permeate carriers (12) and are bonded directly to the insert (1 1).
  • the bond shown in Figure 2A is provided by an adhesive (40) but another form of bonding could be used.
  • Figure 2B shows another option in which the membranes (14) are bonded to an insert (11), for example by welding (42) or by an adhesive, that passes through permeate carriers (12).
  • An insert (11) is a relatively rigid component manufactured from one or more materials such as plastic, metal, fiber reinforced plastic (FRP) or sintered plastic or metal.
  • a filtration sheet (10) may have a structural insert (1 1) and a membrane (14).
  • the insert (11) serves as a support for a flat sheet membrane (14).
  • the insert (11) may also serve as a carrier for the filtered liquid (permeate). In this case, the side faces of the insert
  • the insert (1 1) have a recessed or textured surface that can be obtained through machining or directly in an injection-molding tool.
  • the surface can include channels in a single orientation, multiple orientation, random directions, a rough or textured surface or any other surface that will create a space between the membrane (14) and the insert (11) allowing the filtered liquid to flow towards one or more edges of the insert (11).
  • the insert (11) can also be a porous metal.
  • a permeate spacer (12) may be placed between the membrane (14) and the insert (1 1), or the permeate spacer (12) may replace the insert (12) altogether.
  • the insert (11) may optionally have a smooth surface.
  • a membrane (14) can be attached to an insert (11) for example by gluing or welding.
  • the welding may be done by various methods, like ultrasound, radiofrequency, direct heat, or impulse heat.
  • the attachment may be continuous around the circumference of the membrane.
  • the membrane (14) is not attached to the insert (11) along one or more permeating edges.
  • the membrane (14) can be folded around one edge or multiple edges of the insert (11), attached to the insert (1 1) along two or more edges of the insert (1 1), or attached at any point on the insert (1 1).
  • the membrane (14) can be left open along at least part of at least one permeating edge of the insert (1 1).
  • the membrane (14) can be held in place on a permeating edge of the insert (11) by mechanical means or by a discontinuous line of adhesive or welding until the next assembly operation.
  • the backing surface of the membrane (14) between its edges may or might not be permanently attached to the insert (11).
  • the membrane (14) can be either a flat sheet membrane casted separately and attached to the structural insert (11) or a membrane formed directly on the structural insert (1 1). If the insert (1 1) is made at least partially from a porous material, the membrane (14) can be coated directly on the insert (1 1) using any membrane forming method known in the art.
  • the insert (1 1) and membrane (14) optionally have one or more raised edges.
  • the insert (11) and membrane (14) may be essentially planar.
  • a feed spacer can also be bonded to the membrane
  • a membrane (14) may be provided on only one side of an insert (1 1).
  • Figures 3A and 3B are isometric views of the filtration sheets (10) of Figure 2.
  • the optional cutout (13) in the membrane filtration sheet (10) is for the spacer rings (19) described below and may or may not be required.
  • Figure 3A is an isometric view of the filtration sheet (10) of Figure 2 with the cut-out (13) for the spacer rings (19), while Figure 3B is an isometric view of the filtration sheet (10) of Figure 2 without the cutout.
  • FIG 4 is an isometric view of a bundle (15) having a plurality of the filtration sheets 10 of Figure 2.
  • the filtration sheets (1 1) can be assembled together using mechanical fasteners, adhesives or, preferably, by potting them together.
  • optional feed spacers, end-caps (18) and spacer rings (19) may be placed in between the filtration sheets (10) as shown in Figure 4.
  • the filtration sheets (10) have different widths so that the bundle (15) can be mounted inside of a cylindrical housing.
  • the end-caps (18) are shown in more detail in Figure 5A and Figure 5B.
  • the end caps (18) may be fitted at one or both ends of the bundle (15).
  • the end-caps (18) have openings for the feed or retentate fluid to pass through.
  • the purpose of the end caps (18) is to protect the edges of the filtration sheets (10) and to provide for consistent spacing between the membrane filtration sheets (10).
  • spacer ring (19) is shown in more detail in Figures 6A and 6B.
  • One or more feed spacer rings (19) of different lengths and configurations may be attached to the bundle (15) along the length of the bundle (15).
  • the optional end-caps (18) and spacer rings (19) may be made from one or more materials such as plastic, metal, fiber reinforced plastic (FRP) or sintered plastic or metal, and may be manufactured through different methods, such as machining, extrusion, water-jet cutting, vacuum forming, or directly in an injection-molding tool.
  • FRP fiber reinforced plastic
  • Figures 1 1A and 1 1 B show a longer spacer ring (19) that has been manufactured by vacuum forming in two halves.
  • the two halves of the spacer ring (19) are joined together during assembly of the bundle (15).
  • the filtration sheets (10) fit into notches in the spacer rings (19) so that the filtration sheets (10) are spaced apart and supported during assembly and potting, as well as during use as a filter.
  • a spacer ring (19) can be manufactured in one piece by extrusion.
  • the spacer ring (19) may occupy up to all of the length of the bundle (15) between the end caps (18).
  • the length of the spacer ring (19) and the number of spacer rings (19) used may be selected based on technical, manufacturing, or economic considerations.
  • rods (35) can be placed in between the filtration sheets (10), or between envelopes of a continuous filtration sheet (10) for support and to help maintain adequate and consistent spacing between consecutive filtration sheets (10) or envelopes, as shown in Figure 12.
  • the rods (35) can be made in various shapes such as round, "U” or “V” shaped type rods (35).
  • the length of the rods (35) may extend the entire length of a module in between the end-caps (18).
  • the rods (35) may be made from one or more materials such as plastic, metal, fiber reinforced plastic (FRP) or sintered plastic or metal, and may be manufactured through different methods, such as extrusion or vacuum forming.
  • FRP fiber reinforced plastic
  • Spacer rings (19) may be used to help hold the membrane (14) against the structural insert (11) or to prevent adjacent filtration sheets (10) from flexing into contact with each other.
  • spacers (19) or attaching the membranes (14) to the inserts (11) as in Figure 2 allows backwashing the membranes (10).
  • a pillowing effect of the membrane (14) in between the spacers (19) may be observed, but the pressure levels required for backwashing can be low enough to not jeopardize the membrane integrity.
  • the spacers (19) are optional and can also be omitted, particularly in applications not requiring backwashing or if an alternative means (such as an adhesive or sonic welding) is used to attach the membranes (14) to various points dispersed across the surface the inserts (11).
  • one end of a bundle (15) is potted, or the filtration sheets (10) are not potted on one end of a bundle (15), to form a dead end (i.e. a non-permeating end) and the other end of the bundle (15) is potted to form a permeate end.
  • a dead end i.e. a non-permeating end
  • the other end of the bundle is potted to form a permeate end.
  • a dead end does not need to be attached to a housing and so allows the filtration sheets to freely expand or contract.
  • Figures 13A and 13B show filtration sheets (10) potted in a centrifuge.
  • a set of filtration sheets (10) (only one is shown) have varying widths such that they collectively fit inside of a cylinder with the edges of each permeate sheet 42 optionally being at least close, for example within 10 mm of, the inside of the cylinder.
  • a mold covers at least the ends of the filtration sheets (10).
  • spacers (70), or other devices such as jigs attached to the centrifuge, may be used to help stabilize the filtration sheets (10) in the mold.
  • liquid potting material (16) in the mold is thrown against the sides of the mold and forms a ring having the cross sectional shape shown in Figure 13A.
  • the potting material (16) covers the corners of the filtration sheets (10) and is allowed to harden in this location. After one end of the filtration sheets (10) is potted, the other end of the filtration sheets (10) may optionally also be potted by inverting them in the centrifuge and repeating the process. In another option, the other end of the filtration sheets (10) are not potted.
  • the spacers (70) may be removed or not after the potting material (16) hardens.
  • a set of filtration sheets (10), which optionally all have the same width and length, are placed, spaced apart, in a centrifuge with a mold at one, or optionally both, ends of the filtration sheets (10).
  • the filtration sheets (10) are rotated around an axis (74) perpendicular to the length of the filtration sheets (10) that may be horizontal or vertical.
  • Potting material (16) covers the ends of the filtration sheets (10) and is allowed to harden in this location.
  • the potted filtration sheets (10) may be sealed into a housing or used as an essentially complete immersed membrane filtration element to be immersed when in use in an open tank of water to be treated.
  • a hole (76) drilled through the potting material (16) after it hardens provides a permeate withdrawal port.
  • Figure 14 shows one end of a cylindrical module (80) made with filtration sheets (10) potted as in Figure 13A and then inserted into a tube (82).
  • the potting material (16) is bonded to the inside of the tube (82) or directly to a cap (88).
  • the other ends of the filtration sheets (10) may be similarly potted and bonded to the tube (82) or cap (88), with or without the ability to withdraw permeate from them, or un-potted and left un-connected to the tube (82) or not surrounded by a tube (82).
  • the tube (82) may be porous or omitted.
  • Spacers (70) are optionally left in the tube (82), if any, or may be removed.
  • the spacers (70), if used can help restrain movement of the filtration sheets (10), particularly in very long modules (80).
  • a groove (84) is cut into the potting material (16) around part of the circumference of the module (80) after the filtration sheets (10) are potted.
  • the groove (84) passes through the tube (82), if the tube (82) is provided and optionally extends across the area of the groove (84), and penetrates into the potting material (16).
  • the groove (84) also creates notches in the filtration sheets (10), which exposes the permeate carriers (12) or insert (11) or both of the filtration sheets (10) to the groove (84).
  • a second groove (86) may also be cut into the potting material (16) or tube (82) to provide increased area for permeate to flow around the circumference of the tube to a permeate port (27).
  • a second groove (86) may be used in combination with holes drilled through the tube (82) or potting material, at least one hole passing though each filtration sheet (1 1), to connect the permeate sides of the filtration sheets (1 1) with the second groove (86).
  • One or more permeate ports (27) through the cap (88) in communication with the groove (84) provide ports for permeate to be withdrawn.
  • a hole (92) in the cap (88) in communication with spaces between the filtration sheets (10) allows water or air to enter into, or leave from, the cap (88).
  • Figure 7A is a longitudinal cross section of a cylindrical module (8) with the bundle (15) of Figure 4 that has been potted.
  • Potting material (16) can be either thermoset or thermoplastic. Potting is the preferred method of holding the filtration sheets (10) together. Prior to potting, slot inserts (21) may be fitted in-between filtration sheets (10) to allow for openings in the potting material. The number and shape of the slot inserts (21) may be determined by the number of filtration sheets (10) selected, the actual size of the module (8), the housing geometry, and the potting method, dynamic or static. Regardless of the slot inserts characteristics, the goal is to create openings through which feed or retentate fluid can enter and exit the feed channels (17) created between the filtration sheets (10). Once the potting material (16) is completely cured, the slot inserts (21) are removed. Potting may be achieved either dynamically, by spinning the module in a centrifuge, or statically, without spinning.
  • Dynamic potting of the corners of the filtration sheets (10) is performed by placing the module (8) with the bundle (15) inserted into the housing (20) (or other mold as discussed above) in a generally vertical orientation inside a centrifuge, pouring the potting material (16) in liquid form into the lower end of the housing (20), and spinning at a predetermined rate in order to achieve the desired distribution of potting material (16).
  • the liquid potting material (16) can be present in the housing (20) before the housing (20) beings spinning, but it is preferable for the housing (20) to be already spinning before the potting material is added.
  • the potting material is dispersed in a rotational ellipsoid which appears as two triangles when viewed in cross section, as shown in particular in Figure 7B and in Figure 9.
  • the hardened potting material (16) may be called a ring.
  • the g-forces are moderate compared to conventional centrifugal potting such that the potting material (16) is not dispersed along the entire sidewall of the housing (20).
  • the potting process also tolerates a centrifuge oriented somewhat off of an exact vertical orientation. After one end is potted, the module (8) is optionally inverted in the centrifuge and the other end is potted.
  • the potting in vertical configuration may also be employed to produce other geometries, as required.
  • FIG. 10A, B and C show details of the filtration module (8) with slot inserts (21) fitted between the filtration sheets (10). Potting material (16) in liquid phase is poured into the housing (20) at one end of the bundle (15) and left to cure for a certain amount of time. The opposite end of the module bundle (15) is potted after potting the first end is finished and the potting material (16) is cured to a solid.
  • slot inserts (21) are used between each of the filtration sheets (10) and between the filtration sheets (10) and the housing (20).
  • the slot inserts (21) are removed after the potting material (16) is cured. Removing the slot inserts (21) creates passages or openings in the potting material (16) for the fluid being filtered to enter and exit the feed channels (17) between the filtration sheets (10) or between the filtration sheets (10) and the housing (20).
  • feed channels (17) By placing the filtration sheets (10) side by side but with spacing between their central areas, a number of feed channels (17) are formed inside the bundle (15).
  • the feed channels (17) have a generally rectangular shape but with narrowed ends formed by the shape of the potting material (16) between the filtration sheets (10). Spacing between the filtration sheets (14) can also be "V" shaped, as opposed to rectangular.
  • the feed channels (17) may have a cross section that is oval, arcuate, elliptical, round, rectangular or square.
  • Various cross sectional shapes of the feed channels can be achieved by altering the design of the inserts (1 1) or spacer rings (19).
  • FIG 8 is a schematic cross sectional view of the module (8) of Figure 7 in an elevation view and showing fluid flow through the module (8).
  • Liquid to be filtered is typically fed by means of pressure, for example using a pump or simply a head pressure. Liquid flows from the feeding end (25) through the feed channels (17) to the discharge end (26). Baffles may be added in the housing (20) as required to induce flow through the feed channels (17). The pressure differential between the feed side and the permeate side will force the liquid through the membranes (14) of the bundle (15). Permeate (filtered liquid) will then flow through passages, such as openings, channels or pores, of the inserts (11) or permeate carriers (12) towards the edges of the filtration sheets (10). In Figure 8, permeate is collected at both ends of the bundle (15). Alternatively, permeate may be collected at one end of the bundle (15) only, rather than at both ends. The choice may depend on the intended use or application of the module (8).
  • the permeate carriers (12) of the filtration sheets (10) are in fluid communication with the permeate channel (22).
  • a cap (28) adhered or otherwise sealed onto the end of the housing (20) encloses the permeate channel (22).
  • One or more permeate ports (27) in the cap (28) are in fluid communication with the permeate channel (22).
  • Permeate flows into the permeate channel (22) and out the permeate port (27).
  • the permeate carrier (12) When used for ultrafiltration or microfiltration, the permeate carrier (12) does not need to be able to resist pressures as high as the pressures applied, for example, to reverse osmosis modules.
  • the maximum transmembrane pressure (TMP) might be, for example, 40-100 kPa.
  • a highly pressure resistant permeate carrier (12) such as a tricot fabric commonly used in reverse osmosis membranes, may be used but is not required.
  • a woven or expanded plastic diamond mesh material may be used.
  • reverse osmosis feed carrier material may be used as the permeate carrier, or another suitable material selected or made.
  • Such a permeate carrier (12) offers less resistance to permeate flow compared to a tricot fabric.
  • the maximum TMP may be higher, for example 120 to 200 kPa.
  • the permeate carrier (12) may be compressed in use. In some cases, movement of the permeate carrier (12) at or near the interface with the potting material (16) can cause cracks in the membrane (14) or delamination of the membrane skin. If required, a more pressure resistant permeate carrier (12), for example tricot fabric as used in reverse osmosis modules, can be used.
  • the more compression resistant material can be used throughout the entire filtration sheet (10) or, alternatively, only in parts of the filtration sheet that will be at or near the interface with the potting material (16) is potted, in combination with another material such as a mesh used in other parts of the filtration sheet (10).
  • the permeate carrier (12) is filled with potting material (16) or omitted at or near the interface with the potting material
  • a tube or other conduit is inserted into the filtration sheet (10).
  • the tube connects a porous region of the permeate carrier (12) with the outside of the module (8) and provides a path for permeate to be withdrawn from the filtration sheet (10).
  • FIGs 15 to 18 show an alternative filtration sheet (10) and module (8).
  • the filtration sheets (10) are potted at one end only. The other ends of the filtration sheets (10) are individually sealed and free floating.
  • Feed water flows into the housing (20) from the potted end between the filtration sheets (10).
  • the flowing water separates adjacent filtration sheets (10) from each other.
  • the spacing between filtration sheets (10) downstream of the potting material (16) may vary from the spacing in the potting material (16).
  • the filtration sheets may flap, sway or vibrate in the current, which may help prevent fouling.
  • the water pressure on either side of the filtration sheets (10) is allowed to equalize itself, which may reduce mechanical forces on the filtration sheets (10).
  • the filtration sheets (10) are potted directly in the housing (20) in a centrifuge. As described above, a channel (22) cut into the module housing (20) and through the potting material (16) into the filtration sheets (10) creates a path for permeate to leave the module (8). Permeate is collected either by pressurizing the feed side of the filtration sheets (10), applying a vacuum to the permeate side of the filtration sheets (10) or a combination of the two.
  • a permeate port as described above can be obtained by placing a cap (28) (not shown) over the permeate channel (22).
  • the cap (28) has a permeate port (27) that connects to either a permeate pump or directly to the permeate tank.
  • the filtration sheets (10) in this module (8) can be made according to any of the examples described above.
  • a filtration sheet (10) can be made as shown in Figures 15 and 16 using an inner protective envelope or layers, an outer membrane envelope and a permeate carrier.
  • the inner envelope or layers contains the permeate carrier (12).
  • This envelope or layers may be made of non-woven material such as flat sheet membrane substrate material (44).
  • the outer envelope is made of a membrane (14) coated on a nonwoven material, with the membrane skin facing the inner envelope.
  • the filtration sheets (10) are reinforced with potting material (16) on the inside of the filtration sheets (10) at or near the interface with the potting material (16) on the outsides of the filtration sheets (10).
  • One or more permeate tubes (2) are included inside the inner or outer envelope. In this configuration the potted end of the outer envelope and optionally the inner envelopes can be unsealed such that, during potting, potting material 16 can flow inside the permeate sheet (12). The length of the permeate tubes (2) exceeds the height of the potting material (16). Before potting, the ends of the permeate tubes (2) closer to the end of the module (8) is blocked (i.e. welded, glued or plugged).
  • each filtration sheet (10) can have one or two permeate tubes (2) placed at the edge or edges of the filtration sheet.
  • the permeate tubes (2) have a length and position such that a non-permeable portion of the permeate tube (2) extends at least from the permeate channel (22) to beyond the height of the potting material.
  • a permeable portion of the permeate tube (2) may extend further.
  • the permeate tube (2) can optionally be as long as the filtration sheet (10).
  • a permeate tube (2) is made integrally by applying a strip of sealant (9) inside the filtration sheet (10).
  • the strip of sealant (9) extends upwards from the end of the filtration sheet (10) to above the height of the potting material.
  • sealant also extends from the position shown in Figure 16A to the corner of the filtration sheet (10) this sealing the end of the integral permeate tube (2).
  • Another integral permeate tube (2) may be made in the other side of the filtration sheet (1). The end of the filtration sheet between the integral permeate tubes (2) is otherwise left open.
  • filtration sheets (10) and modules (8) as described above may be made without the inner envelope.
  • the membrane skin can face inwards towards the permeate carrier (12) or outwards towards the feed side of the module (8).
  • the permeate tubes (2) are inserted into the outer envelope next to the permeate carrier (12).
  • the end of the filtration sheet (10) is open such that potting material can flow into the permeate carrier (12) in the area of the potting material (16).
  • the permeate tubes (2) are opened to the permeate channel (22) after the potting material (16) hardens.
  • FIGS 19 to 23 show another module 8 with filtration sheets (10) reinforced at or near an interface with the potting material (16).
  • the reinforcement is provided by an additional element, for example a stiffening part such as stiffening sheets (90) as shown, placed outside of the filtration sheets (10).
  • the stiffening sheets (90) extend upwards to a height or elevation (92), which can be between about 40% and 90% of the height of the potting material (16).
  • the module (8) of Figures 19 to 23 may be potted in one end as in the module (8) of Figures 15 to 18. Alternatively, either of these modules could have filtration sheets (10) potted at both ends.
  • the stiffening sheets (90) are more rigid than the filtration sheets (10).
  • the stiffening sheets (90) may help disperse loads applied to the filtration sheets (10) at or near the edge of the potting material (16) in use.
  • the stiffening sheets (90) may be manufactured from one or more materials such as plastic, metal, fiber reinforced plastic (FRP).
  • the stiffening sheets (90) are placed on the outside of the filtration sheet (10), preferably in the potting area, the potting area being an area where potting material (16) is expected to be.
  • the stiffening sheets (90) may be, for example, between 0.5 mm and 1 mm in thickness.
  • the stiffening sheets (90) are optionally bonded to the filtration sheet (10), for example using any method of making seams in the filtration sheets (10).
  • the stiffening sheets (90) may be bonded to the membranes (14) using seam tape (30) or through direct heat welding, ultrasonic, RF or hot melt sealing.
  • a stiffening sheet (90) may optionally be placed on one side or both sides of the filtration sheet (10). In the example of Figures 19 and 20, stiffening sheets (90) are placed on both sides of a filtration sheet (10).
  • Figures 21 to 23 show a bundle of filtration sheets (10) assembled for centrifugal potting.
  • the filtration sheets (10) have stiffening sheets (90).
  • a stiffening sheet (90) may help compress the filtration sheet (10) in a potting mold (which may be a a housing (20)) or stiffen the filtration sheet (10) in the potting area or both. This helps ensure that the filtration sheets (10) do not change shape or thickness during potting or during normal operation of the module (8).
  • the stiffening sheets (90) are left embedded in the potting material (16) after potting.
  • An end cap (18) may also be used as described above. The stiffening sheets (90) can be inserted partway into the end cap (18), but against the end cap (18) or being slightly beyond the end cap (18).
  • the bundle of filtration sheets (10) may be formed by alternating filtration sheets (10) and spacers (70).
  • the bundle may be held together by a band or clamp (not shown) applied to the bundle before potting, by a jig (not shown) in the mold, or by adding an end cap (18) as described above with the spacers (70) extending into the feed water openings of the end cap (18).
  • the spacers (70) can be wider or thicker or both above the potting area so as to provide, with the filtration sheets (10) between them, an interference fit with the housing (20).
  • the spacers (70) are about as long as the filtration sheets (10). However, the spacers (70) are narrower than the filtration sheets (10) at least in the potting area. The end of the spacers (70) may have a V-shape in elevation view to correspond with the V-shape of a section through the potting material.
  • the centrifuge is spinning as liquid potting material (16) is added to the mold. The potting material (16) is forced outwards as it enters the mold and does not contact the spacers (70).
  • the spacers (70) press against (i.e. compress) the filtration sheets (10) when the bundle is banded or clamped or inserted into an end cap (18) or mold for potting.
  • the stiffening sheets (10) are preferably rigid enough so that the compressive forces applied by the spacers (70) in the middle of the filtration sheet (10) (i.e. inside of the ring of potting material (16)) can be transferred to the portion of the filtration sheets (10) that will be buried in the potting material (16).
  • the spacers (70) as described above are removed after potting.
  • the spacers (70), or a portion of the spacers (70) in the potting area could remain in the potting.
  • the spacers (70) could be corrugated or have passages though them such that feed water can pass through the spacers.
  • a single part that will remain in the potting material (16) could replace the spacer (70) and one or two stiffening sheets (90) between two filtration sheets (10).
  • a module as described herein may be used immersed in an open tank or in an enclosed, optionally pressurized, housing or larger vessel, in a cross flow or dead end configuration.
  • Cross flow through a modular housing, for example housing (20) is the preferred method. This inhibits suspended solids from concentrating on the membrane surfaces as concentration polarization (even without feed spacers) and provides better control of the retentate concentration. In order to prevent premature degradation of the module performance, the pressure difference may be monitored continuously.
  • the feed water to be filtered may have a high concentration of solids, for example 1000 mg/L or more.
  • solids is used loosely and can include a separable liquid or gel phase.
  • the solid may be droplets of bitumen, oil or another organic compound.
  • the solid may be particles of fat or grease.
  • Transmembrane pressure may be provided by pressurizing the feed water, applying suction to the permeate side of the filtration sheets (10) or both.
  • the module may be backwashed periodically by flowing water through the filtration sheets (10) in a reverse direction.
  • the module may be used in a system and process as described in International Application No. PCT/CA2015/050412 filed on May 8, 2015, published as International Publication Number WO 2015/168801 A1 on November 12, 2015.

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Separation Using Semi-Permeable Membranes (AREA)

Abstract

L'invention concerne un élément de filtration qui comporte une ou plusieurs feuilles de filtration, éventuellement dans un boîtier. Une feuille de filtration est constituée d'une enveloppe de membrane à feuille plate entourant un ou plusieurs supports de perméat, un insert non poreux, ou les deux. L'élément est configuré pour fournir des canaux d'alimentation, éventuellement sans éléments d'espacement de canal d'alimentation, entre les feuilles de filtration. Les feuilles de filtration sont empotées au niveau d'un bord, éventuellement seulement au niveau d'une partie d'un bord, telle qu'un coin. Un perméat circule à travers le support de perméat ou le long de l'insert et, dans certains cas, à travers un tube de perméat, vers le bord empoté. Les feuilles de filtration peuvent être empotées dans une centrifugeuse, éventuellement directement dans le boîtier. Les feuilles de filtration peuvent être renforcées au niveau d'une interface avec l'empotage. L'enveloppe de membrane peut comporter une couche de séparation de la membrane sur l'intérieur de l'enveloppe. Une feuille de filtration peut être empotée au niveau de l'une ou des deux extrémités.
PCT/CA2016/051235 2015-10-26 2016-10-26 Module de filtration de membrane à feuille plate empotée WO2017070775A1 (fr)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US201562246381P 2015-10-26 2015-10-26
US62/246,381 2015-10-26
US14/926,311 US20160151743A1 (en) 2014-05-08 2015-10-29 Potted flat sheet membrane filtration module
US14/926,311 2015-10-29

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WO2017070775A1 true WO2017070775A1 (fr) 2017-05-04

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2020118428A1 (fr) 2018-12-11 2020-06-18 Thetis Environmental Inc. Module de filtration à membrane en feuille plate comportant un boîtier cylindrique

Citations (7)

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US4761229A (en) * 1987-06-22 1988-08-02 Thompson John A Multi-leaf membrane module
US5002667A (en) * 1990-10-30 1991-03-26 National Research Council Of Canada Fluid fractionating, stacked permeable membrane envelope assembly, and a fluid distributing and permeable membrane sealing collar
US5264171A (en) * 1991-12-31 1993-11-23 Hoechst Celanese Corporation Method of making spiral-wound hollow fiber membrane fabric cartridges and modules having flow-directing baffles
WO1997022394A1 (fr) * 1995-12-20 1997-06-26 Baldwin Filters, Inc. Cartouche de filtre sans danger pour l'environnement
US20070125642A1 (en) * 2005-12-05 2007-06-07 Balboa Instruments, Inc. Electrolytic cell assembly
WO2012065036A1 (fr) * 2010-11-12 2012-05-18 Siemens Pte. Ltd. Distributeurs d'écoulement pour séparation électrochimique
WO2015153885A1 (fr) * 2014-04-02 2015-10-08 Evoqua Water Technologies Llc Dispositifs de séparation électrochimique à flux transversal et leurs procédés d'assemblage

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4761229A (en) * 1987-06-22 1988-08-02 Thompson John A Multi-leaf membrane module
US5002667A (en) * 1990-10-30 1991-03-26 National Research Council Of Canada Fluid fractionating, stacked permeable membrane envelope assembly, and a fluid distributing and permeable membrane sealing collar
US5264171A (en) * 1991-12-31 1993-11-23 Hoechst Celanese Corporation Method of making spiral-wound hollow fiber membrane fabric cartridges and modules having flow-directing baffles
WO1997022394A1 (fr) * 1995-12-20 1997-06-26 Baldwin Filters, Inc. Cartouche de filtre sans danger pour l'environnement
US20070125642A1 (en) * 2005-12-05 2007-06-07 Balboa Instruments, Inc. Electrolytic cell assembly
WO2012065036A1 (fr) * 2010-11-12 2012-05-18 Siemens Pte. Ltd. Distributeurs d'écoulement pour séparation électrochimique
WO2015153885A1 (fr) * 2014-04-02 2015-10-08 Evoqua Water Technologies Llc Dispositifs de séparation électrochimique à flux transversal et leurs procédés d'assemblage

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2020118428A1 (fr) 2018-12-11 2020-06-18 Thetis Environmental Inc. Module de filtration à membrane en feuille plate comportant un boîtier cylindrique
EP3894057A4 (fr) * 2018-12-11 2022-04-13 Thetis Environmental Inc. Module de filtration à membrane en feuille plate comportant un boîtier cylindrique

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