Investigation of the onset of dislodgment of a nonpermeating oil droplet at a membrane surface: Standard models and a new force balance model

A comprehensive review on the behavior and evolution of oil droplets during oil/water separation by membranes

Membrane separation technology has significant advantages for treating oil-in-water emulsions. Understanding the evolution of oil droplets could reveal the interfacial and colloidal interactions, facilitate the design of advanced membranes, and improve the separation performances. This review on the characteristic behavior and evolution of oil droplets focuses on the advanced analytical techniques, and the subsequent fouling as well as demulsification effects during membrane separation. A detailed introduction is provided on microscopic observations and numerical simulations of the dynamic evolution of oil droplets, featuring real-time in-situ visualization and accurate reconstruction, respectively. Characteristic behaviors of these oil droplets include attachment, pinning, wetting, spreading, blockage, intrusion, coalescence, and detachment, which have been quantified by specific proposed parameters and criteria. The fouling process can be evaluated using Hermia and resistance models. The related adhesion force and intrusion pressure as well as droplet-droplet/membrane interfacial interactions can be accurately quantified using various force analysis methods and advanced force measurement techniques. It is encouraging to note that oil coalescence has been achieved through various effects such as electrostatic interactions, mechanical actions, Laplace pressure/surface free energy gradients, and synergistic effects on functional membranes. When oil droplets become destabilized and coalesce into larger ones, the functional membranes can overcome the limitations of size-sieving effect to attain higher separation efficiency. This not only bypasses the trade-off between permeability and rejection, but also significantly reduces membrane fouling. Finally, the challenges and potential research directions in membrane separation are proposed. We hope this review will support the engineering of advanced materials for oil/water separation and research on interface science in general.

A Rotary Spacer System for Energy-Efficient Membrane Fouling Control in Oil/Water Emulsion Filtration

Membrane fouling deteriorates membrane filtration performances. Hence, mitigating membrane fouling is the key factor in sustaining the membrane process, particularly when treating fouling-prone feed, such as oil/water emulsions. The use of spacers has been expanded in the membrane module system, including for membrane fouling control. This study proposed a rotating spacer system to ameliorate membrane fouling issues when treating an oil/water emulsion. The system’s effectiveness was assessed by investigating the effect of rotating speed and membrane-to-disk gap on the hydraulic performance and the energy input and through computational fluid dynamics (CFD) simulation. The results showed that the newly developed rotary spacer system was effective and energy-efficient for fouling control. The CFD simulation results proved that the spacer rotations induced secondary flow near the membrane surface and imposed shear rate and lift force to exert fouling control. Increasing the rotation speed to an average linear velocity of 0.44 m/s increased the permeability from 126.8 ± 2.1 to 175.5 ± 2.7 Lm⁻²h⁻¹bar⁻¹. The system showed better performance at a lower spacer-to-membrane gap, in which increasing the gap from 0.5 to 2.0 cm lowered the permeability from 175.5 ± 2.7 to 126.7 ± 2.0 Lm⁻²h⁻¹bar⁻¹. Interestingly, the rotary system showed a low energy input of 1.08 to 4.08 × 10⁻³ kWhm⁻³ permeate when run at linear velocities of 0.27 to 0.44 ms⁻¹. Overall, the findings suggest the competitiveness of the rotary spacer system as a method for membrane fouling control.

On the estimation of the size of a droplet emerging from a pore opening into a crossflow field

The problem of terminating a droplet at the surface of a membrane in a crossflow field is an important topic in the context of controlled emulsification of fluids for use in pharmaceutical and other industries. Some of these industries struggle to produce emulsions of uniform sizes for their products requiring higher levels of precision. In this work, we comprehensively investigated one such technique in which droplets were produced via membrane openings and were terminated via a crossflow field. Conditions of permeation and termination were identified. A model was developed to estimate the size of the emerging droplets from information about the interfacial properties, geometry, and operating conditions (i.e., pressure and crossflow velocity). Three forces, including capillary pressure, interfacial tension, and drag forces, were identified that account for a developed torque balance, which was then used to determine the onset of breakup of an emerging droplet. A comprehensive computational fluid dynamics (CFD) analysis has been conducted to highlight the physics involved in the process and also to provide scenarios for comparison exercises. The effects of crossflow velocity, applied pressure, and viscosity contrasts have been studied. It has been determined that the emerging droplet experiences deformation along the crossflow field because of the hydrodynamic drag. The receding portion of the contact line at the surface of the membrane wraps around the pore opening, generating an interfacial tension force that produces an opposing torque due to the crossflow drag and capillary pressure. Using this phenomenon, a framework for estimating the size of the droplet upon breakup is established. Comparisons with the results obtained from the CFD analysis under different conditions show very good agreement, which builds confidence in the modeling approach.

Simplified Formula for the Critical Entry Pressure and a Comprehensive Insight into the Critical Velocity of Dislodgment of a Droplet in Crossflow Filtration

Produced water treatment remains a challenging issue for the oil production industry. Finding ways to effectively treat oily water systems without incurring higher operational costs is the struggle and focus of recent research work. The success in establishing a modeling approach to study the filtration of oily water systems is dependent upon our understanding of the fate of oil droplets at the membrane surface. It has been determined that four fates confront oil droplets at the membrane surface, namely, permeation, breakup, pinning, and rejection. Conditions for manifestation of any of these four fates depend on two operating conditions (transmembrane pressure and crossflow velocity) in comparison with two critical conditions (entry pressure and critical velocity of dislodgment). In this work, a new simplified formula for the critical entry pressure is introduced. It compares very well with the formula already existing in the literature. Furthermore, the complete model for the critical velocity of dislodgment in crossflow filtration is presented and highlighted. More investigations on the physical processes that are involved during the pinning of a droplet at a pore opening are presented. In addition, a thorough analysis of the forces that are involved during the permeation of a droplet that could lead to its breakup is presented. It is found that, once the droplet reaches the pore opening, the interfacial tension force and the pressure force continue to increase. Following the critical configuration, these forces continuously decline and the drag force due to the crossflow field, therefore, becomes sufficient to break up the droplet.

On the design of sustainable antifouling system for the crossflow filtration of oily water systems: A multicontinuum and CFD investigation of the periodic feed pressure technique

The problem of fouling is considered a major reason for deteriorating the performance of porous membranes. Even though the accumulations of materials at the membrane surface are inevitable, efforts are continuously spent to minimize their drawbacks. Several techniques have been tested to minimize the problem of fouling. Some of these methods, however, confront some technical difficulties that make their use unfeasible. For example, in polymeric-type membranes, back flushing may result in the loss of bonding between the active and the support layers resulting thereby to the disintegration of the membrane. Recently, an interestingly new approach has been proposed that minimizes the problem of fouling and maintains the integrity of the membrane. The so-called periodic feed pressure technique, PFPT, cleans the surface of the membrane by reducing the adherence of the droplets to the membrane giving the chance to the crossflow field to sweep off pinned droplets. In this work, some of the features of the PFPT technique are highlighted using results from CFD simulation. Then we further investigate the PFPT technique in the realm of the multicontinuum modeling approach in which both the emulsion and the membrane are treated as overlapping continua. The behavior of the membrane is studied considering different transmembrane pressure values to highlight the fates of the different oil continua upon interacting with membrane continua. From the CFD highlights, it is found that during the half cycle when the TMP is set to zero, oil droplets at the surface of the membrane becomes unstable and it becomes easier for the crossflow field to dislodge them. The multicontinuum study, on the other hand, provides macroscopic analysis on the effects of different TMP cycles on important macroscopic parameters that influence the design, including the rejection capacity of membranes.