Modeling and simulation for design and analysis of membrane-based separation processes

On the Maximum Obtainable Purity and Resultant Maximum Useful Membrane Selectivity of a Membrane Separator

Design considerations concerning the maximum purity of a membrane separator, and the resultant maximum effective selectivity of the membranes were explored by modeling a binary gas membrane separator (pressure-driven permeance) using a dimensionless form. Although the maximum purity has an analytical solution at the limit of zero recovery or stage cut, this solution over-predicts the obtained purity as the recovery is increased. Furthermore, at combinations of high recovery, low feed mole fraction, and low pressure ratio, the maximum purity becomes independent of selectivity above some critical selectivity. As a consequence of this purity limitation, a maximum selectivity is defined at which further increases in selectivity will result in less than a 1% change in the final purity. An equation is obtained that specifies the region in which a limiting purity is less than unity (indicating the existence of a limiting selectivity); operating at less than the limiting pressure ratio results in a purity limitation less than unity. This regime becomes larger and more significant as the inlet mole fraction decreases (e.g., inlet feed mole fraction of 10% and pressure ratio of 100 results in a maximum useful membrane selectivity of only 130 at 95% recovery). These results suggest that membrane research should focus on increasing permeance rather than selectivity for low-concentration separations. The results found herein can be used to set benchmarks for membrane development in various gas separation applications.

Multiscale modelling of transport in polymer-based reverse-osmosis/nanofiltration membranes: present and future

Nanofiltration (NF) and reverse osmosis (RO) processes are physical separation technologies used to remove contaminants from liquid streams by employing dense polymer-based membranes with nanometric voids that confine fluids at the nanoscale. At this level, physical properties such as solvent and solute permeabilities are intricately linked to molecular interactions. Initially, numerous studies focused on developing macroscopic transport models to gain insights into separation properties at the nanometer scale. However, continuum-based models have limitations in nanoconfined situations that can be overcome by force field molecular simulations. Continuum-based models heavily rely on bulk properties, often neglecting critical factors like liquid structuring, pore geometry, and molecular/chemical specifics. Molecular/mesoscale simulations, while encompassing these details, often face limitations in time and spatial scales. Therefore, achieving a comprehensive understanding of transport requires a synergistic integration of both approaches through a multiscale approach that effectively combines and merges both scales. This review aims to provide a comprehensive overview of the state-of-the-art in multiscale modeling of transport through NF/RO membranes, spanning from the nanoscale to continuum media.

Impact of temperature and forward osmosis membrane properties on the concentration polarization and specific energy consumption of hybrid desalination system

This study investigates how temperature and forward osmosis (FO) membrane properties, such as water permeability (A), solute permeability (B), and structural parameter (S), affect the specific energy consumption (SEC) of forward osmosis-reverse osmosis system. The results show that further SEC reduction beyond the water permeability of 3 LMH bar-1 is limited owing to high concentration polarization (CP). Increasing S by 10-fold increases FO recovery by 177.6%, causing SEC decreases by 33.6%. However, membrane with smaller S also increases external CP. To reduce SEC, future work should emphasize mixing strategies to reduce external CP. Furthermore, increasing the temperature from 10 to 40 °C can reduce SEC by 14.3%, highlighting the energy-saving potential of temperature-elevated systems. The factorial design indicates that at a lower temperature, increasing A and decreasing S have a more significant impact on reducing SEC. This underlines the importance of developing advanced FO membranes, particularly for lower-temperature processes.

Novel Study on Cryogenic Distillation Process and Application by Using CHEMCAD Simulation

The purpose of this study was to examine the cryogenic separation process used in air separation plants with the CHEMCAD simulation program. A preliminary analysis was carried out with the literature about the operation of the process. In light of the technical information, the simulation of the cryogenic separation process was utilized with the program. While no changes were analyzed in the basic parts of the process, the filtration of the air and separation from moisture and carbon dioxide were not included in the simulation. The simulation showed the three basic components of air, nitrogen, oxygen, and argon obtained as a product of the desired purity rather than a one-to-one demonstration of the applications in the industry. In addition, the low-temperature separation process of an air separation unit was studied to obtain high-purity products (99.49-99.99%) achieving the expected separation efficiency. As a result, the production of all three substances in desired purity was achieved successfully.

Efficient CO2 absorption through wet and falling film membrane contactors: insights from modeling and simulation

The release of excessive carbon dioxide (CO₂) into the atmosphere poses potential threats to the well-being of various species on Earth as it contributes to global working. Therefore, it is necessary to implement appropriate actions to moderate CO₂ emissions. A hollow fiber membrane contactor is an emerging technology that combines the advantages of separation processes and chemical absorptions. This study investigates the efficacy of wet and falling film membrane contactors (FFMC) in enhancing CO₂ absorption in a monoethanolamine (MEA) aqueous solution. By analyzing factors such as membrane surface area, gas flow rate, liquid inlet flow rates, gas-liquid contact time, and solvent loading, we examine the CO₂ absorption process in both contactors. Our results reveal a clear advantage of FFMC, achieving an impressive 85% CO₂ removal efficiency compared to 60% with wet membranes. We employ COMSOL Multiphysics 6.1 simulation software and finite element analysis to validate our findings, demonstrating a close agreement between predicted and experimental values, with an average relative error of approximately 4.3%. These findings highlight the significant promise of FFMC for applications in CO₂ capture.

Application of different mathematical models based on artificial intelligence technique to predict the concentration distribution of solute through a polymeric membrane

Membrane-based purification of therapeutic agents has recently attracted global attention as a promising replacement for conventional techniques like distillation and pervaporation. Despite the conduction of different investigations, development of more research about the operational feasibility of using polymeric membranes to separate the detrimental impurities of molecular entities is of great importance. The focus of this paper is to develop a numerical strategy based on multiple machine learning methods to predict the concentration distribution of solute through a membrane-based separation process. Two inputs are being analyzed in this study, specifically r and z. Furthermore, the single target output is C, and the number of data points exceeds 8000. To analyze and model the data for this study, we used the Adaboost (Adaptive Boosting) model over three different base learners (K-Nearest Neighbors (KNN), Linear Regression (LR), and Gaussian Process Regression (GPR)). In the process of hyper-parameter optimization for models, the BA optimization algorithm applied on the adaptive boosted models. Finally, Boosted KNN, Boosted LR, and Boosted GPR have scores of 0.9853, 0.8751, and 0.9793 in terms of R² metric. Based on the recent fact and other analyses, boosted KNN model is introduced as the most appropriate model of this research. The error rates for this model are 2.073 × 10¹ and 1.06 × 10^-2 in terms of MAE and MAPE metrics.

Design of a Gas Permeation and Pervaporation Membrane Model for an Open Source Process Simulation Tool

Gas permeation and pervaporation are technologies that emerged several decades ago. Even though they have discovered increasing popularity for industrial separation processes, they are not represented equally within process simulation tools except for commercial systems. The availability of such a numerical solution shall be extended due to the design of a membrane model with Visual Basic based on the solution-diffusion model. Although this works approach is presented for a specific process simulator application, the algorithm can generally be transferred to any other programming language and process simulation solver, which allows custom implementations or modeling. Furthermore, the modular design of the model enables its further development by operators through the integration of physical effects. A comparison with experimental data of gas permeation and pervaporation applications as well as other published simulation data delivers either good accordance with the results or negligible deviations of less than 1% from other data.

Modelling Sorption and Transport of Gases in Polymeric Membranes across Different Scales: A Review

Professor Giulio C. Sarti has provided outstanding contributions to the modelling of fluid sorption and transport in polymeric materials, with a special eye on industrial applications such as membrane separation, due to his Chemical Engineering background. He was the co-creator of innovative theories such as the Non-Equilibrium Theory for Glassy Polymers (NET-GP), a flexible tool to estimate the solubility of pure and mixed fluids in a wide range of polymers, and of the Standard Transport Model (STM) for estimating membrane permeability and selectivity. In this review, inspired by his rigorous and original approach to representing membrane fundamentals, we provide an overview of the most significant and up-to-date modeling tools available to estimate the main properties governing polymeric membranes in fluid separation, namely solubility and diffusivity. The paper is not meant to be comprehensive, but it focuses on those contributions that are most relevant or that show the potential to be relevant in the future. We do not restrict our view to the field of macroscopic modelling, which was the main playground of professor Sarti, but also devote our attention to Molecular and Multiscale Hierarchical Modeling. This work proposes a critical evaluation of the different approaches considered, along with their limitations and potentiality.

Thermoeconomic Analysis of Biomethane Production Plants: A Dynamic Approach

This work analyses the two most diffused technologies for biogas upgrading, namely water scrubbing and membrane separation. In order to carry out such analysis, these two technologies are coupled with photovoltaic panels and an electric energy storage system. The optimal water scrubbing renewable plant achieves a primary energy saving of 5.22 GWh/year and an operating cost saving of 488 k€/year, resulting in the best plant. It was compared to a reference system based on a cogenerator unit, directly supplied by biogas, producing thermal and electric energy, and delivered to the district heating network and to the electric grid. The profitability of both plants depends on the electric energy and biomethane exporting price. The proposed bigas upgrading plant achieves a payback period lower than 10 years with a biomethane selling price greater than 0.55 €/Sm3 and a primary energy saving index around 25–30% with a null share of thermal energy exported by the cogeneration plant.

Design of membrane systems

Membrane separation systems have been used in process industry since decades; however, their designs are based mainly on experienced-based and use of trial-and-error approach, especially in case of membrane selection. This chapter reviews recent advancements in the design of membrane systems used either for separation or creation of mixtures from the perspective of industry 4.0 and data management. Additionally, computer-aided design tools have been reviewed with aim of possible use in the design of membrane separation systems.