FIB-SEM tomography reveals the nanoscale 3D morphology of virus removal filters

Three-Dimensional Reconstruction-Characterization of Polymeric Membranes: A Review

Polymeric membranes serve as vital separation materials in diverse energy and environmental applications. A comprehensive understanding of three-dimensional (3D) structures of membranes is critical to performance evaluation and future design. Such quantitative 3D structural information is beyond the limit of most employed conventional two-dimentional characterization techniques such as scanning electron microscopy. In this review, we summarize eight types of 3D reconstruction-characterization techniques for membrane materials. Originated from life and materials science, these techniques have been optimized to reveal the 3D structures of membrane materials in the separation field. We systematically introduce the theories of each technique, summarize the sample preparation procedures developed for membrane materials, and demonstrate step-by-step data processing, including 3D model reconstruction and subsequent characterization. Representative case studies are introduced to show the progress of this field and how technical challenges have been overcome over the years. In the end, we share our perspectives and believe that this review can serve as a useful reference for 3D reconstruction-characterization techniques developed for membrane materials.

Leveraging bioanalytical characterization of fractionated monoclonal antibody pools to identify aggregation-prone and less filterable proteoforms during virus filtration

Monoclonal antibodies (mAbs) are an essential class of biotherapeutics. A platform process is used for mAb development to ensure clinically safe and stable molecules. Regulatory authorities ensure that mAb production processes include sufficient viral clearance steps to achieve less than one virus particle per million doses of product. Virus filtration is used for size-based removal of enveloped and nonenveloped viruses during downstream processing of mAbs. Process development in mAb purification relies on empirical approaches and often includes adsorptive prefiltration to mitigate virus filter fouling. Opportunities for molecular-level prediction of mAb filterability are needed to plug the existing knowledge gap in downstream processing. A molecular-level approach to understanding the factors influencing mAb filterability may reduce process development time, material loss, and processing costs due to oversized virus filters. In this work, pH step gradient fractionation was applied on polished bulk mAb feed to obtain concentrated pools of fractionated mAb variants. Biophysical properties and quality attributes of fractionated pools, including oligomeric state (size), isoelectric point profile, diffusion interaction parameters, and glycoform profile, were determined using bioanalytical methods. Filterability (loading and throughput) of fractionated pools were evaluated. Statistical methods were used to obtain correlations between quality attributes of mAb fractions and filterability on the Viresolve Pro virus filter.

Evolutions of extracorporeal membrane oxygenator (ECMO): perspectives for advanced hollow fiber membrane

Hollow fiber membrane is incorporated into an extracorporeal membrane oxygenator (ECMO), and the function of the membrane determines the ECMO's functions, such as gas transfer rate, biocompatibility, and durability. In Japan, the membrane oxygenator to assist circulation and ventilation is approved for ECMO support. However, in all cases, the maximum use period has been only 6 h, and so-called 'off-label use' is common for ECMO support of severely ill COVID-19 patients. Under these circumstances, the HLS SET Advanced (Getinge Group Japan K.K.) was approved in 2020 for the first time in Japan as a membrane oxygenator with a two-week period of use. Following this membrane oxygenator, it is necessary to establish a domestic ECMO system that is approved for long-term use and suitable for supporting patients. Looking back on the evolution of ECMO so far, Japanese researchers and manufacturers have also contributed to the developments of ECMO globally. Currently, excellent membrane oxygenators and systems have been marketed by Japanese manufacturers and some of them are globally acclaimed, but in fact, most of the ECMO membranes are not made in Japan. Fortunately, Japan has led the world in the fields of membrane separation technology and hollow fiber membrane production. In the wake of this pandemic, from the perspective of medical and economic security, the practical use of purely domestic hollow fiber membranes and membrane oxygenators for long-term ECMO is imperative in anticipation of the next pandemic.

Lipids and Proteins Differentiation in Membrane Fouling Using Heavy Metal Staining and Electron Microscopy at Cryogenic Temperatures

The detailed characterization of fouling in membranes is essential to understand any observed improvement or reduction on filtration performance. Electron microscopy allows detailed structural characterization, and its combination with labeling techniques, using electron-dense probes, typically allows for the differentiation of biomolecules. Developing specific protocols that allow for differentiation of biomolecules in membrane fouling by electron microscopy is a major challenge due to both as follows: the necessity to preserve the native state of fouled membranes upon real filtration conditions as well as the inability of the electron-dense probes to penetrate the membranes once they have been fouled. In this study, we present the development of a heavy metal staining technique for identification and differentiation of biomolecules in membrane fouling, which is compatible with cryofixation methods. A general contrast enhancement of biomolecules and fouling is achieved. Our observations indicate a strong interaction between biomolecules: A tendency of proteins, both in solution as well as in the fouling, to surround the lipids is observed. Using transmission electron microscopy and scanning electron microscopy at cryogenic conditions, cryo-SEM, in combination with energy-dispersive X-ray spectroscopy, the spatial distribution of proteins and lipids within fouling is shown and the role of proteins in fouling discussed.

Protein fouling during constant-flux virus filtration: Mechanisms and modeling

As biomanufacturers consider the transition from batch to continuous processing, it will be necessary to re-examine the design and operating conditions for many downstream processes. For example, the integration of virus removal filtration in continuous biomanufacturing will likely require operation at low and constant filtrate flux instead of the high (constant) transmembrane pressures (TMPs) currently employed in traditional batch processing. The objective of this study was to examine the effect of low operating filtrate flux (5-100 L/m2 /h) on protein fouling during normal flow filtration of human serum Immunoglobulin G (hIgG) through the Viresolve® Pro membrane, including a direct comparison of the fouling behavior during constant-flux and constant-pressure operation. The filter capacity, defined as the volumetric throughput of hIgG solution at which the TMP increased to 30 psi, showed a distinct minimum at intermediate filtrate flux (around 20-30 L/m2 /h). The fouling data were well-described using a previously-developed mechanistic model based on sequential pore blockage and cake filtration, suitably modified for operation at constant flux. Simple analytical expressions for the pressure profiles were developed in the limits of very low and high filtrate flux, enabling rapid estimation of the filter performance and capacity. The model calculations highlight the importance of both the pressure-dependent rate of pore blockage and the compressibility of the protein cake to the fouling behavior. These results provide important insights into the overall impact of constant-flux operation on the protein fouling behavior and filter capacity during virus removal filtration using the Viresolve® Pro membrane.

Effect of protein fouling on filtrate flux and virus breakthrough behaviors during virus filtration process

Virus filtration process is used to ensure viral safety in the biopharmaceutical downstream processes with high virus removal capacity (i.e., >4 log₁₀ ). However, it is still constrained by protein fouling, which results in reduced filtration capacity and possible virus breakthrough. This study investigated the effects of protein fouling on filtrate flux and virus breakthrough using commercial membranes that had different symmetricity, nominal pore size, and pore size gradients. Flux decay tendency due to protein fouling was influenced by hydrodynamic drag force and protein concentration. As the results of prediction with the classical fouling model, standard blocking was suitable for most virus filters. Undesired virus breakthrough was observed in the membranes having relatively a large pore diameter of the retentive region. The study found that elevated levels of protein solution reduced virus removal performance. However, the impact of prefouled membranes was minimal. These findings shed light on the factors that influence protein fouling during the virus filtration process of biopharmaceutical production.

Microporous Polyethersulfone Membranes Grafted with Zwitterionic Polymer Brushes Showing Microfiltration Permeance and Ultrafiltration Bacteriophage Removal

Virus removal from water using microfiltration (MF) membranes is of great interest but remains challenging owing to the membranes' mean pore sizes typically being significantly larger than most viruses. We present microporous membranes grafted with polyzwitterionic brushes (N-dimethylammonium betaine) that combine bacteriophage removal in the range of ultrafiltration (UF) membranes with the permeance of MF membranes. Brush structures were grafted in two steps: free-radical polymerization followed by atom transfer radical polymerization (ATRP). Attenuated total reflection Fourier transform infrared (ATR-FTIR) and X-ray photoelectron (XPS) verified that grafting occurred at both sides of the membranes and that the grafting increased with increasing the zwitterion monomer concentration. The log reduction values (LRVs) of the pristine membrane increased from less than 0.5 LRV for T4 (∼100 nm) and NT1 (∼50 nm) bacteriophages to up to 4.5 LRV for the T4 and 3.1 LRV for the NT1 for the brush-grafted membranes with a permeance of about 1000 LMH/bar. The high permeance was attributed to a high-water fraction in the ultra-hydrophilic brush structure. The high measured LRVs of the brush-grafted membranes were attributed to enhanced bacteriophages exclusion from the membrane surface and entrapment of the ones that penetrated the pores due to the membranes' smaller mean pore-size and cross-section porosity than those of the pristine membrane, as seen by scanning electron microscopy (SEM) and measured using liquid-liquid porometry. Micro X-ray fluorescence (μ-XRF) spectrometry and nanoscale secondary ion mass spectrometry showed that 100 nm Si-coated gold nanospheres accumulated on the surface of the pristine membrane but not on the brush-coated membrane and that the nanospheres that penetrated the membranes were entrapped in the brush-grafted membrane but passed the pristine one. These results corroborate the LRVs obtained during filtration experiments and support the inference that the increased removal was due to a combined exclusion mechanism and entrapment. Overall, these microporous brush-grafted membranes show potential for use in advanced water treatment.

A review on optimistic development of polymeric nanocomposite membrane on environmental remediation

Current health and environmental concerns about the abundance and drawbacks of municipal wastewater as well as industrial effluent have prompted the development of novel and innovative treatment processes. A global shortage of clean water poses significant challenges to the survival of all life forms. For the removal of both biodegradable and non-biodegradable harmful wastes/pollutants from water, sophisticated wastewater treatment technologies are required. Polymer membrane technology is critical to overcoming this major challenge. Polymer matrix-based nanocomposite membranes are among the most popular in polymer membrane technology in terms of convenience. These membranes and their major components are environmentally friendly, energy efficient, cost effective, operationally versatile, and feasible. This review provides an overview of the drawbacks as well as promising developments in polymer membrane and nanocomposite membranes for environmental remediation, with a focus on wastewater treatment. Additionally, the advantages of nanocomposite membranes such as stability, antimicrobial properties, and adsorption processes have been discussed. The goal of this review was to summarize the remediation of harmful pollutants from water and wastewater/effluent using polymer matrix-based nanocomposite membrane technology, and to highlight its shortcomings and future prospects.

High-Resolution Numerical Simulation of Microfiltration of Oil-in-Water Emulsion Permeating through a Realistic Membrane Microporous Structure Generated by Focused Ion Beam Scanning Electron Microscopy Images

Owing to the limitations of visualization techniques in experimental studies and low-resolution numerical models based on computational fluid dynamics (CFD), the detailed behavior of oil droplets during microfiltration is not well understood. Hence, a high-resolution CFD model based on an in-house direct numerical simulation (DNS) code was constructed in this study to analyze the detailed dynamics of an oil-in-water (O/W) emulsion using a microfiltration membrane. The realistic microporous structure of commercial ceramic microfiltration membranes (mullite and α-alumina membranes) was obtained using an image processing technique based on focused ion beam scanning electron microscopy (FIB-SEM). Numerical simulations of microfiltration of O/W emulsions on the membrane microstructure obtained by FIB-SEM were performed, and the effects of different parameters, including contact angle, transmembrane pressure, and membrane microporous structure, on filtration performance were studied. Droplet deformation had a strong impact on filtration behavior because coalesced droplets with diameters larger than the pore diameter permeated the membrane pores. The permeability, oil hold-up fraction inside the pores, and rejection were considerably influenced by the contact angle, while the transmembrane pressure had a little impact on the permeability and oil hold-up fraction. The membrane structure, especially the pore size distribution, also had a significant effect on the microfiltration behavior and performance.