A closer look on the development and commercialization of membrane contactors for mass transfer and separation processes

Electrodialysis desalination: The impact of solution flowrate (or Reynolds number) on fluid dynamics throughout membrane spacers

The incorporation of a spacer among membranes has a major influence on fluid dynamics and performance metrics. Spacers create feed channels and operate as turbulence promoters to increase mixing and reduce concentration/temperature polarization effects. However, spacer geometry remains unoptimized, and studies continue to investigate a wide range of commercial and custom-made spacer designs. The in-depth discussion of the present systematic review seeks to discover the influence of Reynolds number or solution flowrate on flow hydrodynamics throughout a spacer-filled channel. A fast-flowing solution sweeping one membrane's surface first, then the neighboring membrane's surface produces good mixing action, which does not happen commonly at laminar solution flowrates. A sufficient flowrate can suppress the polarization layer, which may normally require the utilization of a simple feed channel rather than complex spacer configurations. When a recirculation eddy occurs, it disrupts the continuous flow and effectively curves the linear fluid courses. The higher the flowrate, the better the membrane performance, the higher the critical flux (or recovery rate), and the lower the inherent limitations of spacer design, spacer shadow effect, poor channel hydrodynamics, and high concentration polarization. In fact, critical flow achieves an acceptable balance between improving flow dynamics and reducing the related trade-offs, such as pressure losses and the occurrence of concentration polarization throughout the cell. If the necessary technical flowrate is not used, the real concentration potential for transport is relatively limited at low velocities than would be predicted based on bulk concentrations. Electrodialysis stack therefore may suffer from the dissociation of water molecules. Next studies should consider that applying a higher flowrate results in greater process efficiency, increased mass transfer potential at the membrane interface, and reduced stack thermal and electrical resistance, where pressure drop should always be indicated as a consequence of the spacer and circumstances used, rather than a problem.

CO2 Absorption Using Hollow Fiber Membrane Contactors: Introducing pH Swing Absorption (pHSA) to Overcome Purity Limitation

Recently, membrane contactors have gained more popularity in the field of CO₂ removal; however, achieving high purity and competitive recovery for poor soluble gas (H₂, N₂, or CH₄) remains elusive. Hence, a novel process for CO₂ removal from a mixture of gases using hollow fiber membrane contactors is investigated theoretically and experimentally. A theoretical model is constructed to show that the dissolved residual CO₂ hinders the capacity of the absorbent when it is regenerated. This model, backed up by experimental investigation, proves that achieving a purity > 99% without consuming excessive chemicals or energy remains challenging in a closed-loop system. As a solution, a novel strategy is proposed: the pH Swing Absorption which consists of manipulating the acido–basic equilibrium of CO₂ in the absorption and desorption stages by injecting moderate acid and base amount. It aims at decreasing CO₂ residual content in the regenerated absorbent, by converting CO₂ into its ionic counterparts (HCO3− or CO32−) before absorption and improving CO₂ degassing before desorption. Therefore, this strategy unlocks the theoretical limitation due to equilibrium with CO₂ residual content in the absorbent and increases considerably the maximum achievable purity. Results also show the dependency of the performance on operating conditions such as total gas pressure and liquid flowrate. For N₂/CO₂ mixture, this process achieved a nitrogen purity of 99.97% with a N₂ recovery rate of 94.13%. Similarly, for H₂/CO₂ mixture, a maximum H₂ purity of 99.96% and recovery rate of 93.96% was obtained using this process. Moreover, the proposed patented process could potentially reduce energy or chemicals consumption.

Modelling the Molecular Permeation through Mixed-Matrix Membranes Incorporating Tubular Fillers

Membrane-based processes are considered a promising separation method for many chemical and environmental applications such as pervaporation and gas separation. Numerous polymeric membranes have been used for these processes due to their good transport properties, ease of fabrication, and relatively low fabrication cost per unit membrane area. However, these types of membranes are suffering from the trade-off between permeability and selectivity. Mixed-matrix membranes, comprising a filler phase embedded into a polymer matrix, have emerged in an attempt to partly overcome some of the limitations of conventional polymer and inorganic membranes. Among them, membranes incorporating tubular fillers are new nanomaterials having the potential to transcend Robeson's upper bound. Aligning nanotubes in the host polymer matrix in the permeation direction could lead to a significant improvement in membrane permeability. However, although much effort has been devoted to experimentally evaluating nanotube mixed-matrix membranes, their modelling is mostly based on early theories for mass transport in composite membranes. In this study, the effective permeability of mixed-matrix membranes with tubular fillers was estimated from the steady-state concentration profile within the membrane, calculated by solving the Fick diffusion equation numerically. Using this approach, the effects of various structural parameters, including the tubular filler volume fraction, orientation, length-to-diameter aspect ratio, and permeability ratio were assessed. Enhanced relative permeability was obtained with vertically aligned nanotubes. The relative permeability increased with the filler-polymer permeability ratio, filler volume fraction, and the length-to-diameter aspect ratio. For water-butanol separation, mixed-matrix membranes using polydimethylsiloxane with nanotubes did not lead to performance enhancement in terms of permeability and selectivity. The results were then compared with analytical prediction models such as the Maxwell, Hamilton-Crosser and Kang-Jones-Nair (KJN) models. Overall, this work presents a useful tool for understanding and designing mixed-matrix membranes with tubular fillers.