A Critical Review on Electric Field-Assisted Membrane Processes: Implications for Fouling Control, Water Recovery, and Future Prospects

Electrofiltration, an electric field-assisted membrane process, has been a research topic of growing popularity due to its ability to improve membrane performance by providing in situ antifouling conditions in a membrane system. The number of reports on electrofiltration have increased exponentially over the past two decades. These reports explored many innovations, such as novel configurations of an electric field, engineered membrane materials, and interesting designs of foulant compositions and membrane modules. Recent electrofiltration literature focused mainly on compiling results without a comprehensive comparative analysis across different works. The main objective of this critical review is to, first, organize, compare and contrast the results across various electrofiltration studies; second, discuss various types of mechanisms that could be incorporated into electrofiltration and their effect on membrane system performance; third, characterize electrofiltration phenomenon; fourth, interpret the effects of various operational conditions on the performance of electrofiltration; fifth, evaluate the state-of-the-art knowledge associated with modeling efforts in electrofiltration; sixth, discuss the energy costs related to the implementation of electrofiltration; and finally, identify the current knowledge gaps that hinder the transition of the lab-scale observations to industry-scale electrofiltration as well as the future prospects of electrofiltration.

Tanning Wastewater Treatment by Ultrafiltration: Process Efficiency and Fouling Behavior

Ultrafiltration is a promising, environment-friendly alternative to the current physicochemical-based tannery wastewater treatment. In this work, ultrafiltration was employed to treat the tanning wastewater as an upstream process of the Zero Liquid Discharge (ZLD) system in the leather industry. The filtration efficiency and fouling behaviors were analyzed to assess the impact of membrane material and operating conditions (shear rate on the membrane surface and transmembrane pressure). The models of resistance-in-series, fouling propensity, and pore blocking were used to provide a comprehensive analysis of such a process. The results show that the process efficiency is strongly dependent on the operating conditions, while the membranes of either PES or PVDF showed similar filtration performance and fouling behavior. Reversible resistance was the main obstacle for such process. Cake formation was the main pore blocking mechanism during such process, which was independent on the operating conditions and membrane materials. The increase in shear rate significantly increased the steady-state permeation flux, thus, the filtration efficiency was improved, which resulted from both the reduction in reversible resistance and the slow-down of fouling layer accumulate rate. This is the first time that the fouling behaviors of tanning wastewater ultrafiltration were comprehensively evaluated, thus providing crucial guidance for further scientific investigation and industrial application.

Influence of Ceramic Membrane Surface Characteristics on the Flux Behavior of a Complex Fermentation Broth

The valorization of agro-industrial residues using yeasts as biocatalysts requires efficient methods for biomass separation. Filtration with ceramic membranes is suitable for this task, however, the challenge of flux decline and the unavoidable cleaning must be taken into account. We investigated the filtration of fermentation broth and its components using tubular microfiltration and ultrafiltration membranes, and hollow-fiber ultrafiltration membranes, with cut-offs of 30 and 200 nm. The steady-state flux was limited by fouling under comparable wall shear stress conditions but increased when the wall shear stress was higher. Single-component filtration with two 30 nm tubular ultrafiltration membranes, whose average surface roughness ranged from 1.0 to 3.9 µm, showed that smoother surfaces experience less biomass fouling under more intense hydrodynamic conditions. Furthermore, we showed experimentally and by scanning electron microscopy in filtration with 30 nm tubular membranes that the thickness of the first separation layer is responsible for the degree of irreversible resistance caused by the deposition of organic material in the membrane pores. The thickness of this layer should therefore be minimized without compromising mechanical stability.

Performance of Single and Two-Stage Cross-Flow Ultrafiltration Membrane in Fractionation of Peptide from Microalgae Protein Hydrolysate (Nannochloropsis gaditana)

Cross-flow ultrafiltration (UF) membrane with two different configurations; single (10 kDa and 5 kDa) and two-stage (10/5 kDa) in fractionating microalgae protein hydrolysate (MPH) were studied to obtain a low molecular weight of peptide. The effect of flow rate, trans-membrane pressure (TMP), and pH in fractionating MPH were evaluated based on permeate flux and peptide transmission. The results showed that, for single UF membrane, optimum operating parameters were at a flow rate of 23 mL/min, TMP of 1.5 bar, and pH of 9, with permeate flux of 43.65 L/m2 h (10 kDa) and 55.42 L/m2 h (5 kDa) and peptide transmission of 58.20% (10 kDa) and 67.34% (5 kDa). Meanwhile, for two-stage (10/5 kDa) UF membrane, the best parameters were observed at a flow rate of 23 mL/min, TMP of 1.5 bar, and pH of 2, with permeate flux of 69.85 L/m2 h and peptide transmission of 79.13%. Fractionation of MPH with two-stage UF membrane was observed to be better at producing a low molecular weight of peptide compared to single UF membrane. In conclusion, it was possible to produce permeate flux with a high amount of low molecular weight of peptide by controlling the operating parameters with the suitable configuration membrane.

Prediction of the Limiting Flux and Its Correlation with the Reynolds Number during the Microfiltration of Skim Milk Using an Improved Model

Limiting flux (J_L) determination is a critical issue for membrane processing. This work presents a modified exponential model for J_L calculation, based on a previously published version. Our research focused on skim milk microfiltrations. The processing variables studied were the crossflow velocity (CFV), membrane hydraulic diameter (d_h), temperature, and concentration factor, totaling 62 experimental runs. Results showed that, by adding a new parameter called minimum transmembrane pressure, the modified model not only improved the fit of the experimental data compared to the former version (R² > 97.00%), but also revealed the existence of a minimum transmembrane pressure required to obtain flux (J). This result is observed as a small shift to the right on J versus transmembrane pressure curves, and this shift increases with the flow velocity. This fact was reported in other investigations, but so far has gone uninvestigated. The J_L predicted values were correlated with the Reynolds number (Re) for each d_h tested. Results showed that for a same Re; J_L increased as d_h decreased; in a wide range of Re within the turbulent regime. Finally, from dimensionless correlations; a unique expression J_L = f (Re, d_h) was obtained; predicting satisfactorily J_L (R² = 84.11%) for the whole set of experiments

Structural Characterisation of Deposit Layer during Milk Protein Microfiltration by Means of In-Situ MRI and Compositional Analysis

Milk protein fractionation by microfiltration membranes is an established but still growing field in dairy technology. Even under cross-flow conditions, this filtration process is impaired by the formation of a deposit by the retained protein fraction, mainly casein micelles. Due to deposition formation and consequently increased overall filtration resistance, the mass flow of the smaller whey protein fraction declines within the first few minutes of filtration. Currently, there are only a handful of analytical techniques available for the direct observation of deposit formation with opaque feed media and membranes. Here, we report on the ongoing development of a non-invasive and non-destructive method based on magnetic resonance imaging (MRI), and its application to characterise deposit layer formation during milk protein fractionation in ceramic hollow fibre membranes as a function of filtration pressure and temperature, temporally and spatially resolved. In addition, the chemical composition of the deposit was analysed by reversed phase high pressure liquid chromatography (RP-HPLC). We correlate the structural information gained by in-situ MRI with the protein amount and composition of the deposit layer obtained by RP-HPLC. We show that the combination of in-situ MRI and chemical analysis by RP-HPLC has the potential to allow for a better scientific understanding of the pressure and temperature dependence of deposit layer formation.

In situ measurement of deposit layer formation during skim milk filtration by MRI

Filtration and separation via membranes are key processes in food processing. One major application of membrane filtration is in the dairy industry, aiming for the separation of different milk proteins. The various chemical components of milk possess different physiochemical properties and can be used most effectively in food processing if they are separately available and remain in their native state. Microfiltration of skim milk allows a fractionation of the milk proteins casein and whey by size. A deposit is formed on the membrane surface mainly but not exclusively by micellar casein proteins during filtration. Membrane pore blockage by whey proteins and fouling occur during membrane filtration, negatively affecting the yield of the whey protein fraction. Skim milk filtration and the deposit layer formation were measured time and spatially resolved by in situ magnetic resonance imaging (MRI). The nature of the fouling layer was investigated during dead-end filtration in ceramic hollow fiber membranes. MRI was used to further clarify the influence of operating conditions on separation and filtration mechanisms that are responsible for growth of the fouling layer and its reversibility. The MRI measurements were analyzed for a detailed description of skim milk filtration by modeling the signal intensity distribution.

Technical Concepts for the Investigation of Spatial Effects in Spiral-Wound Microfiltration Membranes

Existing works on the influence of spatial effects on flux and permeation of proteins in microfiltration (MF) have focused on ceramic membranes. There is little information on spiral-wound membranes (SWMs). Since the inner core of a SWM is practically inaccessible by non-destructive techniques, three different prototypes were constructed in this study to optimize suitability for the investigation of spatial effects on filtration performance. To measure the pressure drop, shortened SWMs 0.25, 0.50, and 0.75 times the length of a standard industrial SWM (0.96 m) were designed. Second, a sectioned membrane (0.96 m) with separated compartments on the permeate side was constructed to analyze spatial effects on flux and protein permeation along the flow path of a SWM. Three different features characterized this sectioned module: sectioned permeate pockets, a sectioned permeate collection tube, and sectioned permeate drain and measurement systems. Crossflow filtration experiments showed that these modifications did not alter the filtration performance compared to an unmodified control SWM. Thus, it can be applied to assess spatially-resolved filtration performance in SWMs. The third prototype designed was a test cell with accessible flat sheet membranes and spacer material, as in SWMs. The flow path in this test cell was designed to match the characteristics of the channels between the membrane sheets in a standard SWM as closely as possible. The flow path length and the combination of membrane material and spacer architecture were the same as in the control SWM. This test cell was designed to assess the effects of length and processing conditions on the formation of a deposit layer. The combined results of these test modules can yield new insights into the spatial distribution of flux, permeation of target components, and deposit formation.

Codeposition Modification of Cation Exchange Membranes with Dopamine and Crown Ether To Achieve High K+ Electrodialysis Selectivity

Surface modification has been proven to be an effective approach for ion exchange membranes to achieve separation of counterions with different valences by altering interfacial construction of membranes to improve ion transfer performance. In this work, we have fabricated a series of novel cation exchange membranes (CEMs) by modifying sulfonated polysulfone (SPSF) membranes via codeposition of mussel-inspired dopamine (DA) and 4'-aminobenzo-15-crown-5 (ACE), followed by glutaraldehyde cross-linking, aiming at achieving selective separation of specific cations. The as-prepared membranes before and after modification were systematically characterized in terms of their structural, physicochemical, electrochemical, and electrodialytic properties. In the electrodialysis process, the modified membranes exhibit distinct perm selectivity to K⁺ ions in binary (K⁺/Li⁺, K⁺/Na⁺, K⁺/Mg²⁺) and ternary (K⁺/Li⁺/Mg²⁺) systems. In particular, at a constant current density of 5.0 mA·cm^-2, modified membrane M-co-0.50 shows significantly prominent perm selectivity [Formula: see text] in the K⁺/Mg²⁺ system and M-co-0.75 exhibits remarkable performance in the K⁺/Li⁺ system [Formula: see text], superior to commercial monovalent-selective CEM (CIMS, [Formula: see text], [Formula: see text]). Besides, in the K⁺/Li⁺/Mg²⁺ ternary system, K⁺ flux reaches 30.8 nmol·cm^-2·s^-1 for M-co-0.50, while it reaches 25.8 nmol·cm^-2·s^-1 for CIMS. It possibly arises from the effects of pore-size sieving and the synergistic action of electric field driving and host-guest molecular recognition of ACE and K⁺ ions. This study can provide new insights into the separation of specific alkali metal ions, especially on reducing influence of coexisting cations K⁺ and Na⁺ on Li⁺ ion recovery from salt lake and seawater.

Milk Protein Concentration Using Negatively Charged Ultrafiltration Membranes

In this work, milk protein concentrate (MPC) was made using wide-pore negatively charged ultrafiltration membranes. The charged membranes were used for a six-fold volume concentration of skim milk and subsequent diafiltration to mimic the industrial MPC process. The charged 100 kDa membranes had at least a four-fold higher permeate flux at the same protein recovery as unmodified 30 kDa membranes, which are currently used in the dairy industry to make MPC. By placing a negative charge on the surface of an ultrafiltration membrane, the negatively charged proteins were rejected by electrostatic repulsion and not simply size-based sieving. Mass balance models of concentration and diafiltration were developed and the calculations matched the experimental observations. This is the first study to use wide-pore charged tangential-flow membranes for MPC manufacturing. Additionally, a unique mass balance model was applied, which accurately predicted experimental results.

Concentration of Immunoglobulins in Microfiltration Permeates of Skim Milk: Impact of Transmembrane Pressure and Temperature on the IgG Transmission Using Different Ceramic Membrane Types and Pore Sizes

The use of bioactive bovine milk immunoglobulins (Ig) has been found to be an alternative treatment for certain human gastrointestinal diseases. Some methodologies have been developed with bovine colostrum. These are considered in laboratory scale and are bound to high cost and limited availability of the raw material. The main challenge remains in obtaining high amounts of active IgG from an available source as mature cow milk by the means of industrial processes. Microfiltration (MF) was chosen as a process variant, which enables a gentle and effective concentration of the Ig fractions (ca. 0.06% in raw milk) while reducing casein and lactose at the same time. Different microfiltration membranes (ceramic standard and gradient), pore sizes (0.14–0.8 µm), transmembrane pressures (0.5–2.5 bar), and temperatures (10, 50 °C) were investigated. The transmission of immunoglobulin G (IgG) and casein during the filtration of raw skim milk (<0.1% fat) was evaluated during batch filtration using a single channel pilot plant. The transmission levels of IgG (~160 kDa) were measured to be at the same level as the reference major whey protein β-Lg (~18 kDa) at all evaluated pore sizes and process parameters despite the large difference in molecular mass of both fractions. Ceramic gradient membranes with a pore sizes of 0.14 µm showed IgG-transmission rates between 45% to 65% while reducing the casein fraction below 1% in the permeates. Contrary to the expectations, a lower pore size of 0.14 µm yielded fluxes up to 35% higher than 0.2 µm MF membranes. It was found that low transmembrane pressures benefit the Ig transmission. Upscaling the presented results to a continuous MF membrane process offers new possibilities for the production of immunoglobulin enriched supplements with well-known processing equipment for large scale milk protein fractionation.

Effect of transmembrane pressure control on energy efficiency during skim milk concentration by ultrafiltration at 10 and 50°C

The efficiency of the ultrafiltration process during skim milk concentration was studied using both dynamic and constant (465 or 672kPa) transmembrane pressure experiments at refrigerated temperature (10°C) and high temperature (50°C). The pilot-scale module was equipped with a 10-kDa polyethersulfone spiral-wound membrane element with a surface area of 2.04m². Permeation flux, resistance-in-series model, mineral and protein rejection, and energy consumption were studied as a function of temperature and transmembrane pressure applied. Higher permeation flux values were systematically obtained at 50°C. Also, a significant temperature effect was found for calcium rejection, which was lower at 10°C compared with 50°C. Total hydraulic resistance and reversible fouling resistance were higher at 50°C than at 10°C. No change in protein rejection was observed, depending on the operating mode studied. Permeation flux, which was higher at 50°C, had lower pumping energy consumption compared with ultrafiltration at the colder temperature. Also, the low ultrafiltration temperature required a higher total energy consumption to reach the 3.6× retentate compared with ultrafiltration at 50°C. Overall, our study shows that the operating parameters and temperature can be optimized using an energy efficiency ratio.