Industrial scale membrane

This section describes the use of separation processes which utilize membranes. Placement in this chapter is in recognition of the recent ascendency of industrial-scale membrane-based separations, but it also reflects the view that within a decade, many of these separation processes will be mainstream unit operations. Some approach that status already. Figure 22-46 shows the relative size of things important in membrane separations. 

While waiting for industrial-scale membrane reactors, the most intriguing field in which modeling work still has to be done is that of transport through molecular-sieve membranes [56]. 

In order to be used on an industrial scale, membrane reactors need to be produced at a scale much larger than those currently employed in laboratory set-ups. This implies that membrane fabrication methods for large scale systems need to be defined, as well as the engineering related to module preparation. 

Electrodialysis can be applied to the continuous-flow type of operation needed in industry. Multi-membrane stacks can be built by alternately spacing anionic- and cationic-selective membranes. Among the technical problems associated with the electrodialysis process, concentration polarization is perhaps the most serious (discussed later). Other problems in practical applications include membrane scaling by inorganics in feed solutions as well as membrane fouling by organics. 

At present moment, no generally feasible method exists for the large-scale production of optically pure products. Although for the separation of virtually every racemic mixture an analytical method is available (gas chromatography, liquid chromatography or capillary electrophoresis), this is not the case for the separation of racemic mixtures on an industrial scale. The most widely applied method for the separation of racemic mixtures is diastereomeric salt crystallization [1]. However, this usually requires many steps, making the process complicated and inducing considerable losses of valuable product. In order to avoid the problems associated with diastereomeric salt crystallization, membrane-based processes may be considered as a viable alternative. 

In general, high selectivities can be obtained in liquid membrane systems. However, one disadvantage of this technique is that the enantiomer ratio in the permeate decreases rapidly when the feed stream is depleted in one enantiomer. Racemization of the feed would be an approach to tackle this problem or, alternatively, using a system containing the two opposite selectors, so that the feed stream remains virtually racemic [21]. Another potential drawback of supported enantioselective liquid membranes is the application on an industrial scale. Often a complex multistage process is required in order to achieve the desired purity of the product. This leads to a relatively complicated flow scheme and expensive process equipment for large-scale separations. 

The main disadvantage of all these systems is the Hmitation of scale-up. Monoclonal antibodies are produced by multiplying the hollow fiber systems and stirred tank reactors with membrane aeration are known up to 100 liter. Small quantities of product can be produced by these systems but they are not suitable for real industrial scale-up. 

Gas separation through membranes achieved commercialization after the introduction of the Prism process by Monsanto a decade ago. Originated for hydrogen recovery, high area membrane equipment is now used for other gases, notably C02 [1]. Hydrogen, carbon dioxide, and other components are now being removed from mixtures on an industrial scale [2, 3],... 

Although considerable research has been conducted with Pd-alloy foils, tubes, and thinner composite membranes, long-term durability and stability need to be further demonstrated, especially in the fuel reforming or WGS operating conditions, for acceptance of this technology in a commercial sector. Furthermore, mass-scale and cost-effective production of industrial-scale Pd-alloy thin-film composite membranes need to be demonstrated to be competitive in the hydrogen production and purification market. 

Figure 6.6 ULtrafiLtration separates molecules based on size and shape, (a) Diagrammatic representation of a typical laboratory-scale ultrafiltration system. The sample (e.g. crude protein solution) is placed in the ultrafiltration chamber, where it sits directly above the ultrafilter membrane. The membrane, in turn, sits on a macroporous support to provide it with mechanical strength. Pressure is then applied (usually in the form of an inert gas), as shown. Molecules larger than the pore diameter (e.g. large proteins) are retained on the upstream side of the ultrafilter membrane. However, smaller molecules (particularly water molecules) are easily forced through the pores, thus effectively concentrating the protein solution (see also (b)). Membranes that display different pore sizes, i.e. have different molecular mass cut-off points, can be manufactured, (c) Photographic representation of an industrial-scale ultrafiltration system (photograph courtesy of Elga Ltd, UK)...

Membrane equipment for industrial scale operation of microfiltration, ultrafiltration and reverse osmosis is supplied in the form of modules. The area of membrane contained in these basic modules is in the range 1-20 m2. The modules may be connected together in series or in parallel to form a plant of the required performance. The four most common types of membrane modules are tubular, flat sheet, spiral wound and hollow fibre, as shown in Figures 8.9-8.12. 

In the development of cell or enzyme-based processes, many process configurations exist, including batch, fed batch and continuous operation. In general, the conversion and the separation processes (downstream processing) are regarded as separate units, and most industrial processes are based on this approach. In the last decades, however, more attention is paid to the integration of conversion and separation, leading to the development of membrane bioreactors [49, 50], and some of these concepts have reached an industrial scale. The membranes used for this type of reactors are almost exclusively polymeric, as temperatures seldomly exceed 100 °C for obvious reasons. 

On an industrial scale, ion-exchange membranes are most frequently used for the separator material [2], Cationic and anionic types are both available and a sul-phonated polytetrafluoroethene cation exchange resin, which can withstand aggressive conditions, is frequently used. Arrangements for sealing this type of separator into a laboratory scale glass cell are also available. 

PEM ED - To develop thermally stable protonic membranes based on sulfonated polymers and hybrid inorganic-organic systems that can be produced on an industrial scale. 

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