Membrane processes downstream

Fermentation Processes. The efficient production of penicillin, yeasts, and single-ceUed protein by fermentation requires defoamers to control gas evolution during the reaction. Animal fats such as lard [61789-99-9] were formerly used as a combined defoamer and nutrient, but now more effective proprietary products are usually employed. Defoamer appHcation technology has also improved. For example, in modem yeast production faciHties, the defoamers are introduced by means of automatic electrode-activated devices. One concern in the use of defoamers in fermentation processes is the potential fouHng of membranes during downstream ultrafiltration (qv). SiHcone antifoams (43,44) seem less troubled by this problem than other materials. 

When ionic liquids are used as replacements for organic solvents in processes with nonvolatile products, downstream processing may become complicated. This may apply to many biotransformations in which the better selectivity of the biocatalyst is used to transform more complex molecules. In such cases, product isolation can be achieved by, for example, extraction with supercritical CO2 [50]. Recently, membrane processes such as pervaporation and nanofiltration have been used. The use of pervaporation for less volatile compounds such as phenylethanol has been reported by Crespo and co-workers [51]. We have developed a separation process based on nanofiltration [52, 53] which is especially well suited for isolation of nonvolatile compounds such as carbohydrates or charged compounds. It may also be used for easy recovery and/or purification of ionic liquids. 

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. 

This chapter discusses the use of membrane processes for recovery, concentration, and purification of biologically active compounds from complex media. This chapter is not organized and written as a review paper aiming at referring all major developments in the use of membranes for downstream processing but, rather, it presents the author s perspective aboutthis field, its main constraints and challenges. 

The main constraints and problems associated with the use of membrane processes for downstream processing have been extensively discussed in the literature and the understanding of their nature and mechanisms has driven research towards the development of new solutions. 

Membrane pretreatment includes microfiltration (MF), ultrafiltration (UF), and nanofiltration (NF). Microfiltration and UF membrane processes can remove microbes and algae. However, the pores of MF and UF membranes are too large to remove the smaller, low-molecular weight organics that provide nutrients for microbes. As a result, MF and UF can remove microbes in the source water, but any microbes that are introduced downstream of these membranes will have nutrients to metabolize. Therefore, chlorination along with MF and UF is often recommended to minimize the potential for microbial fouling of RO membranes. The MF or UF membranes used should be chlorine resistant to tolerate chlorine treatment. It is suggested that chlorine be fed prior to the MF or UF membrane and then after the membrane (into the clearwell), with dechlorination just prior to the RO membranes. See Chapter 16.1 for additional discussion about MF and UF membranes for RO pretreatment. 

Permselectivity is crucial to the utility of any types of membranes. If the permselectivity toward a particular reaction species is high, the separation is quite clean and the need for further separation processing downstream of the membrane reactor is reduced. When a permeate of very high purity is required in some cases, dense membranes are preferred. While a high permselectivity is generally desirable, there may be situations where a high permeate flux in combination with a moderate permselectivity is a better alternative to a high permselectivity with a low permeability, particularly when recycle streams are used. 

As in the case of gas separation discussed in Chapter 7, which reaction component(s) in a membrane reactor permeates through the membrane determines if any gas recompression is required. If the permeate(s) is one of the desirable products and needs to be further processed downstream at a pressure comparable to that before the membrane separation, recompression of the permeate will be required. On the other hand, if the retentate(s) continues to be processed, essentially no recompression will be necessary. Recompressing a gas can be rather expensive and its associated costs can be pivotal in deciding whether a process is economical. 

Selective separation of hquids by pervaporation is a result of selective sorption and diffusion of a component through the membrane. PV process differs from other membrane processes in the fact that there is a phase change of the permeating molecules on the downstream face of the membrane. PV mechanism can be described by the solution-diffusion mechanism proposed by Binning et al. [3]. According to this model, selective sorption of the component of a hquid mixture takes place at the upstream face of the membrane followed by diffusion through the membrane and desorption on the permeate side. 

Pervaporation is a membrane process in which a liquid is maintained on the feed side of a membrane and permeate is removed as a vapor on the downstream side of the membrane. Pervaporation is used, because of its low energy consumption and low cost, to separate dissolved organics from water, purify waste water or volatile chemicals, and break azeotropes. Pervaporation plants range from processing a few grams per hour up to thousands of tons per year. For waste water treatment flow of less than 76 L min pervaporation is more cost-effective than other treatment options, such as chemical oxidation, ultraviolet destruction, air stripping followed by carbon adsorption, steam stripping, or distillation/incineration [262]. 

Vapor permeation and pervaporation are membrane separation processes that employ dense, non-porous membranes for the selective separation of dilute solutes from a vapor or liquid bulk, respectively, into a solute-enriched vapor phase. The separation concept of vapor permeation and pervaporation is based on the molecular interaction between the feed components and the dense membrane, unlike some pressure-driven membrane processes such as microfiltration, whose general separation mechanism is primarily based on size-exclusion. Hence, the membrane serves as a selective transport barrier during the permeation of solutes from the feed (upstream) phase to the downstream phase and, in this way, possesses an additional selectivity (permselectivity) compared to evaporative techniques, such as distillation (see Chapter 3.1). This is an advantage when, for example, a feed stream consists of an azeotrope that, by definition, caimot be further separated by distillation. Introducing a permselective membrane barrier through which separation is controlled by solute-membrane interactions rather than those dominating the vapor-liquid equilibrium, such an evaporative separation problem can be overcome without the need for external aids such as entrainers. The most common example for such an application is the dehydration of ethanol. 

Figure 3.23 Major process steps in downstream processing. Membrane processes may include MF, UF, RO, and/or ED for concentration, separation and purification.

In membrane processes, the increase in feed impurity concentrations tend to cause a decrease in product purity, which, however, can be maintained for small feed composition changes by adjusting the feed-to-permeate pressure ratio. In most refinery membrane applications, however, the major product impurity is methane, and this can be allowed to increase slightly in the product without major downstream impact. The response time of membrane systems is essentially instantaneous, and corrective action has immediate results. The start-up time required by the process is extremely short. 

Pervaporation membranes In the pervaporation separation process, a liquid mixture is brought in direct contact with the feed side of the membrane, and the permeate is removed as vapor from the other side of the membrane. The mass flux is driven by maintaining the downstream partial pressure below the saturation pressure of the liquid feed solution. The transport of liquids through the membranes differs from other membrane processes such as gas separation because the permeants in pervaporation usually show high solubility in polymeric membranes. 

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