Membrane Separation Processes

AST Sanjay Patel

Global Industry Analysts (GIA): June, 2010 Report GIA: Membrane Separation Market to Exceed $11.6 B GIA developed new report on "Membrane Separation Technologies: A Global Strategic Business Report" Reviews market trends Competitive scenario Product overview Product introduction/launches Recent industry activity across global Key regional markets

The study also analyzes market data in terms of value sales for regions United States, Canada, Japan, Europe, Asia-Pacific, Middle East and Rest of World.
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Major Global Companies dealing in Membrane Processes Air Liquide Celgard LLC Culligan International Company CUNO Incorporated Degremont SA Dow Chemical Company FilmTec Corporation, E.I. DuPont De Nemours & Co. GE Water & Process Technologies Ion Exchange India Ltd ITT Corporation Koch Membrane Systems Millipore Corporation Nitto Denko Corporation Pall Corporation Parker Hannifin Corporation Praxair Siemens Water Tech. Spectrum Laboratories Thermax Permionics

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Diversified Applications of Membrane Processes

Production of Potable water Wastewater treatment and processing of water Food and Beverages industry Replacement of traditional filtration equipment Biological Applications Power Generation Chemicals Separation Medical Applications Production of pharmaceuticals Separation of a wide variety of emulsion, surfactant, and chelating mixtures

Membrane filtration is emerging as a viable alternative to conventional granular media-based processes. There has been a significant shift in preferences of key industries towards membranes from traditional filtration & Adsorption devices : GIA
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Potential for Membrane based Applications

Municipalities in Europe are increasingly employing membrane separation systems to ensure supply of pure drinking water. Moreover, in view of stringent environment regulations, there has been significant increase in the deployment of membranes in w a s t e w a t e r t r e a t m e n t s y s t e m s .
Rising demand for pure water is expected to boost market growth in Asia-Pacific. India is considered one of the more lucrative and bigger markets for membrane separation technologies in Asia-Pacific. With rapid advancements and development of novel technologies, there has also been significant rise in application areas for membrane technology in recent times in China.

Reverse osmosis is one of the fastest growing segments primarily on account of growing adoption of water desalination and its ability to achieve very high levels of purity cost-effectively and efficiently. The Middle East has emerged as the most promising market for seawater desalination thereby offering significant prospects for r e v e r s e o s m o s i s .
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Advantages of Membrane Processes

High Surface area Very much useful when Mixtures of similar Chemical compounds to be separated Separation of Mixtures of thermally unstable components (since no heating is needed). Also HT equipments are not required In conjunction with conventional separation methods (Separation of azeotropic mixtures before feeding them to a distillation column) When conventional method doesnt work, membranes are useful Huge & Complex machineries are not required Complex Instrumentation is not required The method does not require constant attention Energy savings No Phase change or Interphase MT No re-separation is required like Extraction, Leaching etc Whenever technology is new profit margin is higher
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Disadvantages of Membrane Processes

Membranes are expensive Low Flux Membranes are highly selective Narrow Operating conditions Membrane preparation is complex Upper Solid limit is lower (i.e. RO can be used for low solute conn) Certain solvents can quickly and permanently destroy the
membrane Certain colloidal solids, especially graphite and residues can permanently foul the membrane surface The mechanical energy requirement is higher Difficult to Separate Highly Viscous Liquids Poor Cleaning
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Example of Membrane
Definition of Membrane: A membrane is a discrete, thin Interface that moderates the Permeation of Chemical Species in contact with it.

Shrinking & Swelling of Grapes

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Semi Permeable Membrane

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Types of Membranes

Solid Membranes Organic (Polymer) Membranes

According to Pore Size

Inorganic Membranes
Ceramic, Alumina, Zeolite & Silica

Porous Membranes
(0.1-10 m)

Microporous Membranes
(1-100 nm)

Ti

Metallic Membranes

Noble Metals (Pt, Pd, Au, Ag, Rh),

Non-Porous Membranes
(0.5-5 nm)

Liquid Membranes

Glass Membranes
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Causes of Membrane Separation Processes

Pore Size of Membrane Solubility & Selectivity of Components Mobility of Component in Membrane Phase (Depends
upon membrane chemistry & phase) Driving force acting on Individual Component: P, T, C, Electric field
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Membrane Separation

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2-50 nm pore size

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10 m

2 m

UF
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MF
100 m

2 m

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Types of Membranes

Solid Membranes Organic (Polymer) Membranes

According to Pore Size

Inorganic Membranes
Ceramic, Alumina, Zeolite & Silica

Porous Membranes
(0.1-10 m)

Microporous Membranes
(1-100 nm)

Ti

Metallic Membranes

Noble Metals (Pt, Pd, Au, Ag, Rh),

Non-Porous Membranes
(0.5-5 nm)

Liquid Membranes

Glass Membranes
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Spiral wound - Organic

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Ceramic Membranes

Metal Membranes
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Hollow Fiber Membranes

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Plate & Frame Membranes

Tubular Membranes
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Membrane Separation Processes to be Studied

Micro Filtration Ultra Filtration

Membrane Distillation

Membrane Contactors
Membrane Reactors Hemo Dialysis

Nano Filtration
Reverse Osmosis Dialysis

Electro Dialysis
Donan Dialysis Pervaporation Gas Permeation

Blood Oxygenators
Controlled Drug Delivery Liquid Membranes

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Micro Filtration

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Ultra Filtration

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Nano Filtration

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Reverse Osmosis

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MF

UF

RO NF
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Examples of Applications and Alternative Separation Processes

Process
Microfiltration Ultrafiltration Nanofiltration

Applications
Separation of bacteria and cells from solutions

Alternative Processes Sedimentation, Centrifugation Centrifugation Distillation, Evaporation Distillation, Evaporation, Dialysis Reverse osmosis Crystallization, Precipitation Distillation Absorption, Adsorption, Condensation Distillation

Separation of proteins and virus, Break up of oil-in-water emulsions

Separation of dye and sugar, water softening

Reverse Osmosis
Dialysis Electrodialysis Pervaporation Gas Permeation

Desalination of sea and brackish water, Process water purification

Purification of blood (artificial kidney) Separation of electrolytes from non-electrolytes Dehydration of ethanol and organic solvents Hydrogen recovery, NG purification, Dehydration and separation of air
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Membrane

Water purification and desalination

Size of Materials Retained, Driving Force and Type of Membrane

Process Microfiltration Ultrafiltration Nanofiltration Reverse Osmosis Dialysis Separation Range 0.1 - 10 m microparticles 10 - 100 nm macromolecules Driving force Pressure difference (0.5 - 2 bar) Pressure difference (1 - 10 bar) Type of membrane Porous Microporous Microporous Nonporous Nonporous or microporous Nonporous or Microporous Nonporous Nonporous Microporous

0.5 - 10 nm molecules
< 1 nm molecules < 1 nm molecules < 1 nm molecules < 1 nm molecules < 1 nm molecules

Pressure difference (10 - 70 bar)

Pressure difference (10 - 100 bar) Concentration difference Electrical potential difference Concentration difference Partial pressure difference (1 - 100 bar)

Electrodialysis
Pervaporation Gas Permeation

Membrane Distillation

< 1 nm Partial pressure molecules AST Sanjay Patel difference

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Applications in Dairy Industry

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Differences between Strainer, Filter and Membrane

Separation for more than 10-25 Separation from 1 m to 1

m size Mechanical Operation Driving force: P Same size particles cannot be separated No phase change Solute cannot transfer Flux by Darcys Law Filter Thickness larger Equipments: Plate & Frame, Rotary etc size Mass Transfer & MO P, T, C, Solubility, Mobility Same size particles can be separated Phase change May be Solute can transfer Flux by Ficks Law Membrane Thickness lower Equipments: Spiral Wound, Hollow Fiber etc

Strainers: Solid visible to the Eye i.e. >25 m

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Membrane: A membrane is a discrete, thin Interface that moderates the Permeation of Chemical Species in contact with it. Permeate: The species passes through the membrane and collected at down stream side. Flux: Permeate rate per unit cross sectional are of membrane. Retentate: The species do not pass through the membrane and retained at front side. Concentrate: Another term for the reject stream. Cut : Ratio of Permeate flow rate to Feed Flow rate. Rejection: Ratio of difference between Feed and Permeate concentration to Feed AST Sanjay Patel concentration.

Glossary of Membrane Processes

Selectivity: Ratio of permeability of high permeable species to permeability of low permeable species. For UF: Ratio of Hydrodynamic diameter of Solute to Apparent pore diameter. Membrane Module: A unit package in which membrane separation is carried out also called as Membrane Separator. Barrier Layer: This refers to the active layer of membrane material that actually separates the impurities from the product stream or permeate. This barrier layer is supported by a micro-porous support layer, usually made from polysulfone, which is cast on a non-woven support material.

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Concentration Polarization: Accumulation of less permeable component on the membrane surface during separation. Fouling: Accumulation of collodial, particulates and/or biological contaminants on the membrane surface which are coming along with feed. Blinding: If Membrane pore chocked with species of larger diameter (considered as impurities in feed) than pore diameter is called Blinding. Dope: In the preparation of membrane the solution of polymers from which membrane s to be formed called Dope. Casting: It is used to indicate either laying down of a polymer solution (dope) on support or the spinning of a dope in the form of a hollow fiber. Phase Inversion: Basic phenomenon underlying the formation of micro porous membrane structure. Exposing a homogeneous polymer solution to certain chemical or thermal environment cause phase separation in solution. The resultant polymer poor and polymer rich regimes developing pores and continuous solid polymer matrix. TDS (Total Dissolved Solids): This is a measure, usually given in PPM (Parts Per Million) or in milligrams per liter (mg/l) that is used to specify the concentration. AST Sanjay Patel

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Osmosis The diffusion of a solvent through a semipermeable membrane from a less concentrated solution to a more concentrated solution. Osmotic Pressure: This is the pressure differential that develops as a result of a solution containing water and a particular concentration of dissolved solids, including minerals and salts. Cartridge Filter: Cartridge filters are a widely used and have been utilized for water treatment for many decades. Cartridges are usually rated in microns. 40 microns is considered the largest particle visible to the human eye. Typical prefiltration requirements for reverse osmosis systems are around 5 microns. Recovery Rate: This term refers to the percentage of water recovered as product water from a given quantity of feed water. Anion A negatively charged ion. Cation A positively charged ion. Ion An atom or group of atoms with an electrical charge that is positive (cation) or negative (anion) as a result of having lost or gained electrons. Auto flush An automatic temporary increase in the reject flow. This helps prevent membrane fouling. Scale The mineral deposits that can coat the insides of boiler or the surfaces of RO membranes. It consists mainly of calcium carbonate, which precipitates out of solution under certain conditions of pH, alkalinity and hardness.
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MSP with Tubular modules

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MSP with spiral-wound modules High Throughput

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Overview of different Membrane Processes

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Micro & Ultra Filtration

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Micro & Ultra Filtration

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Reverse Osmosis

Osmosis

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Gas Permeation

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Gas Permeation

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Dialysis

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Electrodialysis

Feed
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Pervaporation

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Pervaporation

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Pervaporation

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Membrane Contactor

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Membrane Distillation

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Membrane Distillation

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Membrane Distillation

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Hemodialysis

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Hemodialysis

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Membrane Reactors

Pd Membrane reactor for Methane Reforming

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Membrane Reactors

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CO + H2O CO2 + H2

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Membrane Reactors

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Next Membrane Preparation

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