A three mechanism model to describe fouling of microfiltration membranes

Mathematical modeling of flux decline during filtration plays an important role in both sizing membrane systems and in the understanding of membrane fouling. Protein fouling is traditionally modeled using one of three classical fouling mechanisms: pore blockage, pore constriction or cake filtration. Here, we have developed a mathematical model to describe flux decline behavior during microfiltration accounting for all three classical fouling mechanisms. Pore constriction was assumed to first reduce the size of internal pores. Pore blockage then occurs at the top of the membrane, preventing further fouling to the interior structure. Finally the foulants at the top of the membrane form a cake, which controls the late stages of the filtration. The model prediction shows excellent agreement with experimental data for 0.25 μm polystyrene microspheres filtered through 0.22 μm Isopore membranes (where pore constriction is expected to be minimal) as well as non-aggregated bovine serum albumin solution through hydrophobic Durapore membranes (where pore constriction is expected to dominate). The effects of different fouling mechanisms on the flux decline were characterized by the ratio of characteristic fouling times of the different mechanisms. In this way the model can provide additional insights into the relative importance of different fouling mechanisms as compared to an analysis by a single mechanism model or by derivative plots, and it can be used to provide important insights into the flux decline characteristics.     

A Combined Pore Blockage and Cake Filtration Model for Protein Fouling during Microfiltration

Previous studies of protein fouling during microfiltration have shown significant discrepancies between filtrate flux data and predictions of the classical pore blockage, pore constriction, and cake filtration models. A new mathematical model was developed for the filtrate flux which accounts for initial fouling due to pore blockage and subsequent fouling due to the growth of a protein cake or deposit over these initially blocked regions. The model explicitly accounts for the inhomogeneity in the cake layer thickness over different regions of the membrane arising from the time-dependent blockage of the pore surface. The model was shown to be in excellent agreement with experimental data obtained during the stirred cell filtration of bovine serum albumin solutions through polycarbonate track-etched microfiltration membranes over the entire course of the filtration. The model provides a smooth transition from the pore blockage to cake filtration regimes, eliminating the need to use different mathematical formulations to describe these two phenomena. In addition, the model provides the first quantitative explanation for some of the unusual observations reported previously in investigations of protein microfiltration. The results provide important insights into the underlying mechanisms of protein fouling during microfiltration. Copyright 2000 Academic Press.     

Influence of permeate flux on fouling during the microfiltration of β-lactoglobulin solutions under cross-flow conditions

Experiments to investigate the microfiltration fouling behaviour of a β-lactoglobulin solution were performed on a constant-flux, computer-controlled, cross-flow membrane rig equipped with zirconium oxide membranes. Fouling was dependent upon the permeate flux, being light at low flux (50 l/m² h) and severe at high flux (200 l/m² h). The fouling increased in severity as the flux was increased from 50 to 200 l/m² h. At 50 l/m² h, protein transmissions of>90% were observed. At higher fluxes, the protein transmission decreased with increasing fouling resistance. The relationship between fouling resistance and protein transmission was similar for 50 and 100 nm membranes and was independent of the starting permeate flux. Standard poreplugging and pore-narrowing models did not describe the observed behaviour. Development of a model to predict protein transmission from the fouling resistance indicated that fouling occurred only in a small part of the membrane pore, most likely at the pore entrance. It is proposed that the microfiltration pore acts in a way similar to a pressure-relief valve where shear-induced protein denaturation has been observed. Shear forces on the protein perhaps lead to protein denaturation and aggregation, and narrowing of the pore in the immediate vicinity of the pore entrance.     

Analysis of humic acid fouling during microfiltration using a pore blockage–cake filtration model

Fouling by natural organic matter, such as humic substances, is a major factor limiting the use of microfiltration for water purification. The objective of this study was to develop a fundamental understanding of the underlying mechanisms governing humic acid fouling during microfiltration using a combined pore blockage–cake filtration model. Data were obtained over a range of humic acid concentrations, transmembrane pressures, and stirring speeds. The initial flux decline was due to pore blockage caused by the deposition of large humic acid aggregates on the membrane surface, with a humic acid deposit developing over those regions of the membrane that have first been blocked by an aggregate. The rate of cake growth approaches zero at a finite filtrate flux, similar to the critical flux concept developed for colloidal filtration. The data were in good agreement with model calculations, with the parameter values providing important insights into the mechanisms governing humic acid fouling during microfiltration. In addition, the basic approach provides a framework that can be used to analyze humic acid fouling under different conditions.     

In situ three-dimensional characterization of membrane fouling by protein suspensions using multiphoton microscopy

Fouling of microfiltration membranes leads to severe flux declines and the need to clean or replace the membrane. In situ 3D characterization of protein fouling both on the surface and within the pores of the membrane was achieved using multiphoton microscopy. Time-lapse images of the fouled membrane were obtained for single suspensions and mixtures of fluorescently labeled bovine serum albumin and ovalbumin. Deposited protein aggregates were visible on the membrane and evidently play an important role in fouling. A combination of 3D images and resistance versus time data was used to identify the dominant fouling mechanism. Fouling is initially internally dominated, but after 1 and 15 min for ovalbumin and bovine serum albumin, respectively, the fouling becomes externally dominated. This is in good agreement with two-stage protein fouling models.     

Performance of partially permeable microfiltration membranes under low fouling conditions

Controlling the onset of fouling and concentration polarization is critical in many membrane operations, particularly in the bioseparation area. By using stepping and constant flux experiments, the fouling threshold or `incipient fouling' region was studied for various microfiltration membranes, pH's, and bulk concentrations using bovine serum albumin. Experiments were conducted to try to decouple effects such are porosity and pore size on incipient fouling by using a combination of tracked etched and polyvinylidene difluoride membranes. Changes in protein transmission and wall concentrations near the fouling threshold were also compared across these membranes. While porosity determined the fouling rate after the exceeding the fouling threshold, pore size appear to be an dominant factor in determining level of the fouling threshold itself. The effect of pH also supports the hypothesis that the rejections are initially dominated by membrane–solute interactions but are subsequently modified by protein adsorption to the surface as the wall concentration increases. Repulsive forces between membrane and solute allow greater rejection (greater wall concentration) to be maintained without fouling but did not increase the critical flux substantially. Attractive electrostatic forces allow greater passage of solute (lower wall concentration), but the protein adsorption soon dominated and the onset of fouling occurred much more quickly. Using a conventional concentration polarization model, analysis of the results indicates that the onset of fouling is occurring at a relatively low wall concentrations.     

Negatively charged poly(vinylidene fluoride) microfiltration membranes by sulfonation

Negatively charged PVDF microfiltration membranes were prepared using direct sulfonation with chlorosulfonic acid. The effect of sulfonation on the surface chemical properties, morphology, pore size distribution, hydrophilicity, water uptake, pure water flux, fouling and rejection were investigated. As the sulfonation reaction time was furthered, the degree of sulfonation and ion-exchange capacity increased and the membranes became more hydrophilic due to introduction of sulfonyl groups to the membrane surface. Using X-ray photoelectron spectroscopy, the composition of sulfonyl group with respect to sulfur concentration increased with time. From the SEM and porosity measurements, both the untreated and treated membranes did not reveal a substantial change in its morphology. The pure water flux increased significantly having a decreasing intrinsic resistance trend with degree of sulfonation. Both fouling phenomena and rejection were enhanced, with fouling of charged poly(styrene sulfonic acid) molecules on the surface-modified membrane decreased and rejection values increased with increasing degree of sulfonation mainly due to the effective electrostatic repulsion between the negatively charged PSSA and the negatively charged membrane.     

Membrane formation mechanism and permeation properties of a novel porous polyimide membrane

The transport properties of a novel porous fluorinated polyimide membrane fabricated by a wet phase inversion process were studied with a stirred dead‐end filtration cell. The porous membrane‐forming solvents were tetrahydrofuran (THF), acetone, N,N‐dimethylacetamide (DMAc), N‐methylpyrrolidone (NMP), N,N‐dimethylformamide (DMF), and dimethylsulfoxide (DMSO). The phase separation phenomena in a ternary system of polyimide/solvent/water were investigated from cloud point curves by a titration method and binary interaction parameters. Solvent–water demixing in the system has been found to play very important roles in determining the structure and surface morphology of the polyimide membrane. The porous fluorinated polyimide membranes showed pore sizes from 4 to 500 nm and permeation properties from ultrafiltration to a microfiltration range. In this study, we particularly focused on fouling of the polyimide membranes, because fouling decreases the flux and increases the resistance. Interestingly, the porous polyimide membrane showed excellent water flux recovery after water cleaning compared with that of the polyethersulfone (PSf) membrane, which suggest that for a 6FDA‐6FAP membrane, the protein–membrane and protein–protein interaction was not so strong compared with those in a PSf membrane. Copyright © 2002 John Wiley & Sons, Ltd.     

Influence of membrane structure on fouling layer morphology during apple juice clarification

The flux behavior of 0.2 μm nylon, polysulfone (PS), polyvinylidene fluoride (PVDF) and polyethersulfone (PES) membranes was examined during dead-end microfiltration of commercial apple juice. On nylon membranes, a 0.1 μm thick surface fouling layer rapidly formed that acted as a secondary membrane. The colloidal particles retained by this surface layer aggregated to form a thick loose gel structure, producing an anisotropic fouling structure. In contrast, the 4 μm thick surface fouling layer of PES was slower to form and had a more open structure with a lower flux resistance per unit thickness. The morphology of the PES surface layer also did not differ dramatically from the loose gel structure that subsequently formed on top of this secondary membrane. The PS surface fouling layer was similar in structure to nylon whereas the PVDF layer more closely resembled that found with PES. The density of the surface fouling layer did not directly correlate to membrane surface hydrophobicity or pure water flux. Atomic force microscopy (AFM) indicated that surface roughness strongly influenced surface fouling layer morphology. The membrane surface appears to act as a template for the fouling process; therefore, smooth membranes (nylon and PS) produce a dense surface fouling layer whereas this same layer on rough membranes (PES and PVDF) is much more open. Consequently, the fluxes of PES and PVDF membranes are less affected by fouling formation.     

Microfiltration performance of regenerated cellulose membrane prepared at low temperature for wastewater treatment

A series of regenerated cellulose membranes with pore diameters ranging from 21 to 52 nm have been prepared by dissolving cellulose in 5 wt% LiOH/12 wt% urea aqueous solution re-cooled to −12 °C. The influences of cellulose concentration on the structure, pore size, and the mechanical properties of the membrane were studied by using Wide angle X-ray diffraction, scanning electron micrography and tensile testing. Their pore size, water permeability, equilibrium-swelling ratio and fouling behaviors of the cellulose membranes were characterized. The water-soluble synthetic and natural polymers as organic matter were used to evaluate the microfiltration performance of the regenerated cellulose membrane for wastewater treatment in aqueous system. The results revealed that the organic matter with molecular weight more than 20 kDa effected significantly on the membrane pore density, and reducing factor a _2, whereas that having molecular weight less than 20 kDa exhibited a little influence on the membrane pore size reducing factor a ₁. Furthermore, a simple model to illustrate of microfiltration process of the RC membrane for wastewater treatment was proposed.     

Use of gas-liquid porometry measurements for selection of microfiltration membranes

The process of crossflow microfiltration is hindered by the significant problem of fouling due to a pore size which favours penetration of the solutes. This leads to an internal fouling (adsorption and pore obstruction) which reduces permeate flux and makes any regeneration difficult. This study outlines a method of choosing an appropriate microfiltration membrane. Choice of membrane nature and pore size has been made in accordance with rapid dead-end filtration tests and the use of liquid-gas permporometry. Measuring pore size by porometry allows a choice of material which is non-adsorbent with regard to specific solutions to be microfiltered. Moreover, the internal fouling can be detected quickly by backflush washing after several minutes of dead-end filtration, and by measuring pore size distribution of the fouled membrane. Thus, choice of pore size will tend towards a membrane which bears slight internal fouling. The methodology described in this paper has allowed an appropriate choice of microfiltration membrane for use in recycling alkaline cleaning solutions in the dairy products industry.     

Recognition based separation of HIV-Tat protein using avidin–biotin interaction in modified microfiltration membranes

Recognition based separation using modified microfiltration membranes provides an efficient and cost-effective alternative to conventional column chromatography for the separation and purification of a specific protein from mixture of proteins. In this study, Tat protein, which has been proposed as the specific target for AIDS vaccine, was separated and purified from a complex mixture of proteins, known as bacterial lysate (BL) using avidin–biotin interaction in 4-stack microfiltration membranes system. It was established by SDS-PAGE and Western Blot analysis that membrane based process recovered more pure form of Tat compared to conventional packed-bead column chromatography. The critical factors involved in the process, mainly, the accessibility of the covalently immobilized avidin sites by the biotinylated protein and the associated fouling of the membranes due to the permeation of proteins, were also studied. The accessibility of immobilized avidin sites in membrane was quantified by biotinylated solutions of different types and compositions. It was observed that permeation of proteins caused substantial fouling on the membrane matrix. The resistance offered by the protein layer and the approximate thickness of the protein layer were also quantified.     

Characterization and theoretical analysis of protein fouling of cellulose acetate membrane during constant flux dead-end microfiltration

A rapid characterization method was used to study protein fouling of cellulose acetate membrane during dead-end, in-line, constant flux microfiltration. Based on pressure-permeate volume profiles, two fouling phases could be identified and compared at different permeate fluxes. Using protein staining dyes, the model foulant (bovine serum albumin) was found to deposit on the upstream side of the membrane as a loose cake at its isoelectric point. The effects of solution pH on both the nature and extent of membrane fouling, and membrane cleaning were examined. To further understand and quantitatively analyze the fouling behavior, a combined mathematical model which took into account pore blocking, cake formation and pore constriction was developed based on existing fouling models. The data obtained by modeling was in good agreement with experimental fouling data. Theoretical analysis of data clearly indicated that cake formation was the main fouling mechanism. Using methods such as dynamic light scattering, the significant role of large protein aggregates in membrane fouling was confirmed. The dimer composition of protein did not change significantly during the fouling experiments, clearly indicating that smaller aggregates played less important role in membrane fouling.     

Sieve mechanism of microfiltration separation

A theoretical model of dead-end microfiltration (MF) of dilute suspensions is proposed. The model is based on a sieve mechanism of MF and takes into account the probability of membrane pore blocking during MF of dilute colloidal suspensions. An integro-differential equation (IDE) that includes both the membrane pore size and the particle size distributions is deduced. According to the suggested model a similarity property is applicable, which allows one to predict the flux through the membrane as a function of time for any pressure, and dilute concentration, based on one experiment at a single pressure and concentration. The suggested model includes only one fitting parameter, β>1, which takes into account the range of the hydrodynamic influence of a single pore. For a narrow pore size distribution in which one pore diameter predominates (track-etched membranes), the IDE is solved analytically and the derived equation is in good agreement with the measurements on different track-etched membranes. A simple approximate solution of the IDE is derived and that approximate solution, as well as the similarity principal of MF processes, is in good agreement with measurements using a commercial Teflon microfiltration membrane. The theory was further developed to take into account the presence of multiple pores (double, triple and so on pores) on a track-etched membrane surface.

A series of new dead-end filtration experiments are compared with the proposed initial and modified pore blocking models. The challenge suspension used was nearly monodispersed suspension of latex particles of 0.45 μm filtered on a track-etched membrane with similar sized pores 0.4 μm. The filtered suspension concentration ranged from 0.00006 to 0.01% (w/w) and the cross-membrane pressures varied from 1000 to 20,000 Pa. Three stages of microfiltration have been observed. The initial stage is well described by the proposed pore blocking model. The model required only a single parameter that was found to fit all the data under different experimental operational conditions. The second stage corresponds to the transition from the blocking mechanism to the third stage, which is cake filtration. The latter stage occurred after approximately 10–12 particle layers were deposited (mass = 0.006 g) on the surface of the microfiltration membrane.     

Beer clarification by microfiltration — product quality control and fractionation of particles and macromolecules

Beer clarification by microfiltration demands a finely balanced retention of colloidal particulates (yeast cells, chill haze flocs, etc.) and transmission of soluble macromolecules including carbohydrates, proteins, flavour, and colour compounds which give the “whole some” quality of a beer. The required porous transmission of these macromolecular species led to an unavoidable, complex and dynamic in-pore membrane fouling in terms of fouling constituents, formation, structure and kinetics, which are the main obstacles in obtaining an economically viable flux and consistency in permeate quality.This experimental study was carried out with the aims of understanding the dynamic inter-relation between flux, fouling and system selectivity during a cross-flow beer microfiltration process so that an effective operating strategy for flux optimisation could be formulated in conjunction with the parallel objective of good product (permeate) quality control. Tubular ceramic membranes (Ceramem) with nominal pore diameters of 0.2, 0.5, and 1.3 μm were used. Simultaneous measurement of flux and permeate qualities, such as specific gravity and chill haze level enabled identification of the effect of anti-fouling techniques, such as backflushing on transmission of essential beer components and on the filtered beer quality. The experimental evidence lead to an understanding that the drastic flux enhancement achieved by employing backflushing at reversed membrane morphology was associated with enhanced solute transmission which could, without careful control, upset a balanced transmission of essential beer components and the retention of unwanted “chill haze” components. Further operating parameters and varying system configurations were investigated over their effect on both flux performance and system selectivity. These include membrane pore size, filtration temperature, and the addition of an amorphous silica particles as coagulation agent for hydrophilic proteins.     

Fouling in direct contact membrane distillation process

The formation of deposit on the membrane surface (fouling) is one of the major operating problems of membrane distillation process. The influence of fouling on the performance of this process was investigated during the concentration of wastewater with proteins, bilge water, brines, and the production of demineralized water. The experiments were performed with polypropylene capillary membranes. The morphology and composition of the fouling layer were studied using Fourier transform infrared with diffuse reflectance spectroscopy and scanning electron microscopy coupled with the energy dispersing spectrometry. Fouling with various intensity was observed in most of the studied cases. Permeate flux decline was mainly caused by an increase in the heat resistance of the fouling layer. However in the case of non-porous deposit, a magnitude of the permeate flux was also determined by a resistance of water transport through the deposit layer. It was found the deposits were formed not only on the membrane surface, but also inside the pores. Salt crystallization in the membrane pores besides their wetting, also caused the mechanical damage of the membrane structure. The intensity of the fouling can be limited by the pretreatment of feed and a selection of the operating conditions of membrane distillation.     

Enhanced microfiltration of γ-globulin solution upon treatment of NaCl addition and/or DNase digestion

Microfiltration of a γ-globulin solution has been investigated through the virus removal membranes having different pore sizes (i.e. r=15, 35 and 75 nm) and a dialysis membrane (r=3.4 nm), which were all made of the same regenerated cellulose material. The addition of NaCl in the γ-globulin feed solution was effective to enhance the flux and transmission through the membranes having a pore size ranging from 15 to 75 nm. DNase treatment of a γ-globulin solution with Micrococcal nuclease enhanced the flux and transmission of γ-globulin through the membranes either with or without NaCl. The membranes having a pore size of 35 nm showed dramatically enhanced flux in the microfiltration of a γ-globulin solution containing NaCl and/or being treated with Micrococcal nuclease. This can be explained as a DNase treatment and NaCl addition in the protein solution dissociate protein aggregates of DNA–γ-globulin complex, which plugs the pores in the microfiltration membranes.     

Improved microfiltration and bacteria removal performance of polyethersulfone membranes prepared by modified vapor‐induced phase separation

Polyethersulfone (PES) microfiltration membranes were fabricated by a combined vapor‐induced phase separation and wet phase separation method. The effect of different non‐solvent additives in casting solution, ie, acetone, diethylene glycol, and triethylene glycol (TEG) was investigated on the membrane morphology and performance. Scanning electron microscopy images showed that the membrane containing TEG additive had a skinless symmetric structure with well interconnected pores. The permeability of the PES/PVP/TEG membranes increased by decreasing PES and TEG and increasing PVP concentration. Bacteria removal performance of the prepared membranes was investigated by the filtration of E. coli suspension. The membrane made from casting solution containing 15 wt.% PES, 16 wt.% PVP, and 20wt.% TEG showed a pure water flux of ~ 5370 L/m² h at low transmembrane pressure of 10 psi and 100% bacteria removal efficiency. The results of in vitro cytotoxicity test and cell viability assay showed non‐toxic nature of the prepared membranes.     

Microfiltration of protein solutions at thin film composite membranes

An experimental study of the interaction of the enzyme yeast alcohol dehydrogenase (YADH) with polysulfone thin film composite microfiltration membranes (Dow-Danmark) has been carried out. It was found that the membranes adsorbed only 3/4 of a monolayer of the enzyme under the conditions studied. Even so, under filtration conditions, the membrane permeation rate decreased continuously with time. This decrease in permeation rate was due neither to concentration polarisation nor to protein adsorption alone. However, it could be quantified using the standard blocking filtration law, which describes a decrease in pore volume due to deposition of protein in the interior structure of the membrane. Reversal of the membrane, so that the supporting matrix faced the feed solution, gave more stable permeation rates. Implications for the microfiltration of industrial fermentation broths are discussed.     

Pore morphologies in disordered nanoporous thin films

Materials with nanometer size heterogeneities are commonplace in the chemical and biological sciences (e.g, polymer blends, microemulsions, gels) and often exhibit complex morphologies. Although this morphology has a dramatic effect on the materials' properties, it is often difficult to accurately characterize. We describe a method, using small-angle X-ray scattering data, of generating representative three-dimensional morphologies of isotropic two-phase materials where the morphology is disordered, and we apply this to thin films containing nanometer sized pores with a range of porosities (4-44%). These representations provide a visualization of the pore morphology, give the pore size scale and extent of interconnection, and permit the determination of the transitions from closed pore to interconnected pores to bicontinuous morphology.