Modeling of the permeate flux decline during MF and UF cross-flow filtration of soy sauce lees

Cross-flow ultrafiltration and microfiltration have been used to recover refined soy sauce from soy sauce lees for over 25 years. The precise mechanism which dominated the permeate flux during batch cross-flow filtration has not been clarified. In the present study, we proposed a modified analytical method incorporated with the concept of deadend filtration to determine the initial flux of cross-flow filtration and carried out the permeate recycle and batch cross-flow filtration experiments using soy sauce lees. We used UF and MF flat membrane (0.006 m² polysulfone) module under different transmembrane pressures (TMP) and cross-flow velocities. The modified analysis provided an accurate prediction of permeate flux during the filtration of soy sauce lees, because this model can consider the change in J₀ at initial stage of filtration which was caused by the pore constriction and plugging inside membrane, and these changes may not proceed when the cake was formed on the membrane surface. Mean specific resistance of the cake increased with TMP due to the compaction of the cake and decreased with cross-flow velocity due to the change of deposited particle size, but less depended on the membrane in the present study. These results indicate that the value of J₀ determined by modified method was relevant to exclude the effects of the initial membrane fouling by pore constriction due to protein adsorption and plugging with small particles. The modified analytical method for the cake filtration developed in the present study was considered to be capable of selecting an appropriate operating conditions for many cross-flow filtration systems with UF, MF membranes.     

Fouling of a ceramic microfiltration membrane by corn starch hydrolysate

The effect of operating parameters on fouling of a ceramic microfiltration membrane by corn starch hydrolysate of 95 dextrose equivalence was studied. Transmembrane pressures above 100 kPa had little or no effect on flux. Cross-flow velocity had a significant beneficial effect. The rate of flux decline was reduced significantly when the feed was adjusted from its natural pH of 4.2 to 10. However, this resulted in a dark brown clarified syrup (permeate). Scanning electron microscopy showed extensive fouling layers on the alumina surface with conventionally processed dextrose solutions and the least fouling layer with corn starch hydrolysate adjusted to pH 10. Maximum steady state flux for unconcentrated hydrolysate at its natural pH was 178 LMH obtained at low transmembrane pressures (103 kPa, 15 psi) and high cross-flow velocities (5 m s⁻¹). Adjustment of the pH to 10 can increase the flux by 40%.     

Controlled flux behaviour of membrane processes

Controlling ultrafiltration (UF) and microfiltration (MF) membrane fluxes at or around a region where fouling is minimal can provide an interesting and economic operating regime. Selectivity may be enhanced and cleaning may be easier. For a given flux it is sometimes possible to filter a product suspension at the same trans-membrane pressure (TMP) as for pure water (PWP), but this can require a lot of energy input to maintain cross-flow or high shear in other ways if high fluxes are required. The critical flux is the flux above which one starts to observe fouling. By operating at lower cross-flow velocities and just above the critical flux, and thus, with lower TMPs, periodic cleaning can be effected by temporarily stopping permeation. A change in feed rate demands a change in flux which is obtained by temporarily increasing energy inputs. Controlled flux improves macromolecular fractionation. As flux increases the rejection of high molecular weight materials decreases whilst that of lower molecular weight materials decreases. This paper discusses the causes of fouling and the use controlled flux operation to mitigate its effects.     

Flux decline behaviors in dead-end microfiltration of activated sludge and its supernatant

The properties of dead-end microfiltration were explored under constant pressure using two types of activated sludge controlled under the condition of different air flow rates. The activated sludge cultured at the air flow rate of 0.15 L min⁻¹ (the anaerobic condition) exhibited a significant flux decline compared with the case of the air flow rate of 2.33 L min⁻¹ (the aerobic condition). It was found from the results of microfiltration of the supernatant separated by centrifugation that the constituents in the supernatant caused a major cake resistance in microfiltration of the activated sludge. The average specific filtration resistance for filtration of the activated sludge was closely consistent with that for filtration of the supernatant at low pressure (49 kPa). However, the cake resistance of the microbial floc in microfiltration of the activated sludge became substantial with increasing filtration pressure because of high compressibility of the microbial floc. Moreover, the foulant and the fouling mechanism in microfiltration of the supernatant were evaluated from both microfiltration test of the supernatant and microfiltration test of the filtrate collected thereby. As a result, the effects of the pore size and material of the microfiltration membrane on the flux decline behaviors in dead-end microfiltration were reasonably elucidated.     

Study on the microfiltration of Escherichia coli-containing fermentation broth by a ceramic membrane filter

Microfiltration (MF) of a fermentation broth containing Escherichia coli is reported in this article. We used a ceramic membrane filter (zirconia on sintered carbon) having a nominal pore size of 0.2 μm. Our results indicate that the filtration resistance was mainly caused by the cake formed on the membrane surface. Both transmembrane pressure (TMP) and fluid sweeping velocity influenced this cake resistance. Resistances due to membrane itself and due to internal pore blockage by E. coli were less important and insensitive to both TMP and fluid sweeping velocity. Preliminary results also showed that the cell density could be significantly increased when we connected such a ceramic filter on-line with our fermentation system. In particular it was found that the gas bubbles entrained in the broth side of the filter could increase the filtration flux by as much as 80%.     

Productivity enhancement in a cross-flow ultrafiltration membrane system through automated de-clogging operations

A membrane system only has a limited operational lifetime, whereby it becomes so severely fouled that continued operation must be stopped. In the cross-flow configuration of membrane filtration of wastewater, both increased cross-flow velocities and decreased operational transmembrane pressures can be used to decrease membrane fouling and extend the life cycle of the membrane separation process. The study found that an optimised usage of two de-clogging techniques, with a 1 h production period followed by a 1 min relaxation period and then a 1 min high cross-flow rate period, resulted in a net productivity increase of 14.8%.

The study involved a detailed investigation into the utilization of two automated cleaning techniques to reduce fouling problems encountered when cross-flow membrane systems are operated with high permeate flux rates. The two cleaning techniques studied were periodic membrane relaxation and a periodic high rate cross-flow. During both the relaxation and high rate cross-flow periods, permeate production was stopped. This results in an operational loss in productivity. When each cleaning technique was operated individually, there was a net productivity decrease of 0.7%, due to the 3.2% operational loss due to cleaning technique being implemented.

The system was developed using a Programmable Logic Controller (PLC) and a Supervisory Control and Data Acquisition (SCADA) system to accurately control and monitor the process.     

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.     

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.     

Separation of cells and proteins from fermentation broth in a shear-enhanced cross-flow ultrafiltration module as the first step in the refinement of lactic acid

A shear-enhanced, cross-flow ultrafiltration module was used to separate cells and proteins from the fermentation broth. Three (fermented) media were studied: rich medium, rich medium with hydrolytic enzymes added after fermentation, and wheat flour hydrolysate. To find a membrane with as high a flux as possible, but still capable of separating cells and proteins from the lactic acid containing broth, the performance of three hydrophilic membranes of varying cutoffs (10,000, 20,000, and 30,000) and one hydrophobic membrane (cutoff 25,000) was investigated. The proteins produced by the lactic acid bacteria during fermentation and the hydrolytic proteins were retained by the hydrophilic membrane with a cutoff of 20,000, whereas wheat flour proteins were detected in the permeate. In the permeates from the hydrophobic membrane (cutoff 25,000), almost no proteins were detected. The flux of the whole-wheat flour hydrolysate was significantly lower than that of rich medium, for both the hydrophilic and the hydrophobic membranes. The flux was, in all cases, higher for the hydrophilic membrane (12–85 L/[m²·h], depending, on which medium was treated) than for the hydrophobic one (8–45 L/[m²·h]), even though the nominal cutoffs of the hydrophobic and hydrophilic membranes were almost the same. However, the difference in flux was smaller when the whole-wheat flour hydrolysate was processed (12 vs 8 L/[m²·h]) than when the rich medium was processed (85 vs 45 L/[m²·h]). Protein retention was higher for the hydrophobic membrane than for the hydrophilic membrane (cutoff 20,000) owing to blocking of the pores by proteins adsorbed on to the hydrophobic membrane surface.     

Blended chitosan and polyvinyl alcohol membranes for the pervaporation dehydration of isopropanol

Homogeneous membranes were prepared by casting the solution of blended chitosan and polyvinyl alcohol (PVA) on a glass plate. The percent weight of chitosan in the membrane was varied from 0 to 100%. The membrane thickness was in the range of 15–30 μm. The membranes were heat treated at 150 °C for an hour. After that the membranes were crosslinked by glutaraldehyde and sulfuric acid in acetone aqueous solution. The membranes were tested at 30–60 °C for dehydration performance of 50–95% isopropanol aqueous solutions. At around 90% of isopropanol in the feed mixture, permeate flux increased whereas the percent of water in permeate tended to decrease when the feed temperature increased for all membranes, except that the water content in permeate from the membrane containing 75 wt.% chitosan remained constant. The swelling degree in water and the total flux increased with increasing chitosan content in membranes. The effect of temperature on permeate flux followed the Arrhenius relationship. The permeate flux decreased when isopropanol in the feed increased for all membranes. However, water content in permeate and isopropanol concentration in the feed formed complex relationship for different chitosan content membranes. Sorption did not appear to have significant effects on separation. The membrane containing chitosan 75% performed the best. For a feed solution containing 90% isopropanol at 60 °C, the permeate flux was 644 g/m² h with water content of nearly 100% in the permeate. At 55% isopropanol in the feed at 60 °C, the permeate flux was 3812 g/m² h. In the range of 55–95% of isopropanol in the feed, the water content in permeate was more than 99.5%. This membrane showed very excellent performance with good mechanical strength. It is promising to develop this membrane for industrial uses.     

Microfiltration membranes prepared from polyethersulfone powder grafted with acrylic acid by simultaneous irradiation and their pH dependence

Polyethersulfone (PES) powder was grafted with acrylic acid (AAc) by simultaneous γ-ray irradiation. The kinetics of the radiation induced graft polymerization was studied and the grafted PES powder was characterized. Then, microfiltration (MF) membranes were prepared from PES-g-PAAc powder with different degrees of grafting (DG) under phase inversion method. The swelling behavior and the mean pore size of MF membranes were measured, and the filtration property was tested. The results showed that the pore size and the flux of MF membranes increased with the increase in DG. And, MF membranes’ properties were dependent on the pH value.     

Microfiltration membranes with pH dependent property prepared from poly(methacrylic acid) grafted polyethersulfone powder

Poly(methacrylic acid) (PMAA) grafted polyethersulfone (PES) powder was prepared by γ-ray irradiation-induced graft polymerization. The existing of the PMAA side chains in the grafted powder was proved by FT-IR spectroscopy. Then, pH dependent microfiltration (MF) membranes were cast from PES-g-PMAA powder with different degree of grafting (DG) under phase inversion method. The contact angle, mean pore size and swelling behavior of MF membranes were measured. The morphology was studied and the water filtration property was also tested. The results showed that the mean pore sizes and filtration properties of MF membranes cast from PES-g-PMAA powder varied with pH. In the most variant case, the flux of acid solution was about four times as that of basic solution for the MF membrane cast from PES-g-PMAA with DG of 20.0%.     

Self-forming dynamic membrane for ultrafiltration of pineapple juice

The formation of self-forming dynamic membrane on a porous ceramic support was studied. Pineapple juice of 12° Brix concentration was used in the experiments which were carried out at 25°C by circulating the pineapple juice at the applied pressure of 100, 200, and 300 kPa and at cross-flow velocities of 1.30–2.95 m s⁻¹ through the ceramic membrane module for 1 h. The experimental data of flux and rejections showed that the dynamic membrane was well-formed after 30 min of circulation under the applied pressure of 300 kPa and at a cross-flow velocity of 2.0 m s⁻¹ in which the steady values of flux and rejections of macromolecules and sugars obtained from the filtration mode were 6.0×10⁻³ m³/m² h, 84–87% and 6%, respectively. The corresponding values for ultrafiltration by alumina membrane of MW cut-off 50,000, using equivalent conditions, were 15.8×10⁻³ m³/m² h, 91% and 10.5%. Ultrafiltration was found to be more promising. The stability of the self-forming dynamic membrane was acceptable when subjected to change of filtration conditions. The permeation flux increased with cross-flow velocity and decreased when the applied pressure was reduced. The resistances for filtration by dynamic membrane and by ultrafiltration were calculated. For a porous support of large pore sizes, an in-pore blockage of solutes which were smaller than the membrane pores reduced the pore volume and induced fouling. Internal fouling resistance (R_f) was, therefore significant and responsible for the values of flux and rejection and was approximately 70% of total resistance. While in ultrafiltration, in which membrane with a smaller pore diameter was used, R_f was only 20% but R_p, the polarized layer resistance, was as high as 60% of total resistance.     

Polysilicato-iron for improved NOM removal and membrane performance

The natural organic matter (NOM) removal efficiency of polysilicato-iron (PSI) coagulants and the fouling potential of PSI pretreated waters have been studied using two microfiltration (MF) membrane types: polyvinylidene fluoride (PVDF-2) and polypropylene (PP). The results showed that PSI coagulant with a Si/Fe ratio of 1 (PSI-1) was the most effective, compared to conventional coagulants, in removing dissolved organic carbon (DOC) and in improving the fouling potential. A relative flux of unity through PVDF-2 membrane was achieved for both water sources pretreated with PSI-1.

Aluminium-based coagulants, particularly aluminium chlorohydrate (ACH), worked best at lower coagulant dose. Increasing the coagulant dose to improve DOC removal led to increased membrane fouling, possibly due to increased level of unsettleable flocs and pore blocking. For PSI with larger floc size, the advantage of increased DOC removal was not overridden by the adverse effect of pore blocking. In addition, the residual neutral fraction in the waters and/or the presence of a filter cake on the membrane surfaces seemed to have a limiting effect on the fouling rates through both PP and PVDF-2 membranes to the extent that similar rates were obtained, despite substantial differences in DOC removal.

In contrast, these limiting factors did not influence the fouling potential of PSI-1 treated waters through the PVDF-2 membrane, as suggested by the relative flux of unity for both water sources. It is suggested that the oxide deposits on the PVDF-2 membrane may act as a ‘screening layer’, acting as pre-filtration by the filter cake. This layer may be effectively removed by backwashing, together with deposited NOM, throughout the experiment to maintain the flux at unity. The hydrophobic nature of the PP membrane may discourage the deposition of the oxides, thus minimising the positive effects of the oxides in the system. The high removal of hydrophobic fractions by PSI-1 may also lead to less association between residual NOM and less binding to the membranes, particularly on the PVDF-2 membrane.     

Reversibility of fouling formed in activated sludge filtration

This paper investigates the reversibility of membrane fouling by activated sludge in a membrane bioreactor equipped with a 0.1 μm pore ceramic membrane. The membrane was submitted to a series of tests in which the permeate flux, the transmembrane pressure (TMP) or the circulation velocity were successively varied in cycles by step increments or decreases. When the permeate flux is set below the critical flux, the TMP remains stable and fouling is reversible. On the contrary, when the critical flux is exceeded, the TMP increases and does not stabilize, as in dead-end filtration. The fouling formed is partly irreversible when the flux is lowered again. When the TMP is first increased up to 400 kPa and then decreased back at constant velocity, no hysteresis is found on the flux–TMP graph, showing that fouling is reversible in this case. Velocity cycles were performed by first lowering the velocity from 5 to 1 m/s and raising it again to 5 m/s. In this case again, the fouling induced by reducing the velocity was found to be reversible. However, when the same pressure and velocity cycle tests were performed with activated sludge collected in the aeration tank of a classical wastewater treatment plant, fouling was found to be partly irreversible, showing that the cake formed in the absence of shearing is much more cohesive. In the final part of the paper, we tested a hydrodynamic method of fouling control consisting in alternating short periods of filtration (1–4 s) and short periods of washing (1 or 2 s) at low TMP and high velocity. This method yielded to a 20% permeate flux increase with a 10% reduction in hydraulic energy consumption for classical plant activated sludge.     

Adsorption behavior of BSA in microfiltration with porous glass membrane

The fouling mechanism during dead-end microfiltration of bovine serum albumin (BSA) with porous glass membrane was investigated from the point of BSA adsorption onto the pore surface of membrane under the condition of pH 5.0 and ionic strength 0.01. The location of BSA retention was confirmed by comparing the filtration performance between dead-end mode and cross-flow mode. During the dead-end microfiltration BSA was retained only by the adsorption on the pore surface. The adsorption was irreversible and of multilayer type, which consists of the adsorption on clean pore surface, i.e. the primary adsorption, and that on preadsorbed pore surface, i.e. the secondary one. The adsorption isotherm was high affinity type. The adsorption rate was proportional to the feed rate of BSA, and the proportional coefficient was dependent on the adsorption process. The flux decline was correlated quantitatively with the amount of adsorbed BSA from the pore radius narrowing model by adsorption.     

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.     

Resistance-in-series analysis in cross-flow ultrafiltration of fermentation broths of Bacillus subtilis culture

Quantitative analysis of various resistances that lead to flux decline during cross-flow ultrafiltration (UF) of the fermentation broth of Bacillus subtilis ATCC (American Type Culture Collection) 21332 culture was studied. Polyethersulfone membrane with a molecular weight cut-off (MWCO) of 100 kDa was used. Prior to cross-flow UF, the broth was treated by acid precipitation (pH 4.0) and centrifugation, and the precipitate was re-dissolved in NaOH solution. Experiments were performed at a feed pH of 7.0, a feed surfactin concentration of 1.48 g L⁻¹, and a cross-flow velocity of 0.32 m s⁻¹ but at different transmembrane pressures (ΔP, 20–100 kPa). The resistance-in-series model was used to analyze the flux behavior, which involves the resistances of membrane itself and cake as well as those due to adsorption and solute concentration polarization. It was shown that the resistance due to solute concentration polarization and of membrane dominated under the conditions examined. The resistances due to cake formation and solute adsorption were comparable, and their sum contributed below 20% of the overall resistance.     

A model for determining the steady state flux of inorganic microfiltration membranes

The present paper provides a model based on dimensional analysis that gives the basis for design of the cross-flow microfiltration processes. This gives the permeate flux f in terms of the pressure drop across the filtration membrane ΔP and the velocity V of cross-flow of the feed fluid in the membrane tubes. The model is compared with an extensive series of experimental results with magnesium hydroxide slurries. The model has certain similarities with previous ones and can be used for unit optimization.     

The effect of uni-axial stretching on the roughness of microfiltration membranes

Atomic force microscopy (AFM) was used to characterize the surface morphology of uni-axially stretched and non-stretched microporous microfiltration (MF) membranes. The effect of stretching on the pore structure and bulk properties of MF membranes has been previously reported [J.A. Morehouse, L.S. Worrel, D.L. Taylor, D.R. Lloyd, B.D. Freeman, D.F. Lawler, The effect of uni-axial orientation on macroporous membrane structure, J. Porous Mater. 13 (2006) 63–75.]; this paper focuses solely on the use of AFM to characterize the surface of stretched and non-stretched MF membranes. A new way of representing surface roughness that may prove useful in relating roughness to performance in cross-flow applications is presented.