Multi-stage premix membrane emulsification for preparation of agarose microbeads with uniform size

Uniform-sized agarose beads with diameters less than 10 μm and agarose content as high as 14 wt% were prepared by premix membrane emulsification. Agarose aqueous solution was used as the water phase. A mixture of liquid paraffin and petroleum ether containing hexaglycerin penta ester (PO-500) was used as the oil phase. The water phase was mixed with the oil phase at 60 °C and a coarse W/O emulsion was produced in a homogenizer. Then, the coarse emulsion was extruded through a hydrophobic membrane under high pressure to form an emulsion, which was slowly cooled under gentle agitation to form gel beads. The effects of preparation conditions on emulsification results were investigated and it showed that the pressure, number of passes, petroleum ether/liquid paraffin (v/v) in the oil phase, the concentration of PO-500 and concentration of agarose in the water phase, all affected the size and uniformity; coarse emulsion did not affect the emulsification results. The coefficient variation (C.V.) of agarose beads under optimal preparation conditions was 9.8%. This method realized microbeads with both uniform sizes and high agarose contents that are difficult to be prepared by conventional emulsion methods.     

A Comparison of Membrane Emulsification Obtained Using SPG (Shirasu Porous Glass) and PTFE [Poly(Tetrafluoroethylene)] Membranes

SPG (Shirasu porous glass) membrane emulsification used to prepare uniform polymeric microspheres is briefly reviewed, and the performance of a hydrophilically treated PTFE [poly(tetrafluoroethylerie)] membrane is described and compared with that of the SPG membrane. A mixture of styrene. divinyl benzene and hexadecane (HD) was extruded through the membranes and dispersed in an aqueous phase containing polyvinylalcohol (PVA) and sodium lauryl sulfate (SLS) as mixed stabilizers. A hvdrophilically treated PTFE membrane was used with a stainless steel mesh support so that the membrane would not expand to affect the pore size during the emulsification. The nominal pore size of the PTFE membrane was replaced with the calculated one using a theoretical expression derived from the force balance between the external pressure and the interfacial tension between oil and water phases. The emulsion droplets prepared with the PTFE membrane revealed a broader size distribution than those obtained with the SPG membrane, and the rate of emulsificaton was nearly same for both membranes. Droplet size control was readily possible. The performance was significantly affected by the adsorption behavior of the stabilizers on the membrane surfaces. The contact angle profile of oil droplets on the PTFE membrane implied that the hydrophilically treated PTFE membrane is still hydrophobic compared to the SPG membrane. This tendency was reflected by the dependence of the average droplet diameter (and coefficient of variation, CV) on the concentration and composition of mixed stabilizers.     

Fabrication strategy for amphiphilic microcapsules with narrow size distribution by premix membrane emulsification

Amphiphilic co-polymer, which can maintain the stability of proteins and increase the protein loading efficiency, is considered as an exploring-worthy biodegrade polymer for drug delivery. However, amphiphilic microcapsules prepared by conventional methods, such like mechanical stirring and spray-drying methods, exhibit broad size distributions due to its hydrophilic sequences, leading to poor reproducibility. In this study, we employed poly(monomethoxypoly ethylene glycol-co-D,L-lactide) (mPEG-PLA, PELA), one of common amphiphilic polymers, as model to focus on investigating the process parameters and mechanisms to prepare PELA microcapsules with narrow size distribution and regular sphericity by combining premix membrane emulsification and double emulsion technique. The coarse double emulsion with broad size distribution was repeatedly pressed through Shirasu Porous Glass (SPG) membrane with relatively high pressure to form the fine emulsion with narrow size distribution. Then, the microcapsules with narrow size distribution can be obtained by solvent extraction method. It was found that it was more difficult to obtain PELA microcapsules with narrow size distribution and smooth surface due to its amphiphilic property, compared with the cases of PLA and PLGA. The smooth surface morphology was found to be related to several factors including internal water phase with less volume, slower stirring rate during solidification and using ethyl acetate as oil phase. It was also found that mass ratio of hydrophilic mPEG, stabilizer PVA concentration in external water phase and transmembrane pressure played important role on the distribution of microcapsules size. The suitable preparation conditions were determined as follows: for the membrane with pore size of 2.8 μm, the mass ratio of PLA/mPEG was 19:1, volume ratio of W(1)/O was 1:10 and O/W(2) was 1:5, PVA concentration (w/v) was 1.0%, magnetic stirring rate during solidification was 60 rpm and 300 kPa was chosen as transmembrane pressure. There was a linear relationship between the diameter of microcapsules and the pore size of the membranes. Finally, by manipulating the process parameters, PELA microcapsules with narrow size distributions (coefficient of variation was less than 15%), smooth morphology and various sizes, were obtained. Most importantly, the key factors affecting fabrication have been revealed and mechanisms were illustrated in detail, which would shed light on the research of amphiphilic polymer formulation.     

Study of SPG membrane emulsification processes for the preparation of monodisperse core-shell microcapsules

Experimental investigations on the Shirasu-porous-glass (SPG)-membrane emulsification processes for preparing monodisperse core-shell microcapsules with porous membranes were carried out systematically. The results showed that, to get monodisperse oil-in-water (O/W) emulsions by SPG membrane emulsification, it was more important to choose an anionic surfactant than to consider hydrophile-lipophile balance (HLB) matching. Increasing the viscosity of either the disperse phase or the continuous phase or decreasing the solubility of the disperse phase in the continuous phase could improve both the monodispersity and the stability of emulsions. With increasing monomer concentration inside the disperse phase, the monodispersity of emulsions became slightly worse and the mean diameter of emulsions gradually became smaller. Monodisperse monomer-containing emulsions were obtained when the SPG membrane pore size was larger than 1.0 micro m, and from these emulsions satisfactory monodisperse core-shell microcapsules with a porous membrane were prepared. On the other hand, when the SPG membrane pore size was smaller than 1.0 mciro m, no monodisperse emulsions were obtained because of the formation and chokage of solid monomer crystals in the pores or at the end of the pores of the SPG membrane. This was due to the remarkable solvation and diffusion of the solvent in water. With increasing the emulsification time the average emulsion diameter generally decreased, and the monodispersity of the emulsions gradually became worse.     

Effects of organic solvents on ultrafiltration polyamide membranes for the preparation of oil-in-water emulsions

Hydrophilic ultrafiltration membranes made of polyamide with molecular weight cutoff 10 and 50 kDa have been studied for the preparation of oil-in-water emulsions by a cross-flow membrane emulsification technique. Isooctane and phosphate buffer were used as disperse and continuous phase, respectively. The permeation of apolar isooctane through the polar hydrophilic membrane was achieved by pretreatment of membranes with a gradient of miscible solvents of decreasing polarity to remove water from the pores and replace it with isooctane. Four different procedures were investigated, based on the solvent mixture percentage and contact time with membranes. After pretreatment, the performance of the membranes in terms of pure isooctane permeate flux and emulsion preparation was evaluated. The influence of organic solvents on polyamide (PA) membranes has been studied by SEM analysis, which showed a clear change in the structure and morphology of the thin selective layers. The effects proved stronger for PA 10 kDa than for 50 kDa. In fact, similar pretreatment procedures caused larger pore size and pore size distribution for PA 10 kDa than for 50 kDa. The properties of emulsions in terms of droplet size distribution reflected the membrane pore sizes obtained after pretreatment. The correlation between pore size and droplet size, for the physicochemical and fluid dynamic conditions used, has been evaluated.     

The drop size in membrane emulsification determined from the balance of capillary and hydrodynamic forces

Here, we investigate experimentally and theoretically the factors that determine the size of the emulsion droplets produced by membrane emulsification in "batch regime" (without applied crossflow). Hydrophilic glass membranes of pore diameters between 1 and 10 mum have been used to obtain oil-in-water emulsions. The working surfactant concentrations are high enough to prevent drop coalescence. Under such conditions, the size of the formed drops does not depend on the surfactant type and concentration, on the interfacial tension, or on the increase of viscosity of the inner (oil) phase. The drops are monodisperse when the working transmembrane pressure is slightly above the critical pressure for drop breakup. At higher pressures, the size distribution becomes bimodal: a superposition of a "normal" peak of monodisperse drops and an "anomalous" peak of polydisperse drops is observed. The theoretical model assumes that, at the moment of breakup, the hydrodynamic ejection force acting on the drop is equal to the critical capillary force that corresponds to the stability-instability transition in the drop shape. The derived equations are applied to predict the mean size of the obtained drops in regimes of constant flow rate and constant transmembrane pressure. Agreement between theory and experiment is established for the latter regime, which corresponds to our experimental conditions. The transition from unimodal to bimodal drop size distribution upon increase of the transmembrane pressure can be interpreted in terms of the transition from "dripping" to "jetting" mechanisms of drop detachment.     

HBPE-g-PVDF/PVDF blend nanofiltration membrane: preparation and characterization

Hyperbranched polyester-grafted poly(vinylidene fluoride) (HBPE-g-PVDF) was synthesized and used as additive in preparation of PVDF blend membranes. HBPE-g-PVDF copolymer was characterized with FTIR and TGA techniques. The prepared membranes were also characterized with SEM, AFM and contact angle measurement. The performance of prepared membranes as nanofiltration membrane was studied by pure water flux (PWF), salt rejection, dynamic and static fouling tests. The results showed that hydrophilicity of prepared membranes greatly increased after blending, and their pore size and pore size distribution and so PWF of blend membranes increased.     

A review of: “Nineteenth Century Attitudes: Men of Science (Chemists and Chemistry Series,Vol. 13)”. Sydney Ross. Kluwer Academic Publishers; Dordrecht, 1991. pp. xi+235. $69.00.

Abstract

The potential of polytetrafluoroethylene (PTFE) membranes as water‐in‐oil (W/O) emulsification devices was investigated to obtain uniformly sized droplets and to convert them into microcapsules and polymer particles via subsequent treatments. Uniform W/O emulsion droplets have not been achieved using glass membranes unless the membrane was rendered hydrophobic by treatment with silanes. If a PTFE membrane is capable of providing uniform droplets for a W/O emulsion, a coordinated membrane emulsification system can be established since glass membranes have been so successful for O/W (oil‐in‐water) emulsification. In order to examine the feasibility of PTFE membrane emulsification, O/W and W/O emulsion characteristics prepared using PTFE membranes were compared with those prepared by the conventional SPG (Shirasu porous glass) membrane emulsification method. A 3 wt.% sodium chloride solution was dispersed in kerosene using a low HLB surfactant. Effects of the membrane pore size, permeation pressure, and the type of emulsifiers and concentration on the droplet size and on the size distribution (CV, coefficient of variation) were investigated. The CV of the droplets was fairly low, and the average droplet size was correlated with the critical permeation pressure of the dispersed phase, revealing that the PTFE membrane could be used as a one‐pass membrane emulsification device. Low CV values were maintained with a Span 85 (HLB = 1.8) concentration, 0.2–5.0 wt.% and a range of HLB from 1.8–5.0. For a brief demonstration of practical applications, nylon‐6,10 microcapsules prepared by interfacial polycondensation and poly(acrylamide) hydrogels from inverse suspension polymerization are illustrated.     

Status of cross-flow membrane emulsification and outlook for industrial application

Cross-flow membrane emulsification has great potential to produce monodisperse emulsions and emulsions with shear sensitive components. However, until now, only low disperse phase fluxes were obtained. A low flux may be a limiting factor for emulsion production on a commercial scale. Therefore, the effects of membrane parameters on the disperse phase flux are estimated. Besides, the effects of these parameters on the droplet size and droplet size distribution are qualitatively described. Wetting properties, pore size and porosity mainly determine the droplet size (distribution). Membrane morphology largely determines the disperse phase flux. As an example, industrial-scale production of culinary cream was chosen to evaluate the required membrane area of different types of membranes: an SPG membrane, an -Al₂O₃ membrane and a microsieve. Due to the totally different morphologies of these membranes, the fraction of active pores is 1 for a microsieve and is very low for the other membranes. The choice of the optimal membrane did not depend on the production strategy: either to produce large quantities or to produce monodisperse emulsions, the best suitable was a microsieve with an area requirement of around 1 m². In general, the total membrane resistance should be low to obtain a large disperse phase flux. In contrast, the membrane resistance should be high to obtain monodisperse emulsions when using membranes with a high porosity.     

Production of porous suspension polymer beads with a narrow size distribution using a cross-flow membrane and a continuous tubular reactor

The work described focuses on a two-stage process for the production of large porous suspension polymer beads of defined particle size and narrow size distribution. Emulsification has been performed using purpose built cross-flow membrane equipment, which allows controlled production of large emulsion droplets with a much narrower size distribution. The work described compares the production of large emulsion droplets of monomer prepared both by agitation and using a cross-flow membrane. The effects of variations in the pore size of the membrane and flow-rates on the size of the emulsion droplets produced are also investigated. The second stage of the process is polymerisation of performed monomer emulsion droplets using a continuous tubular reactor. Samples polymerised using such a method show a narrower size distribution than similar systems polymerised as a batch.     

Preparation of uniform-sized PELA microspheres with high encapsulation efficiency of antigen by premix membrane emulsification

Relatively uniform-sized poly(lactide-co-ethylene glycol) (PELA) microspheres with high encapsulation efficiency were prepared rapidly by a novel method combining emulsion-solvent extraction and premix membrane emulsification. Briefly, preparation of coarse double emulsions was followed by additional premix membrane emulsification, and antigen-loaded microspheres were obtained by further solidification. Under the optimum condition, the particle size was about 1 mum and the coefficient of variation (CV) value was 18.9%. Confocal laser scanning microscope and flow cytometer analysis showed that the inner droplets were small and evenly dispersed and the antigen was loaded uniformly in each microsphere when sonication technique was occupied to prepare primary emulsion. Distribution pattern of PEG segment played important role on the properties of microspheres. Compared with triblock copolymer PLA-PEG-PLA, the diblock copolymer PLA-mPEG yielded a more stable interfacial layer at the interface of oil and water phase, and thus was more suitable to stabilize primary emulsion and protect coalescence of inner droplets and external water phase, resulting in high encapsulation efficiency (90.4%). On the other hand, solidification rate determined the time for coalescence during microspheres fabrication, and thus affected encapsulation efficiency. Taken together, improving the polymer properties and solidification rate are considered as two effective strategies to yield high encapsulation.     

Demulsification of water-in-oil emulsions via filtration through a hydrophilic polymer membrane

It is known that hydrophobic microfiltration membranes can be used for demulsification of oil-in-water (o/w) emulsion due to coalescence of oil droplets in membrane pores. This study demonstrates that a hydrophilic polymer membrane can be used for the demulsification of surfactant-stabilized water-in-oil (w/o) emulsions. The success of demulsification is dependent on the type of emulsions and membrane used. Membrane pore size and transmembrane pressure were found to affect demulsification efficiency (DM), while other factors, such as membrane thickness and initial water content have slight or almost no effect. A coalescence mechanism of the demulsification phenomenon is also discussed. The separation process is not based on sieving effects due to a difference in membrane pore size, but is determined by droplet interactions with membrane surface.     

Preparation and characterization of PLGA particles for subcutaneous controlled drug release by membrane emulsification

Uniformly sized microparticles of poly(d,l-lactic-co-glycolic) (PLGA) acid, with controllable median diameters within the size range 40–140 μm, were successfully prepared by membrane emulsification of an oil phase injected into an aqueous phase, followed by solvent removal. Initially, simple particles were produced as an oil in water emulsion, where dichloromethane (DCM) and PLGA were the oil phase and water with stabiliser was the continuous phase. The oil was injected into the aqueous phase through an array type microporous membrane, which has very regular pores equally spaced apart, and two different pore sizes were used: 20 and 40 μm in diameter. Shear was provided at the membrane surface, causing the drops to detach, by a simple paddle stirrer rotating above the membrane. Further tests involved the production of a primary water in oil emulsion, using a mechanical homogeniser, which was then subsequently injected into a water phase through the microporous membrane to form a water in oil in water emulsion. These tests used a water-soluble model drug (blue dextran) and encapsulation efficiencies of up to 100% were obtained for concentrations of 15% PLGA dissolved in the DCM and injected through a 40 μm membrane.

Solidification of the PLGA particles was followed by removal of the DCM through the surrounding aqueous continuous phase. Different PLGA concentrations, particle size and osmotic pressures were considered in order to find their effect on encapsulation efficiency. Osmotic pressure was varied by changing the salt concentration in the external aqueous phase whilst maintaining a constant internal aqueous phase salt concentration. Osmotic pressure was found to be a significant factor on the resulting particle structure, for the tests conducted at lower PLGA concentrations (10% and 5% PLGA). The PLGA concentration and particle size distribution influence the time to complete the solidification stage and a slow solidification, formed by stirring gently overnight, provided the most monosized particles and highest encapsulation efficiency.     

Biofouling potentials of microporous polysulfone membranes containing a sulfonated polyether-ethersulfone/polyethersulfone block copolymer: correlation of membrane surface properties with bacterial attachment

Multivariate methods were used to identify relationships between bacterial attachment (biofouling potential), water transport, and the surface properties of nine modified polysulfone (MPS) membranes comprising blends of polysulfone (PS) with a sulfonated polyether-ethersulfone/polyethersulfone block copolymer. The topology of the microporous MPS membranes, including surface roughness, surface height, pore size and pore geometry were determined by atomic force microscopy (AFM) and digital image analysis. Other measurements included relative surface hydrophobicity by captive bubble contact angle, surface charge (i.e., degree of sulfonation) by uranyl cation binding, wt% solids, porosity, membrane thickness, water flux, and the affinity of membranes for a hydrophilic Flavobacterium and hydrophobic Mycobacterium species. The mycobacteria attached best to the MPS membranes, but the attachment of both organisms was inversely correlated with the mean aspect ratio of pores, suggesting that irregular or elliptic pores discouraged attachment. Multivariate regression analyses identified the pore mean aspect ratio, mean surface height, PS content, and the n-methylpyrrolidone+propionic acid (NMP–PA) solvent concentration as influential factors in Mycobacterium attachment, whereas membrane thickness, surface roughness, pore mean aspect ratio, porosity, and the mean pore area/image area ratio influenced Flavobacterium attachment. Cluster analyses revealed that Mycobacterium attachment was associated with hydrophobic determinants of the MPS membranes, including PS content, wt% solids, and air bubble contact angle. In contrast, Flavobacterium attachment was primarily associated with membrane thickness and charge (i.e., uranyl cation binding or degree of sulfonation). Membrane flux was inversely correlated with surface hydrophobicity and PS content, but (in contrast to cell attachment) positively correlated with most pore geometry parameters including the mean aspect ratio, suggesting that pore geometry can be optimized to minimize cell attachment and maximize water transport. Other variables influencing water flux included the NMP–PA solvent concentration and membrane roughness. The results should facilitate the design of novel microporous PS membranes having reduced biofouling potentials and greater water fluxes.     

Demulsification of water-in-oil emulsion by using porous glass membrane

The hydrophilic porous glass membranes were used to demulsify water-in-oil emulsion, and demulsification efficiency can reach more than 96.2%. Effects of pore size of the membrane, transmembrane pressure and volumetric ratio of oil phase to internal aqueous phase in the emulsion on demulsification were investigated. It was found that pore size of membrane and transmembrane pressure can significantly affect demulsification efficiency. The smaller the pore size of the membrane, the better the demulsification efficiency. However, smaller pore size of the membrane has to be exerted a greater transmembrane pressure in order to make internal aqueous phase enter the membrane pore. Correspondingly, effect of transmembrane pressure on permeation flux of the droplets was also studied. In addition, recovered-oil phase by the demulsification were reused five times to extract cadmium from simulated aqueous waste. The results indicated that the extracting efficiency could arrive at 96.5%.     

Determination of pore size distribution in hollow fibre membranes

Isopropanol displacement under nitrogen pressure was used for the determination of pore size distribution in microfiltration polypropylene hollow fibres. Applying various assumptions about gas transport process two completely different characteristics of pore sizes were obtained. To verify these results an analysis of SEM images of the investigated membrane was conducted concerning its porous structure (pore diameters, surface occupied by pores). According to the SEM analysis the mean coverage of membrane surface by pore entrances should be about 20% of total area. For the distribution which accounted for pore evacuation according to Young–Laplace equation with contact angle θ=67° surprisingly dense coverage amounting to over 70% of total surface (by calculated total pore number over 10¹³ per m²) was predicted. Results for the distribution which accounted for gas bubble formation at the membrane surface (equivalent to θ=0°) fit into the expected range of pore numbers and membrane coverages (about 10¹¹ per m² and about 10%, respectively). It is concluded that the mechanism of bubble formation, determined by an actual pressure, liquid surface tension and pore size, is the crucial process while the value of contact angle θ does not play any role in the determination of pore size distribution.     

Fabrication of superporous agarose beads for protein adsorption: Effect of CaCO3 granules content

Agarose gels were fabricated by water-in-oil emulsification with the addition of CaCO₃ granules at 8–16 wt%. Thus agarose beads of different superporosities were produced after dissolving the solid porogen. The superporous agarose (SA) and homogeneous agarose gels were double cross-linked and modified with diethylaminoethyl chloride to produce anion exchangers. We have proposed to use a superporous replica (porous titania microspheres) to examine the superporous structure and pore size distribution of the soft gel. The replica was prepared with the agarose gel entrapping CaCO₃ granules by a sol–gel-templating method. It was found that the superpores created by CaCO₃ granules were uniformly distributed and ranged from 0.95 μm to 1.33 μm. The physical properties of the gels were significantly affected by the porogen content. Importantly, by increasing the solid porogen to 12 wt%, the bed permeability and effective porosity increased about 48% and 33%, respectively. Further increase in the porogen to 16 wt% led to a decrease of the mechanical strength. With increasing superpores in the beads, the dynamic adsorption capacity of the packed columns increased obviously at 305–916 cm/h. Besides, the column efficiency changed less with increasing flow velocity up to 1200 cm/h. It was concluded that the use of 12 wt% CaCO₃ granules in agarose solution was beneficial for the fabrication of the SA gel with good mechanical stability and promising performance for protein chromatography.     

Using the Surface Evolver to model droplet formation processes in membrane emulsification

A model was developed to describe the droplet formation mechanism in membrane emulsification from the point of view of Gibbs free energy with the help of the Surface Evolver, which is an interactive finite element program for the study of interfaces shaped by surface tension. A program to test the model was written and run which allows the user to track the droplet shape as it grows, to identify the point of instability due to free energy, and thus predict droplet size. The inputs of the program are pore geometry, oil-aqueous phase interfacial tension, and contact angle. The model reasonably predicted droplet sizes for oblong-shaped pores under quiescent conditions where the force balance approach is not applicable. The model was validated against experimental conditions from the literature where the average error of the predictions compared to the mean droplet sizes was 8%.     

Production of porous silica microparticles by membrane emulsification

A method for the production of near-monodispersed spherical silica particles with controllable porosity based on the formation of uniform emulsion droplets using membrane emulsification is described. A hydrophobic metal membrane with a 15 μm pore size and 200 μm pore spacing was used to produce near-monodispersed droplets, with a mean size that could be controlled between 65 and 240 μm containing acidified sodium silicate solution (with 4 and 6 wt % SiO(2)) in kerosene. After drying and shrinking, the final silica particles had a mean size in the range between 30 and 70 μm. The coefficient of variation for both the droplets and the particles did not exceed 35%. The most uniform particles had a mean diameter of 40 μm and coefficient of variation of 17%. By altering the pH of the sodium silicate solution and aging the gel particles in water or acetone, the internal structure of the silica particles was successfully modified, and both micro- and mesoporous near-monodispersed spherical particles were produced with an average internal pore size between 1 and 6 nm and an average surface area between 360 and 750 m(2) g(-1). A material balance and particle size analysis provided identical values for the internal voidage of the particles, when compared to the voidage as determined by BET analysis.     

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.