Convertible Hollow Fiber Membrane Bundle for Gas Separation
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Solution Overview
Problem
The existing manufacturing processes for gas separation membrane modules require separate inventory and manufacturing lines for cross-flow and countercurrent-flow configurations, leading to a large footprint and significant investment, as well as increased complexity and downtime.
Innovation Solution
A hollow fiber membrane bundle that can be converted into either a cross-flow or countercurrent configuration, utilizing a porous support tube, cured resin tubesheets, and collection tubes with orifices, allowing for the same structure to be finished as multiple flow configurations, thereby minimizing inventory and manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate inventory and manufacturing lines are maintained for cross-flow and countercurrent-flow configurations, then each configuration can be produced with optimized design, but the manufacturing facility footprint and inventory investment become very large
Solution Approach 1:
The hollow fiber membrane bundle is designed as a universal intermediate structure that can be converted into either cross-flow or countercurrent configurations through different assembly steps. The same bundle serves multiple functions by varying the collection tube configuration and sealing approach, eliminating the need for separate manufacturing lines for each flow pattern.
2Reliability
If separate inventory and manufacturing lines are maintained for cross-flow and countercurrent-flow configurations, then each configuration can be produced with optimized design, but the inventory investment becomes significant
Solution Approach 1:
A single inventory of hollow fiber membrane bundles can be used to produce both cross-flow and countercurrent configurations. The universal bundle design with flexible collection tube integration allows one inventory to serve multiple product types, significantly reducing the quantity of components that must be stocked.
Solution Approach 2:
The manufacturing process is made dynamic and adaptable rather than fixed. The same intermediate bundle can be routed into different final assembly procedures depending on the desired configuration, allowing the production system to flexibly respond to different customer requirements without maintaining separate static inventories.
3Manufacturing precision
If separate manufacturing lines are used for cross-flow and countercurrent configurations, then each line can be optimized for its specific configuration, but the manufacturing complexity increases
Solution Approach 1:
The manufacturing process is segmented into distinct stages: production of the universal hollow fiber membrane bundle (intermediate product), and subsequent configuration-specific assembly steps. This segmentation allows the common elements to be manufactured once with high precision, while the variable elements are handled in simpler, dedicated final assembly operations.
4Manufacturing precision
If separate manufacturing lines are used for cross-flow and countercurrent configurations, then each line can be optimized for its specific configuration, but the manufacturing downtime increases
Solution Approach 1:
The production system is made dynamic, allowing the same manufacturing line to switch between producing cross-flow and countercurrent configurations by changing the assembly procedure rather than requiring dedicated lines. This flexibility reduces downtime by eliminating the need to idle specialized equipment when demand for a particular configuration changes.
Data Source
AI summary
A hollow fiber membrane bundle useful for manufacturing a wide variety of hollow fiber membrane modules having different flow configurations includes hollow fiber membranes arranged around a porous support tube, a cured resin tubesheet formed at first end of the bundle, and either a cured resin nub or a cured resin tubesheet formed at a second end of the bundle. The bore(s) of the hollow fiber membranes are open at a face of the tubesheet adjacent the first end of the bundle. The tubesheet has an annular structure that encapsulates the hollow fiber membranes and the porous support tube at the first end of the bundle but which does not completely block a bore of the porous support tube, wherein the collection tube has a plurality of orifices formed therein at least at positions adjacent the nub.