Cross-flow membrane emulsification for controlled droplet production
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Solution Overview
Problem
Current emulsion manufacturing techniques face challenges in producing droplets with a good coefficient of variation (CV) at high throughput, as they often result in large droplet size variations and are inefficient with non-Newtonian fluids and products containing solids, leading to high energy consumption and equipment damage.
Innovation Solution
A cross-flow apparatus with a stationary tubular membrane and optional insert, featuring chamfered orifices and a furcation plate, which uses the flow of the continuous phase to detach droplets from the membrane pores, allowing for controlled droplet production with a consistent CV and high flux without agitation or mechanical driving.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If stirrers and homogenisers are used to break up droplets, then droplet production is achieved, but droplet size variation is large and manufacturing precision is poor
Solution Approach 1:
The patent employs a porous membrane with uniformly distributed pores as the core component. The porous structure provides consistent shear forces across all droplets as they pass through the membrane, ensuring uniform droplet sizes. The membrane's porous architecture replaces the turbulent mixing of stirrers and homogenisers, delivering precise control over droplet dimensions while maintaining high productivity.
2Productivity
If high speed stirrers are used to disperse semisolid materials, then droplet breakdown is achieved, but energy consumption is high and equipment damage occurs
Solution Approach 1:
The patent replaces high-speed mechanical stirrers and homogenisers with a membrane-based system that uses capillary pressure and controlled flow through porous structures. This substitution eliminates the need for high-energy mechanical agitation, reducing energy consumption while avoiding equipment damage from viscous semisolid materials. The membrane system handles non-Newtonian fluids and gels without mechanical stress.
3Manufacturing precision
If homogenisers are used to process high viscosity systems, then droplet dispersion is achieved, but pressure drops are high and productivity is low
Solution Approach 1:
The patent changes the operational parameters by using a membrane system that operates at controlled pressure differentials rather than high-shear mechanical forces. The porous membrane structure allows viscous materials to pass through with minimal pressure drop, maintaining high productivity while achieving uniform droplet dispersion. The system is specifically designed to handle high-viscosity non-Newtonian fluids without the pressure penalties of traditional homogenisation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The apparatus achieves droplets with a CV of 5-50% and throughput of 1-106 LMH, enabling efficient production of uniform droplets at high flux rates, suitable for large-scale applications and handling viscous phases without damaging equipment.
Implementation Method 1
Cross-flow membrane emulsification uses the flow of the continuous phase to detach droplets from the membrane pores
Data Source
AI summary
There is described a cross-flow apparatus for producing an emulsion or dispersion by dispersing a first phase in a second phase; said cross-flow apparatus comprising: an outer tubular sleeve (2) provided with a first inlet (3) at a first end (4); an emulsion outlet (5); and a second inlet (7), distal from and inclined relative to the first inlet; a tubular membrane provided with a plurality of pores and adapted to be positioned inside the tubular sleeve (2); and optionally an insert adapted to be located inside the tubular membrane, said insert comprising an inlet end and an outlet end, each of the inlet end and an outlet end being provided with chamfered region; the chamfered region is provided with a plurality of orifices and a furcation plate.