Depth Filter Head Space Optimization for High Solids Clarification

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Solution Overview

Problem

Traditional depth filters with minimized head space compromise performance, especially when used for clarification of feeds with high solids, leading to reduced loading capacity and fouling issues, which is critical for applications involving high biomass and low fouling feed streams.

Innovation Solution

Optimizing the head space volume within depth filters to 4-14 liters per square meter of filtration media area, utilizing a composite of graded layers of non-woven fibers, cellulose, diatomaceous earth, and other materials, to enhance the filtration capacity and reduce fouling, allowing for increased processing volumes without media fouling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If head space volume is minimized to reduce system hold-up volume and device dimensions, then device footprint and recovery are improved, but filtration loading capacity and performance deteriorate

Engineering Contradiction:

Improvehold-up volumeVSAvoidloading capacity

Core Design Contradiction:

Volume of moving objectVSProductivity

Solution Approach 1:

The patent changes the parameter of head space volume from minimum/zero to an optimized range (4-14 liters per square meter of filtration media area). This parameter change resolves the contradiction by showing that adequate head space is necessary for maintaining filtration capacity while still achieving compact device dimensions. The optimized head space volume allows sufficient feed processing capacity without excessive system hold-up volume.

Inventive Principle:

Principle #35Parameter changes

2Loss of substance

If head space volume is reduced to limit flush volumes, then buffer and water requirements are reduced, but depth filter performance and particle retention capacity deteriorate

Engineering Contradiction:

Improvebuffer and waterVSAvoidfilter performance

Core Design Contradiction:

Loss of substanceVSReliability

Solution Approach 1:

The patent optimizes the head space volume parameter to a specific range (4-14 L/m²) that simultaneously achieves adequate filter performance and limits buffer/water requirements. This parameter optimization shows that there is an optimal balance point where the filter can effectively retain particles while minimizing the volume of buffer and water needed for flushing and operation.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If depth filter media is compressed to increase density, then filtration efficiency is improved, but head space volume and processing capacity are reduced

Engineering Contradiction:

Improvefiltration efficiencyVSAvoidprocessing capacity

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent changes the physical state parameter of the filter media from compressed/dense to an expanded state with adequate head space. This parameter change resolves the contradiction by demonstrating that the filter media should not be compressed to maximum density, but rather maintained with sufficient head space volume to allow adequate processing capacity while retaining filtration efficiency.

Inventive Principle:

Principle #35Parameter changes

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

This optimization results in a 70% improvement in filtration capacity, reducing the needed filter area and buffer requirements, while increasing product recovery and scalability, by fully utilizing the depth filter media without media compression.

Implementation Method 1

Particle retention in depth filtration is accepted to use a variety of particle retention methods including size exclusion

Methodology Applied

Scientific EffectSize exclusion:

Implementation Method 2

Particle retention in depth filtration is accepted to use a variety of particle retention methods including hydrophobic adsorption

Methodology Applied

Scientific EffectHydrophobic adsorption: Adsorption

Implementation Method 3

Particle retention in depth filtration is accepted to use a variety of particle retention methods including ionic adsorption

Methodology Applied

Scientific EffectIonic adsorption: Adsorption

Implementation Method 4

Compositions that comprise the depth filter media may be chemically treated to enable the filter media to capture charged particles, such as DNA, host cell proteins, or aggregates through ionic or electrostatic interactions

Methodology Applied

Scientific EffectIonic interactions:

Implementation Method 5

Methodology Applied

Scientific EffectElectrostatic interactions: Electrostatics

Implementation Method 6

the head space volume within the depth filtration device or the physical dirt holding capacity (also known as cake filtration)

Methodology Applied

Scientific EffectCake filtration:

Data Source

PatentUS12076666B2Head space for depth filters and methods of using the same

Publication Date: 2024.09.03 EMD MILLIPORE CORP

AI summary

Depth filters with optimized head space are provided, as well as methods of optimizing the head space in depth filters, and methods of filtration with depth filters having optimized head space, including clarification of flocculated feed streams where pretreatment may include any of lowering cell culture pH, addition of polymers (uncharged or charged), or addition of salts to precipitate out solubilized impurities resulting in high insoluble biomass.