Continuous Membrane Separator Bypass for Fouling Management

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Solution Overview

Problem

Current pharmaceutical manufacturing processes face inefficiencies in batch production, including long lead times, large footprints, and quality control challenges due to the need for manual intervention and frequent membrane replacements in liquid-liquid separation, which disrupt continuous manufacturing processes and lead to contamination and safety issues.

Innovation Solution

A continuous membrane separator bypass system with real-time fouling detection and automated cleaning capabilities, allowing for seamless operation without interrupting the process, using optical sensors and automated valves to divert input streams to clean membranes and maintain stable pressure differentials, enabling continuous separation of biphasic mixtures and filtration of solid matter.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If manual membrane replacement is performed in liquid-liquid separation, then membrane fouling is addressed, but continuous manufacturing process is disrupted and contamination risk increases

Engineering Contradiction:

Improvecontinuous operationVSAvoidcontamination risk

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The system divides the membrane separation function into multiple independent modules (first membrane separator, second membrane separator) that can operate in parallel. When one membrane becomes fouled, the system switches to the other membrane, ensuring continuous operation without disruption to the manufacturing process.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system automatically detects changes in membrane performance parameters (such as pressure differential, flow rate) that indicate fouling and responds by switching between membranes. This parameter-based control enables automatic response to fouling conditions without manual intervention.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If frequent membrane replacements are performed, then fouling is managed, but process efficiency decreases and lead times increase

Engineering Contradiction:

Improvefouling managementVSAvoidprocess efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The system proactively monitors membrane condition using sensors that detect early signs of fouling. By detecting fouling before it severely impacts performance, the system can switch membranes at optimal times, preventing complete fouling and the need for frequent emergency replacements.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system continuously monitors operational parameters and provides feedback to control the switching between membranes. This closed-loop feedback ensures that membranes are replaced based on actual condition rather than fixed schedules, optimizing both fouling management and process efficiency.

Inventive Principle:

Principle #23Feedback

3Reliability

If manual intervention is used for membrane replacement, then fouled membranes are replaced, but safety issues arise and operational complexity increases

Engineering Contradiction:

Improvemembrane replacementVSAvoidoperational complexity

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The system performs membrane replacement automatically through a switching mechanism controlled by sensors and controllers. The system serves itself by detecting fouling conditions and autonomously switching between membranes without requiring operator intervention, thereby improving safety and reducing operational complexity.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system replaces manual mechanical operations with automated control systems. Sensors, controllers, and automated valves substitute for manual membrane replacement operations, reducing the need for human intervention and the associated safety risks and operational complexities.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 system ensures continuous operation with reduced contamination, improved safety, and increased process efficiency by automatically detecting fouling and cleaning membranes, maintaining product quality, and reducing the need for manual intervention and membrane replacements.

Implementation Method 1

a continuous membrane separator that continuously separates at least one input stream into two or more output streams based on specific characteristics of the output streams

Methodology Applied

Scientific EffectSemi-permeable membrane separation: Semipermeable Membrane

Implementation Method 2

using optical sensors and automated valves to divert input streams to clean membranes

Methodology Applied

Scientific EffectOptical detection: Optical Fibre

Data Source

PatentUS11202971B2Continuous separator bypass systems and methods of use thereof

Publication Date: 2021.12.21 CONTINUUS PHARMACEUTICALS INC

AI summary

The present disclosure provides for a continuous membrane separator bypass system and a continuous filtration separator system and methods of using the systems in the separation of liquid-liquid mixtures and filtration of process liquids. The methods and apparatus are useful for the production of fine chemicals and pharmaceuticals, particularly using Integrated Continuous Manufacturing (ICM), but can also be integrated with other manufacturing processes, such as batch and semi-continuous processes.