Porous Metal Membrane Cassettes for Low-Pressure Mass Separation
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Solution Overview
Problem
Conventional membrane technologies, such as reverse osmosis membranes, are ineffective for mass transfer applications due to limitations in processing gas flow streams, high pressure drops under vacuum, and low membrane packing density, which restricts their ability to handle dual flow streams and achieve efficient liquid and vapor-phase separation.
Innovation Solution
A membrane device comprising stacked membrane cassettes with porous metal sheet membranes mounted on a support frame, allowing for cross-current or counter-current flow patterns, and utilizing backing materials and spacers to minimize pressure drops and enhance mass transfer efficiency, while also incorporating zeolite layers for selective separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If conventional reverse osmosis membranes with cylindrical designs are used, then large membrane surface area per unit volume is achieved, but large pressure drops occur when placed under vacuum
Solution Approach 1:
The membrane module is segmented into multiple flat sheet membrane elements arranged in series, with each element having defined inlet and outlet channels. This segmentation allows optimization of flow paths and pressure distribution across the membrane surface, reducing overall pressure drop while maintaining high membrane area.
Solution Approach 2:
The invention transitions from cylindrical membrane geometry to flat sheet membrane geometry with three-dimensional flow channels. This dimensional change enables better pressure distribution and reduces pressure drops by distributing flow across multiple planes and channels rather than through a single cylindrical path.
2Strength
If conventional filters with metal or ceramic tubes are used, then structural strength is achieved, but membrane packing density is lower than polymer membranes by nearly one order of magnitude
Solution Approach 1:
The invention merges the structural strength advantages of metal/ceramic materials with the high packing density advantages of polymer membrane configurations. Flat sheet membranes are mounted within a rigid frame structure, combining the mechanical strength of metal frames with the high surface area-to-volume ratio of densely packed flat sheet elements.
Solution Approach 2:
Multiple membrane elements are nested within a compact frame structure, with each element containing membranes on both sides of the frame. This nested arrangement maximizes membrane packing density by utilizing both surfaces of each frame-mounted membrane element.
3Reliability
If spiral-wound or plate-type RO membrane filters are used, then filtration of single flow stream is achieved, but dual flow streams cannot be processed simultaneously
Solution Approach 1:
The flat sheet membrane configuration with separate inlet and outlet channels on opposite sides enables the membrane to simultaneously process two different flow streams. One stream flows through channels on one side while another stream flows through channels on the opposite side, allowing dual-function operation including mass transfer and heat transfer between streams.
4Reliability
If membranes designed for liquid-phase filtration are used, then liquid filtration is achieved, but vapor-phase separation at low pressures is not suitable
Solution Approach 1:
The flat sheet membrane design with optimized channel dimensions and pressure distribution enables adaptation to different operating conditions including vapor-phase separation at low pressures. The large channel cross-sectional area and optimized flow paths reduce pressure drops that would be significant in vapor-phase applications, allowing the same membrane structure to serve both liquid and vapor applications.
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 membrane device achieves high mass transfer rates with minimal pressure drops, enabling efficient filtration and separation of particulates and molecules across multiple flow streams, including dehumidification and molecular separation with reduced energy consumption.
Implementation Method 1
Porous metal membranes provide a selected mass exchange for components within a feed flow stream introduced to the membrane device and a permeate flow stream removed from the membrane device during operation
Implementation Method 2
incorporating zeolite layers for selective separation
Implementation Method 3
flow channels that transport selected fluids or molecules in a feed flow stream across the surfaces of the porous membranes
Implementation Method 4
transport selected fluids or molecules in a feed flow stream across the surfaces of the porous membranes
Implementation Method 5
a pressure gradient positioned between a feed side and a permeate side of the membrane device
Data Source
AI summary
A membrane device and processes for fabrication and for using are disclosed. The membrane device may include a number of porous metal membranes that provide a high membrane surface area per unit volume. The membrane device provides various operation modes that enhance throughput and selectivity for mass exchange, mass transfer, separation, and/or filtration applications between feed flow streams and permeate flow streams.