Multi-Leaf Spiral Wound Membrane Module Design
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Solution Overview
Problem
Spiral wound membrane modules face challenges withstanding high crossflow velocities and are cumbersome to manufacture, limiting their effectiveness in dewatering highly fouling fluids, particularly in designs with a single membrane leaf.
Innovation Solution
A method for manufacturing a multi-leaf spiral wound membrane module with removable sections in the feed spacer, allowing for a shorter membrane sheet length and reduced pressure drop, enabling greater separation efficiency and increased membrane flux by using a membrane sheet with two or more leaves, each with a feed spacer and permeate structure, which is spirally wound around a permeate fluid flow tube.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single membrane leaf is used in a spiral wound module, then the manufacturing process is simpler, but the module cannot withstand high crossflow velocities and has limited effectiveness in dewatering highly fouling fluids
Solution Approach 1:
The membrane sheet is divided into multiple leaves (at least two) that are stacked together, with each leaf having feed spacers and permeate structures. This segmentation allows the module to handle high crossflow velocities and fouling fluids while maintaining manufacturability through the standardized multi-leaf construction process
Solution Approach 2:
Multiple membrane leaves are combined into a single spiral wound module assembly, where the leaves are stacked and bound together with adhesive. This merging creates a robust structure capable of withstanding high crossflow velocities while processing fouling fluids, overcoming the limitations of single-leaf designs
2Productivity
If a longer membrane sheet is used to increase membrane area, then separation efficiency improves, but pressure drop increases
Solution Approach 1:
Instead of extending the membrane sheet length in one dimension, the invention stacks multiple leaves in a layered configuration. This dimensional change allows increased total membrane area and separation efficiency while maintaining shorter effective flow paths that reduce pressure drop across the module
3Object-affected harmful factors
If feed spacers are removed to create open channels, then fouling control improves, but manufacturing complexity increases
Solution Approach 1:
Removable sections are pre-formed as integral parts of the feed spacers before assembly. During the manufacturing process, these sections are easily removed to create open channels that improve fouling control, while the preliminary preparation simplifies rather than complicates the overall manufacturing process
Solution Approach 2:
Specific sections of the feed spacers are extracted or removed to create open channel configurations. This extraction allows feed fluid to flow directly along the membrane surface without obstruction, significantly improving fouling control while the modular approach keeps manufacturing manageable
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 multi-leaf design reduces pressure drop and increases membrane flux, enhancing the module's ability to handle high crossflow velocities and fouling fluids, while simplifying the manufacturing process and maintaining or improving separation efficiency.
Implementation Method 1
While adhesive in the permeate structure is at least partially uncured, the membrane sheet is spiral wound around a permeate fluid flow tube. The adhesive is allowed to at least partially cure while the membrane sheet is wound around the permeate fluid flow tube.
Implementation Method 2
a permeate structure including at least one membrane and at least one permeate spacer
Data Source
AI summary
Embodiments described herein are directed to methods of manufacturing a multi-leaf membrane module for filtering product fluid flow (e.g., food products or wastewater) and such multi-leaf membrane modules. In an embodiment, a multi-leaf membrane module is disclosed. The multi-leaf membrane module includes a permeate fluid flow tube defining a permeate fluid flow channel for permeate, and a membrane sheet spirally wound about the permeate fluid flow tube. The membrane sheet includes two or more leaves. Each of the two or more leaves includes a feed spacer including at least one opening formed therein that at least partially defines a feed channel for product fluid flow therethrough and a permeate structure defining a permeate fluid flow channel. The permeate structure of each of the two or more leaves includes at least one membrane and at least one porous permeate spacer.