Wafer-Based Electrodeionization for Contrast Agent Desalination
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Solution Overview
Problem
Current methods for purifying X-ray and MR contrast agents, such as iohexol and iodixanol, face challenges in efficiently reducing high salt content generated during primary production, leading to inefficiencies and increased costs due to the need for multiple purification steps and resource consumption.
Innovation Solution
The use of a wafer-based electrodeionization (EDI) device, combined with electrodialysis, to desalinate compositions before or after crystallization, minimizing product loss and energy consumption while achieving low salt levels required for regulatory purity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional purification methods are used to reduce salt content, then salt content is reduced, but multiple purification steps and resource consumption increase
Solution Approach 1:
The patent combines electrodialysis and electrodeionization into a single integrated purification system. The electrodialysis unit removes the bulk of salts through ion-exchange membranes, while the electrodeionization unit with ion-exchange resin beds performs final polishing to achieve the required purity level below 0.02 w/w%. This merged approach replaces multiple separate purification steps with one continuous process.
Solution Approach 2:
The electrodeionization component uses electrical current to continuously regenerate the ion-exchange resin beds in situ, eliminating the need for external chemical regeneration processes. The system performs self-regeneration by applying voltage to reverse the ion exchange reactions, allowing the resin to be reused without removing it from the system or using additional chemicals.
2Manufacturing precision
If conventional purification methods are used to reduce salt content, then salt content is reduced, but energy consumption increases
Solution Approach 1:
The electrodialysis unit performs preliminary salt removal by eliminating the bulk of the salt content before the composition enters the electrodeionization unit. This pre-treatment step reduces the salt load that the energy-intensive electrodeionization process must handle, thereby minimizing overall energy consumption while achieving the final purity requirement.
Solution Approach 2:
By merging electrodialysis (lower energy, bulk removal) and electrodeionization (higher energy, precision polishing) into a single system, the patent optimizes energy usage. The low-energy electrodialysis handles the majority of salt removal, allowing the high-energy electrodeionization to focus only on trace salt elimination, thus reducing total energy consumption compared to using electrodeionization alone for the entire purification task.
3Manufacturing precision
If conventional purification methods are used to reduce salt content, then salt content is reduced, but product loss increases
Solution Approach 1:
The patent employs disposable or easily replaceable ion-exchange resin beds in the electrodeionization unit that can be regenerated in situ through electrical current. These resin beds act as consumable components that capture salt ions and are then electrically regenerated, preventing product loss that would occur with traditional filtration methods requiring chemical washing and disposal of saturated resins or filters.
Solution Approach 2:
The in situ electrical regeneration of ion-exchange resin beds allows the purification media to be restored and reused without removing it from the system or exposing the contrast agent to additional processing steps that could cause product loss. The system continuously regenerates its own purification capacity, maintaining high product recovery throughout extended operation.
4Manufacturing precision
If conventional purification methods are used to reduce salt content, then salt content is reduced, but water usage increases
Solution Approach 1:
The patent replaces water-intensive chemical regeneration processes with an electrical field-based regeneration system. Instead of using large volumes of water to rinse and regenerate ion-exchange media through chemical means, the system applies electrical current to drive reverse ion exchange reactions, eliminating the need for extensive water usage in the regeneration phase while maintaining purification effectiveness.
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 process effectively reduces salt content to below 0.7 w/w% for iodixanol and 0.02 w/w% for iohexol, minimizing product loss and energy consumption, and allows for more efficient and cost-effective production by eliminating the need for chemical regeneration and extensive water usage.
Implementation Method 1
desalinating the composition by electrodeionization (EDI) using a wafer based EDI device
Implementation Method 2
electrodeionization (EDI) device, combined with electrodialysis
Implementation Method 3
desalinating the composition by electrodeionization (EDI) using a wafer based EDI device, wherein the contrast agent is an X-ray contrast agent selected from iohexol and iodixanol and wherein the process includes additional desalinating by electrodialysis (ED) in a separate step before or after the EDI step
Data Source
AI summary
The invention relates to industrial preparation of contrast agents, and further to an improved process for the purification of contrast agents. In particular, it relates to a process for reducing the salt content of compositions comprising an MR contrast agent or an X-ray contrast agent, such as a non-ionic iodinated monomeric compound or a non-ionic iodinated dimeric compound.