Hollow fiber membranes (HFMs) are a class of artificial membranes containing a semi-permeable barrier in the form of a hollow fiber. Originally developed in the 1960s for reverse osmosis applications, hollow fiber membranes have since become prevalent in water treatment, desalination, cell culture, medicine, and tissue engineering. [1] Most commercial hollow fiber membranes are packed into cartridges which can be used for a variety of liquid and gaseous separations.
HFMs are commonly produced using artificial polymers. The specific production methods involved are heavily dependent on the type of polymer used as well as its molecular weight. HFM production, commonly referred to as "spinning", can be divided into four general types:
Common to each of these methods is the use of a spinneret, a device containing a needle through which solvent is extruded and an annulus through which a polymer solution is extruded. As the polymer is extruded through the annulus of the spinneret, it retains a hollow cylindrical shape. As the polymer exits the spinneret, it solidifies into a membrane through a process known as phase inversion. The properties of the membrane -such as average pore diameter and membrane thickness- can be finely tuned by changing the dimensions of the spinneret, temperature and composition of "dope" (polymer) and "bore" (solvent) solutions, length of air gap (for dry-jet wet spinning), temperature and composition of the coagulant, as well as the speed at which produced fiber is collected by a motorized spool. Extrusion of the polymer and solvent through the spinneret can be accomplished either through the use of gas-extrusion or a metered pump. Some of the polymers most commonly used for fabricating HFMs include cellulose acetate, polysulfone, polyethersulfone, and polyvinylidene fluoride. [4]
The properties of HFMs can be characterized using the same techniques commonly used for other types of membranes. The primary properties of interest for HFMs are average pore diameter and pore distribution, measurable via a technique known as porosimetry, a feature of several laboratory instruments used for measuring pore size. [5] Pore diameter can also be measured via a technique known as evapoporometry, in which evaporation of 2-propanol through the pores of a membrane is related to pore-size via the Kelvin equation. [6] [7] Depending on the diameters of pores in an HFM, scanning electron microscopy or transmission electron microscopy can be used to yield a qualitative perspective of pore size.
Hollow fiber membranes are ubiquitously used in industrial separations, especially the filtration of drinking water. [9]
Industrial water filters are mainly equipped with ultrafiltration hollow fiber membranes. Domestic water filtration systems have microfiltration hollow fiber membranes. In microfiltration a membrane pore diameter of 0.1 micrometers cuts-off microorganisms like germs and bacteria, Giardia cysts and other intestinal parasites, as well removing sediments. Ultrafiltration membranes are capable of removing not only bacteria, but also viruses.
Hollow fibers are commonly used substrates for specialized bioreactor systems, with the ability of some hollow fiber cartridges to culture billions of anchorage-dependent cells within a relatively low (<100 mL) bioreactor volume. [10]
Hollow fibers can be used for drug efficacy testing in cancer research, as an alternative to the traditional, but more expensive, xenograft model. [11]
Hollow fiber membranes are used in Membrane oxygenators in extracorporeal membrane oxygenation which oxygenates blood, replacing lungs in critically ill patients.
Ultrafiltration (UF) is a variety of membrane filtration in which forces such as pressure or concentration gradients lead to a separation through a semipermeable membrane. Suspended solids and solutes of high molecular weight are retained in the so-called retentate, while water and low molecular weight solutes pass through the membrane in the permeate (filtrate). This separation process is used in industry and research for purifying and concentrating macromolecular (103–106 Da) solutions, especially protein solutions.
Microfiltration is a type of physical filtration process where a contaminated fluid is passed through a special pore-sized membrane filter to separate microorganisms and suspended particles from process liquid. It is commonly used in conjunction with various other separation processes such as ultrafiltration and reverse osmosis to provide a product stream which is free of undesired contaminants.
NEWater is the brand name given to highly treated reclaimed wastewater produced by Singapore's Public Utilities Board. NEWater is produced by further purifying conventionally treated wastewater through microfiltration, reverse osmosis and ultraviolet irradiation. The water is potable quality and can be added to drinking water supply reservoirs where it is withdrawn and treated again in conventional water treatment plants before being distributed to consumers. However, most NEWater is currently used for non-drinking purposes, mostly by industries with production requirements for high purity water.
Electrospinning is a fiber production method that uses electric force to draw charged threads of polymer solutions or polymer melts up to fiber diameters in the order of some hundred nanometers. Electrospinning shares characteristics of both electrospraying and conventional solution dry spinning of fibers. The process does not require the use of coagulation chemistry or high temperatures to produce solid threads from solution. This makes the process particularly suited to the production of fibers using large and complex molecules. Electrospinning from molten precursors is also practiced; this method ensures that no solvent can be carried over into the final product.
An artificial membrane, or synthetic membrane, is a synthetically created membrane which is usually intended for separation purposes in laboratory or in industry. Synthetic membranes have been successfully used for small and large-scale industrial processes since the middle of the twentieth century. A wide variety of synthetic membranes is known. They can be produced from organic materials such as polymers and liquids, as well as inorganic materials. Most commercially utilized synthetic membranes in industry are made of polymeric structures. They can be classified based on their surface chemistry, bulk structure, morphology, and production method. The chemical and physical properties of synthetic membranes and separated particles as well as separation driving force define a particular membrane separation process. The most commonly used driving forces of a membrane process in industry are pressure and concentration gradient. The respective membrane process is therefore known as filtration. Synthetic membranes utilized in a separation process can be of different geometry and flow configurations. They can also be categorized based on their application and separation regime. The best known synthetic membrane separation processes include water purification, reverse osmosis, dehydrogenation of natural gas, removal of cell particles by microfiltration and ultrafiltration, removal of microorganisms from dairy products, and dialysis.
Nanofibers are fibers with diameters in the nanometer range. Nanofibers can be generated from different polymers and hence have different physical properties and application potentials. Examples of natural polymers include collagen, cellulose, silk fibroin, keratin, gelatin and polysaccharides such as chitosan and alginate. Examples of synthetic polymers include poly(lactic acid) (PLA), polycaprolactone (PCL), polyurethane (PU), poly(lactic-co-glycolic acid) (PLGA), poly(3-hydroxybutyrate-co-3-hydroxyvalerate) (PHBV), and poly(ethylene-co-vinylacetate) (PEVA). Polymer chains are connected via covalent bonds. The diameters of nanofibers depend on the type of polymer used and the method of production. All polymer nanofibers are unique for their large surface area-to-volume ratio, high porosity, appreciable mechanical strength, and flexibility in functionalization compared to their microfiber counterparts.
Nanofiltration is a membrane filtration process that uses nanometer sized pores through which particles smaller than about 1–10 nanometers pass through the membrane. Nanofiltration membranes have pore sizes of about 1–10 nanometers, smaller than those used in microfiltration and ultrafiltration, but a slightly bigger than those in reverse osmosis. Membranes used are predominantly polymer thin films. It is used to soften, disinfect, and remove impurities from water, and to purify or separate chemicals such as pharmaceuticals.
Nanotube membranes are either a single, open-ended nanotube(CNT) or a film composed of an array of nanotubes that are oriented perpendicularly to the surface of an impermeable film matrix like the cells of a honeycomb. 'Impermeable' is essential here to distinguish nanotube membrane with traditional, well known porous membranes. Fluids and gas molecules may pass through the membrane en masse but only through the nanotubes. For instance, water molecules form ordered hydrogen bonds that act like chains as they pass through the CNTs. This results in an almost frictionless or atomically smooth interface between the nanotubes and water which relate to a "slip length" of the hydrophobic interface. Properties like the slip length that describe the non-continuum behavior of the water within the pore walls are disregarded in simple hydrodynamic systems and absent from the Hagen–Poiseuille equation. Molecular dynamic simulations better characterize the flow of water molecules through the carbon nanotubes with a varied form of the Hagen–Poiseuille equation that takes into account slip length.
Membrane bioreactors are combinations of some membrane processes like microfiltration or ultrafiltration with a biological wastewater treatment process, the activated sludge process. These technologies are now widely used for municipal and industrial wastewater treatment. The two basic membrane bioreactor configurations are the submerged membrane bioreactor and the side stream membrane bioreactor. In the submerged configuration, the membrane is located inside the biological reactor and submerged in the wastewater, while in a side stream membrane bioreactor, the membrane is located outside the reactor as an additional step after biological treatment.
Membrane fouling is a process whereby a solution or a particle is deposited on a membrane surface or in membrane pores in a processes such as in a membrane bioreactor, reverse osmosis, forward osmosis, membrane distillation, ultrafiltration, microfiltration, or nanofiltration so that the membrane's performance is degraded. It is a major obstacle to the widespread use of this technology. Membrane fouling can cause severe flux decline and affect the quality of the water produced. Severe fouling may require intense chemical cleaning or membrane replacement. This increases the operating costs of a treatment plant. There are various types of foulants: colloidal, biological, organic and scaling.
Reverse osmosis (RO) is a water purification process that uses a semi-permeable membrane to separate water molecules from other substances. RO applies pressure to overcome osmotic pressure that favors even distributions. RO can remove dissolved or suspended chemical species as well as biological substances, and is used in industrial processes and the production of potable water. RO retains the solute on the pressurized side of the membrane and the purified solvent passes to the other side. It relies on the relative sizes of the various molecules to decide what passes through. "Selective" membranes reject large molecules, while accepting smaller molecules.
A spinneret is a device used to extrude a polymer solution or polymer melt to form fibers. Streams of viscous polymer exit via the spinneret into air or liquid leading to a phase inversion which allows the polymer to solidify. The individual polymer chains tend to align in the fiber because of viscous flow. This airstream liquid-to-fiber formation process is similar to the production process for cotton candy. The fiber production process is generally referred to as "spinning". Depending on the type of spinneret used, either solid or hollow fibers can be formed. Spinnerets are also used for electrospinning and electrospraying applications. They are sometimes called coaxial needles, or coaxial emitters.
Spinning is a manufacturing process for creating polymer fibers. It is a specialized form of extrusion that uses a spinneret to form multiple continuous filaments.
Bioseparation of 1,3-propanediol is a biochemical process for production of 1,3-propanediol (PDO). PDO is an organic compound with many commercial applications. Conventionally, PDO is produced from crude oil products such as propylene or ethylene oxide. In recent years, however, companies such as DuPont are investing in the biological production of PDO using renewable feedstocks such as corn.
Nano-scaffolding or nanoscaffolding is a medical process used to regrow tissue and bone, including limbs and organs. The nano-scaffold is a three-dimensional structure composed of polymer fibers very small that are scaled from a Nanometer scale. Developed by the American military, the medical technology uses a microscopic apparatus made of fine polymer fibers called a scaffold. Damaged cells grip to the scaffold and begin to rebuild missing bone and tissue through tiny holes in the scaffold. As tissue grows, the scaffold is absorbed into the body and disappears completely.
A membrane is a selective barrier; it allows some things to pass through but stops others. Such things may be molecules, ions, or other small particles. Membranes can be generally classified into synthetic membranes and biological membranes. Biological membranes include cell membranes ; nuclear membranes, which cover a cell nucleus; and tissue membranes, such as mucosae and serosae. Synthetic membranes are made by humans for use in laboratories and industry.
Membrane technology encompasses the scientific processes used in the construction and application of membranes. Membranes are used to facilitate the transport or rejection of substances between mediums, and the mechanical separation of gas and liquid streams. In the simplest case, filtration is achieved when the pores of the membrane are smaller than the diameter of the undesired substance, such as a harmful microorganism. Membrane technology is commonly used in industries such as water treatment, chemical and metal processing, pharmaceuticals, biotechnology, the food industry, as well as the removal of environmental pollutants.
A die in polymer processing is a metal restrictor or channel capable of providing a constant cross sectional profile to a stream of liquid polymer. This allows for continuous processing of shapes such as sheets, films, pipes, rods, and other more complex profiles. This is a continuous process, allowing for constant production, as opposed to a sequential (non-constant) process such as injection molding.
Phase inversion or phase separation is a chemical phenomenon exploited in the fabrication of artificial membranes. It is performed by removing the solvent from a liquid-polymer solution, leaving a porous, solid membrane.
Melt blowing is a conventional fabrication method of micro- and nanofibers where a polymer melt is extruded through small nozzles surrounded by high speed blowing gas. The randomly deposited fibers form a nonwoven sheet product applicable for filtration, sorbents, apparels and drug delivery systems. The substantial benefits of melt blowing are simplicity, high specific productivity and solvent-free operation. Choosing an appropriate combination of polymers with optimized rheological and surface properties, scientists have been able to produce melt-blown fibers with an average diameter as small as 36 nm.