Combined biofouling and scaling in membrane feed channels: a new modeling approach.

A mathematical model was developed for combined fouling due to biofilms and mineral precipitates in membrane feed channels with spacers. Finite element simulation of flow and solute transport in two-dimensional geometries was coupled with a particle-based approach for the development of a composite (cells and crystals) foulant layer. Three fouling scenarios were compared: biofouling only, scaling only and combined fouling. Combined fouling causes a quicker flux decline than the summed flux deterioration when scaling and biofouling act independently. The model results indicate that the presence of biofilms leads to more mineral formation due to: (1) an enhanced degree of saturation for salts next to the membrane and within the biofilm; and (2) more available surface for nucleation to occur. The impact of biofilm in accelerating gypsum precipitation depends on the composition of the feed water (eg the presence of NaCl) and the kinetics of crystal nucleation and growth. Interactions between flow, solute transport and biofilm-induced mineralization are discussed.

Custom-designed 3D printed feed spacers and TFN membranes with MIL-101(Fe) for water recovery by forward osmosis.

In this work, a dual-pronged approach- (i) novel thin-film nanocomposite polyether sulfone (PES) membrane with MIL-101 (Fe) and (ii) 3D printed spacers were explored to enhance water recovery by forward osmosis. The concentration of PES, pore former, draw solution, and MIL-101(Fe) was optimised for maximum pure water flux (PWF) and minimum specific reverse solute flux (SRSF). The best membrane exhibited a PWF of 7.52 Lm-2 h-1 and an SRSF of 0.33 ± 0.03 gL-1 using 1.5 M NaCl and DI water feed. The M22 membrane with the diamond-type spacer demonstrated a PWF of 2.53 Lm-2 h-1 and SRSF of 0.75 gL-1 for emulsified oily wastewater feed. The novel spacer design imparted significant turbulence to the feed flow and a lower foulant resistance of 1.3 m-1 as compared to the ladder type (1.5 m-1) or commercial spacer (1.7 m-1). This arrangement could recover 19% pure water within 12 h of operation (98% oil rejection) with a ∼ 94% flux recovery after hydraulic wash.

Superhydrophobic Candle Soot as a Low Fouling Stable Coating on Water Treatment Membrane Feed Spacers.

Membrane separation processes including reverse osmosis are now considered essential techniques for water and wastewater treatment, especially in water-scarce areas where desalination and water reuse can augment the water supply. However, biofouling remains a significant challenge for these processes and in general for marine biological fouling, which results in increased energy consumption and high operational costs. Especially in flat sheet membrane modules, intense biofilm growth occurs on the feed spacer at points of contact to the membrane surface. Here, we developed an ultrastable superhydrophobic antibiofouling feed spacer that resists biofilm growth. A commercial polypropylene feed spacer was coated with poly(dimethylsiloxane) (PDMS), and then, candle soot nanoparticles (CSNPs) were embedded into the ultrathin layer of PDMS, which resulted in a superhydrophobic nanostructured surface with a contact angle >150°. The CSNP-coated spacer was examined for inhibition of biofilm growth by a cross-flow membrane channel using Pseudomonas aeruginosa (PA01), and the coating was examined for effectiveness in marine fouling by testing the adhesion of marine bacterium Cobetia marina and diatom Navicula perminuta in a dynamic accumulation assay. In all cases, the CSNP coatings showed almost complete elimination of biofilm growth under the conditions tested. Confocal laser scanning microscopy and scanning electron microscopy indicated a 99% reduction in biofilm growth on the modified spacers compared to the uncoated controls. This effect was attributed to the superhydrophobic nanostructured surface, where trapped gasses formed a plastron on the coating. This plastron was observed to be extremely stable over time and could even be replenished at elevated temperatures. Development of similar antibiofouling coatings on feed spacers or other marine applications might lead to improvements in many industrial processes including membrane filtration where increased membrane life span and reduced energy consumption are key to implementation.

Roles and performance enhancement of feed spacer in spiral wound membrane modules for water treatment: A 20-year review on research evolvement.

Membrane technologies have been widely applied in water treatment, wastewater reclamation and seawater desalination. Feed spacer present in spiral wound membrane (SWM) modules plays a pivotal role in creating flow channels, promoting fluid mixing and enhancing mass transfer. However, it induces the increase of feed channel pressure (FCP) drop and localized stagnant zones that provokes membrane fouling. For the first time, we comprehensively review the research evolvement on feed spacer in SWM modules for water treatment over the last 20 years, to reveal the impacts of feed spacer on the hydrodynamics and biofouling in the spacer-filled channel, and to discuss the potential approaches and current limitations for the modification of feed spacer. The research process can be divided into three phases, with research focus shifting from hydrodynamics in Phase Ⅰ (the year of 2001-2008), to biofouling in Phase Ⅱ (the year of 2009-2015), and then to novel spacer designs in Phase Ⅲ (the year of 2016-2020). The spacer configuration has a momentous impact on the hydraulic performance regarding flow velocity field, shear stress, mass transfer and FCP drop. Biofouling initially occurs on feed spacer, especially around spacer filaments and the contact zones with membrane surface, and ultimately degrades the overall membrane performance indicating the importance of controlling spacer biofouling. The modification of feed spacer is mainly achieved by altering surface chemistry or introducing novel configurations. However, the stability of spacer coating and the economy and practicality of 3D-printed spacer remain a predicament to be tackled. Future studies are suggested to focus on the standardization of testing conditions for spacer evaluation, the effect of hydrodynamics on membrane fouling control, the design and fabrication of novel feed spacer adaptable for SWM modules, the application of feed spacer for drinking water production, organic fouling control in spacer-filled channel and the role of permeate spacer on membrane performance.

Analysis of Concentration Polarisation in Full-Size Spiral Wound Reverse Osmosis Membranes Using Computational Fluid Dynamics.

A three-dimensional model for the simulation of concentration polarisation in a full-scale spiral wound reverse osmosis (RO) membrane element was developed. The model considered the coupled effect of complex spacer geometry, pressure drop and membrane filtration. The simulated results showed that, at a salt concentration of 10,000 mg/L and feed pressure of 10.91 bar, permeate flux decreased from 27.6 L/(m2 h) (LMH) at the module inlet to 24.1 LMH at the module outlet as a result of salt accumulation in the absence of a feed spacer. In contrast, the presence of the spacer increased pressure loss along the membranes, and its presence created vortices and enhanced fluid velocity at the boundary layer and led to a minor decrease in flux to 26.5 LMH at the outlet. This paper underpins the importance of the feed spacer's role in mitigating concentration polarisation in full-scale spiral wound modules. The model can be used by both the industry and by academia for improved understanding and accurate presentation of mass transfer phenomena of full-scale RO modules by different commercial manufacturers that cannot be achieved by experimental characterization of the mass transfer coefficient or by CFD modelling of simplified 2D flow channels.

Effect of localized hydrodynamics on biofilm attachment and growth in a cross-flow filtration channel.

Biofilm attachment and growth in membrane filtration systems are considerably influenced by the localized flow inside the feed channel. The present work aims to map the biofilm attachment/growth mechanism under varying flow conditions. Effect of varying clearance region (space between the spacer filament and membrane surface) on biofouling pattern is investigated by using three 3D-printed pillar spacers having different filament diameters of 340, 500, and 1000 µm while maintaining the same pillar orientation, diameter and height. Direct Numerical Simulations (DNS) and Optical Coherence Tomography (OCT) were carried out to accurately predict the local hydrodynamics behavior and in-situ monitor the biofilm formation. On spacer filaments, biofouling attachment is primarily observed in the regions where low and non-fluctuating shear stresses are present. Conversely, on membrane surface, highest biofouling attachment was observed under spacer filaments where high shear stresses are prevalent along with low clearance height. Furthermore, as filtration time progresses, the biofilm grows faster on the membrane in the center of spacer cells where low shear stress with steady hydrodynamics conditions are prevalent. The proposed hydrodynamics approach envisages a full spectrum of spacer design constraints that can lead to intrinsic biofilm mitigation while improving filtration performance of membranes based water treatment.

Mass Transport in Osmotically Driven Membrane Processes.

Forward osmosis (FO) and pressure retarded osmosis (PRO) are the two operational modes for osmotically driven membrane processes (ODMPs). ODMPs have gained increasing popularity in the laboratory over the years; however, OMDPs have not been applied in very many cases at full scale because they are still emerging technologies that require further development. Computational fluid dynamics (CFD) modeling coupled with solute transport evaluation provides a tool to study hydrodynamics and concentration polarization in FO and PRO. In this study a series of models were developed to predict water flux. The simulation results of empty-channel (with no feed spacer) membrane cells were verified by comparison with experimental results, showing that CFD simulation with solute transport is a reliable tool. Ensuing 2D and 3D models were built to study the impact of feed spacers on the velocity and concentration distribution inside the flow channels, and investigate whether the presence of spacers would enable enhancement of water flux. The results showed that spacers could change the concentration and velocity profile and they could reduce or enhance water flux depending on the inlet flow velocity and distance between the membrane and spacer.

Impacts of non-uniform filament feed spacers characteristics on the hydraulic and anti-fouling performances in the spacer-filled membrane channels: Experiment and numerical simulation.

Feed spacer is universally used in spiral-wound nanofiltration (NF) and reverse osmosis (RO) membrane modules. It can separate membrane sheets, create flow channels, promote turbulence and enhance mass transfer. However, it also induces increased pressure drop across the flow channel, and generates dead zones for biofilm growth at specific locations. Optimization of feed spacer geometries is highly desirable for energy saving and biofouling control. In this study, four kinds of commercial feed spacers featured with non-uniform filaments were compared in terms of hydraulic and anti-fouling performances. Computational fluid dynamics (CFD) simulations were launched to give insights into the impacts of feed spacer characteristics on the flow field. Results show that the hydraulic performance was substantially affected by the number of filament layers (single or dual layer), the non-uniformity of filament diameter and the width of thinning zones. The design of single layer feed spacer of non-uniform filaments was not recommended due to high flow resistance and poor anti-fouling performance. The feed spacer structure of alternating filament diameter contributed to reducing dead zones and alleviating membrane fouling. The thinning zones located adjacent to the filament junctions achieved better anti-fouling performance, as it disturbed the dead zones and partially washed away the deposited foulants. This study demonstrates for the first time that the characteristics of non-uniform filament feed spacer had a crucial impact on the hydraulic and anti-fouling performances, and suggests that more emphasis should be laid on number of filament layers, variation of filament diameter and width and positioning of thinning zones for the optimization of feed spacer geometries in the future.

Energy efficient 3D printed column type feed spacer for membrane filtration.

Modification of the feed spacer design significantly influences the energy consumption of membrane filtration processes. This study developed a novel column type feed spacer with the aim to reduce the specific energy consumption (SEC) of the membrane based water filtration system. The proposed spacer increases the clearance between the filament and the membrane (reducing the spacer filament diameter) while keeping the same flow channel thickness as compared to a standard non-woven symmetric spacer. Since the higher clearance reduces the flow unsteadiness, column type nodes were added in the spacer structure as additional vortex shading bodies. Fluid flow behaviour in the channel for this spacer was numerically simulated by 3D CFD studies and then compared with the standard spacer. The numerical results showed that the proposed spacer substantially reduced the pressure drop, shear stress at the constriction region and shortened the dead zone. Finally, these findings were confirmed experimentally by investigating the filtration performances using the 3D printed prototypes of these spacers in a lab-scale filtration module. It is observed that the column spacer reduced the pressure drop by three times and doubled the specific water flux. 2D OCT (Optical Coherence Tomography) scans of the membrane surface acquired after the filtration revealed much lower biomass accumulation using the proposed spacer. Consequently, the SEC for the column spacer was found about two folds lower than the standard spacer.

In-situ biofouling assessment in spacer filled channels using optical coherence tomography (OCT): 3D biofilm thickness mapping.

Membrane systems for water purification can be seriously hampered by biofouling. The use of optical coherence tomography (OCT) to investigate biofilms in membrane systems has recently increased due to the ability to do the characterization in-situ and non-destructively. The OCT biofilm thickness map is presented for the first time as a tool to assess biofilm spatial distribution on a surface. The map allows the visualization and evaluation of the biofilm formation and growth in membrane filtration systems through the use of a false color scale. The biofilm development was monitored with OCT to evaluate the suitability of the proposed approach. A 3D time series analysis of biofilm development in a spacer filled channel representative of a spiral-wound membrane element was performed. The biofilm thickness map enables the time-resolved and spatial-resolved evaluation and visualization of the biofilm deposition pattern in-situ non-destructively.

Porosity of spacer-filled channels in spiral-wound membrane systems: Quantification methods and impact on hydraulic characterization.

The porosity of spacer-filled feed channels influences the hydrodynamics of spiral-wound membrane systems and impacts the overall performance of the system. Therefore, an exact measurement and a detailed understanding of the impact of the feed channel porosity is required to understand and improve the hydrodynamics of spiral-wound membrane systems applied for desalination and wastewater reuse. The objectives of this study were to assess the accuracy of porosity measurement techniques for feed spacers differing in geometry and thickness and the consequences of using an inaccurate method on hydrodynamic predictions, which may affect permeate production. Six techniques were applied to measure the porosity namely, three volumetric techniques based on spacer strand count together with a cuboidal (SC), cylindrical (VCC) and ellipsoidal volume calculation (VCE) and three independent techniques based on volume displacement (VD), weight and density (WD) and computed tomography (CT) scanning. The CT method was introduced as an alternative for the other five already existing and applied methods in practice. Six feed spacers used for the porosity measurement differed in filament thickness, angle between the filaments and mesh-size. The results of the studies showed differences between the porosities, measured by the six methods. The results of the microscopic techniques SC, VCC and VCE deviated significantly from measurements by VD, WD and CT, which showed similar porosity values for all spacer types. Depending on the maximum deviation of the porosity measurement techniques from -6% to +6%, (i) the linear velocity deviations were -5.6% and +6.4% respectively and (ii) the pressure drop deviations were -31% and +43% respectively, illustrating the importance of an accurate porosity measurement. Because of the accuracy and standard deviation, the VD and WD method should be applied for the porosity determination of spacer-filled channels, while the CT method is recommended for numerical modelling purposes. The porosity has a linear relationship with the flow velocity and a superlinear effect on the pressure drop. Accurate porosity data are essential to evaluate feed spacer performance in spiral-wound membrane systems. Porosity of spacer-filled feed channels has a strong impact on membrane performance and biofouling impact.

Visualization of hydraulic conditions inside the feed channel of Reverse Osmosis: A practical comparison of velocity between empty and spacer-filled channel.

It is widely accepted that our understanding about the membrane process increases by investigation of the hydraulic conditions of membranes. While numerical studies have been broadly used for this purpose, the experimental studies of a comparable resolution are scarce. In this study, we compared the pressure drop, the temporal and the spatial velocity maps of a spacer-filled channel and an empty channel of the same size to determine the effect of presence of the feeds spacer on hydraulic conditions. The velocity maps are obtained experimentally by using of the Particle Image Velocimetry (PIV) technique. Application of the feed spacer caused 2-8.5 higher pressure drop increase in the experimental conditions in this research. The flow had a spatial distribution in the form of a unimodal symmetric curve of normal distribution in the empty channel and a bimodal asymmetric curve in the spacer-filled channel. The bimodal curve indicates the presence of high- and low-velocity zones. Additionally, the low-velocity zones showed also a lower variation of velocity in time, which indicates the high fouling potential of these locations. The results from this study may be uses for validation of numerical studies.

Development and characterization of 3D-printed feed spacers for spiral wound membrane systems.

Feed spacers are important for the impact of biofouling on the performance of spiral-wound reverse osmosis (RO) and nanofiltration (NF) membrane systems. The objective of this study was to propose a strategy for developing, characterizing, and testing of feed spacers by numerical modeling, three-dimensional (3D) printing of feed spacers and experimental membrane fouling simulator (MFS) studies. The results of numerical modeling on the hydrodynamic behavior of various feed spacer geometries suggested that the impact of spacers on hydrodynamics and biofouling can be improved. A good agreement was found for the modeled and measured relationship between linear flow velocity and pressure drop for feed spacers with the same geometry, indicating that modeling can serve as the first step in spacer characterization. An experimental comparison study of a feed spacer currently applied in practice and a 3D printed feed spacer with the same geometry showed (i) similar hydrodynamic behavior, (ii) similar pressure drop development with time and (iii) similar biomass accumulation during MFS biofouling studies, indicating that 3D printing technology is an alternative strategy for development of thin feed spacers with a complex geometry. Based on the numerical modeling results, a modified feed spacer with low pressure drop was selected for 3D printing. The comparison study of the feed spacer from practice and the modified geometry 3D printed feed spacer established that the 3D printed spacer had (i) a lower pressure drop during hydrodynamic testing, (ii) a lower pressure drop increase in time with the same accumulated biomass amount, indicating that modifying feed spacer geometries can reduce the impact of accumulated biomass on membrane performance. The combination of numerical modeling of feed spacers and experimental testing of 3D printed feed spacers is a promising strategy (rapid, low cost and representative) to develop advanced feed spacers aiming to reduce the impact of biofilm formation on membrane performance and to improve the cleanability of spiral-wound NF and RO membrane systems. The proposed strategy may also be suitable to develop spacers in e.g. forward osmosis (FO), reverse electrodialysis (RED), membrane distillation (MD), and electrodeionisation (EDI) membrane systems.

Hydrogel-coated feed spacers in two-phase flow cleaning in spiral wound membrane elements: a novel platform for eco-friendly biofouling mitigation.

Biofouling is still a major challenge in the application of nanofiltration and reverse osmosis membranes. Here we present a platform approach for environmentally friendly biofouling control using a combination of a hydrogel-coated feed spacer and two-phase flow cleaning. Neutral (polyHEMA-co-PEG10MA), cationic (polyDMAEMA) and anionic (polySPMA) hydrogels have been successfully grafted onto polypropylene (PP) feed spacers via plasma-mediated UV-polymerization. These coatings maintained their chemical stability after 7 days incubation in neutral (pH 7), acidic (pH 5) and basic (pH 9) environments. Anti-biofouling properties of these coatings were evaluated by Escherichia coli attachment assay and nanofiltration experiments at a TMP of 600 kPag using tap water with additional nutrients as feed and by using optical coherence tomography. Especially the anionic polySPMA-coated PP feed spacer shows reduced attachment of E. coli and biofouling in the spacer-filled narrow channels resulting in delayed biofilm growth. Employing this highly hydrophilic coating during removal of biofouling by two-phase flow cleaning also showed enhanced cleaning efficiency, feed channel pressure drop and flux recoveries. The strong hydrophilic nature and the presence of negative charge on polySPMA are most probably responsible for the improved antifouling behavior. A combination of polySPMA-coated PP feed spacers and two-phase flow cleaning therefore is promising and an environmentally friendly approach to control biofouling in NF/RO systems employing spiral-wound membrane modules.

Impact of spacer thickness on biofouling in forward osmosis.

Forward osmosis (FO) indirect desalination systems integrate wastewater recovery with seawater desalination. Niche applications for FO systems have been reported recently, due to the demonstrated advantages compared to conventional high-pressure membrane processes such as nanofiltration (NF) and reverse osmosis (RO). Among them, wastewater recovery has been identified to be particularly suitable for practical applications. However, biofouling in FO membranes has rarely been studied in applications involving wastewater effluents. Feed spacers separating the membrane sheets in cross-flow systems play an important role in biofilm formation. The objective of this study was to determine the influence of feed spacer thickness (28, 31 and 46 mil) on biofouling development and membrane performance in a FO system, using identical cross-flow cells in parallel studies. Flux development, biomass accumulation, fouling localization and composition were determined and analyzed. For all spacer thicknesses, operated at the same feed flow and the same run time, the same amount of biomass was found, while the flux reduction decreased with thicker spacers. These observations are in good agreement with biofouling studies for RO systems, considering the key differences between FO and RO. Our findings contradict previous cross-flow studies on particulate/colloidal fouling, where higher cross-flow velocities improved system performance. Thicker spacers reduced the impact of biofouling on FO membrane flux.

Impact of ZnO embedded feed spacer on biofilm development in membrane systems.

The concept of suppressing biofouling formation using an antibacterial feed spacer was investigated in a bench scale-cross flow system mimicking a spiral wound membrane configuration. An antibacterial composite spacer containing zinc oxide-nanoparticles was constructed by modification of a commercial polypropylene feed spacer using sonochemical deposition. The ability of the modified spacers to repress biofilm development on membranes was evaluated in flow-through cells simulating the flow conditions in commercial spiral wound modules. The experiments were performed at laminar flow (Re = 300) with a 200 kDa molecular weight cut off polysulfone ultrafiltration membrane using Pseudomonas putida S-12 as model biofilm bacteria. The modified spacers reduced permeate flux decrease at least by 50% compared to the unmodified spacers (control). The physical properties of the modified spacer and biofilm development were evaluated using high resolution/energy dispersive spectrometry-scanning electron microscopy, atomic force microscopy and confocal laser scanning microscopy imaging (HRSEM, EDS, AFM and CLSM). HRSEM images depicted significantly less bacteria attached to the membranes exposed to the modified spacer, mainly scattered and in a sporadic monolayer structure. AFM analysis indicated the influence of the modification on the spacer surface including a phase change on the upper surface. Dead-live staining assay by CLSM indicated that most of the bacterial cells attached on the membranes exposed to the modified spacer were dead in contrast to a developed biofilm which was predominant in the control samples.