RELATED METHODS

CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to United States Provisional Application Number

62/326,430 that was filed on April 22, 2016. The entire content of the applications referenced above are hereby incorporated by reference herein.

TECHNICAL FIELD

A ceramic membrane module with a drive plate assembly and related methods.

TECHNICAL BACKGROUND

Many waters contain contaminants that can present a hazard to people or the

environment, or make further processing, such as evaporation or reverse osmosis more difficult. Membranes are commonly used to remove such contaminants. Membrane elements are typically made of polymers or ceramics, both of which are frequently placed inside a pressure vessel to contain the pressurized fluid to be treated. The element and pressure vessel combination are referred to as membrane modules or modules. Such pressure vessels also provide separate ports to allow a feed to enter the module, filtrate to exit after being processed through the membrane, and a retentate for removal of the filtered material.

Ceramic membranes are commonly used as a multilayer structure with a relatively high permeability support, and a thinner separation layer which enables the separation by passing some components (typically water and small solutes) while retaining others. In order to increase surface area a number of channels are typically present in the support, each with a coating. During use of the membrane, feed enters these channels before passing through the membrane into the support structure. To keep feed from passing directly into the support on either end, a face end seal layer is used to prevent transport through the ends. Commonly used materials for face end seals include epoxies, polyurethanes, and glass. In comparison to the other components in a ceramic membrane module, this face end seal is particularly sensitive to mechanical damage due to both the material properties of the face end seal, and the fact that housings which have been used to date leave the face end seal at the end of the housing preventing it from serving as shielding. What is needed is a module design allowing the housing to protect, shield, and/or create an impingement zone or buffer space around the face end seal improving the durability and integrity of the membrane.

Further, ceramic membrane modules are typically heavy and require mechanical support. Conventional ceramic housings require the ceramic in the housing to be supported so that the external end caps which are affixed to the bottom of the housing can be installed before use, or removed while in a system to access the ceramic, for instance to determine whether damage to the face end seal has occurred. This requires a method to support the weight of the ceramic above the ground, which makes routine inspections difficult to perform. This can be

accomplished by recessing the element inside the housing. However to do so there is a need for a process to provide potting material to seal the element to the housing, while preventing the potting material from flowing over the end of the module and blocking capillaries. What is needed is a process to position the module within the housing and seal the capillary area on the end of the element so that potting material can be applied to mount the element within the housing without blocking capillaries.

SUMMARY

In one or more embodiments, a method for forming a ceramic membrane module system comprises disposing at least one membrane within a housing, where the housing has a first housing end and a second housing end, the membrane has capillaries therein, and the capillaries extend from at least a first end of the membrane. The method further includes disposing at least one sealing pad adjacent to the membrane, disposing at least one drive plate assembly adjacent to the at least one sealing pad, coupling the at least one drive plate assembly with the housing, applying force to the sealing pad with the drive plate assembly, sealing the capillaries of first membrane end with the at least one sealing pad and forming a seal between the at least one sealing pad and the membrane, and

disposing potting material into the housing without plugging more than 15% of the capillaries with the potting material.

In one or more embodiments, disposing at least one spacer pad adjacent to the at least one sealing pad, between the drive plate assembly and the at least one sealing pad.

In one or more embodiments, disposing the at least one sealing pad and at least one spacer pad includes disposing at least one sealing pad and at least one spacer pad at each end of the housing.

In one or more embodiments, the method further includes measuring displacement of the at least one sealing pad while force is being applied to the at least one sealing pad. In one or more embodiments, the method further includes removing the sealing pads and spacer pads from the housing.

In one or more embodiments, the method further includes pre-potting the membrane.

In one or more embodiments, disposing potting material includes disposing potting material through a side port of the housing, and closing the side port after the potting.

In one or more embodiments, disposing potting material includes disposing potting material through the at least one sealing pad.

In one or more embodiments, a filtration assembly formation assembly includes a housing, a membrane extending from a first membrane end to a second membrane end, where the membrane is disposed within the housing, and the membrane has capillaries therein, where the capillaries have capillary ends. The assembly further includes at least one sealing pad disposed adjacent to the membrane, and the drive plate assembly configured to apply force to the sealing pad to seal off the capillary ends.

In one or more embodiments, the method further includes at least one spacer pad disposed adjacent to the at least one sealing pad, where the spacer pad is disposed between the drive plate assembly and the at least one sealing pad.

In one or more embodiments, at least one spacer pad is disposed at each end of the membrane, and at least one sealing pad is disposed at each end of the membrane.

In one or more embodiments, the membrane is a pre-potted membrane.

In one or more embodiments, the method further includes a measurement device configured to measure displacement of the at least one sealing pad while force is being applied to the at least one sealing pad.

In one or more embodiments, the housing includes a potting side port.

These and other embodiments, aspects, advantages, and features of the present invention will be set forth in part in the description which follows, and will become apparent to those skilled in the art by reference to the following description of the invention and referenced drawings or by practice of the invention. The aspects, advantages, and features of the invention are realized and attained by means of the instrumentalities, procedures, and combinations particularly pointed out in the appended claims and their equivalents. BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 A illustrates a cross-sectional view of a system according to one or more embodiments.

FIG. IB illustrates an end view of a system according to one or more embodiments.

FIG. 1C illustrates an enlarged cross-sectional view of a portion of a system according to one or more embodiments.

FIG. 2A is a perspective view of a ceramic membrane system according to one or more embodiments.

FIG. 2B is a partially exploded perspective view of a ceramic membrane system according to one or more embodiments.

FIG. 3 A is a perspective view of a ceramic membrane system according to one or more embodiments.

FIG. 3B is a partially exploded perspective view of a ceramic membrane system according to one or more embodiments.

FIG. 4 illustrates a bottom view of a ceramic membrane system according to one or more embodiments.

FIG. 5 illustrates an end view of a ceramic membrane system according to one or more embodiments.

FIG. 6 illustrates an end view of ceramic membranes according to one or more embodiments.

DETAILED DESCRIPTION

The following detailed description includes references to the accompanying drawings, which form a part of the detailed description. The drawings show, by way of illustration, specific embodiments in which the apparatus may be practiced. These embodiments, which are also referred to herein as "examples" or "options," are described in enough detail to enable those skilled in the art to practice the present embodiments. The embodiments may be combined, other embodiments may be utilized or structural or logical changes may be made without departing from the scope of the invention. The following detailed description is, therefore, not to be taken in a limiting sense and the scope of the invention is defined by the appended claims and their legal equivalents. In this document, the terms "a" or "an" are used to include one or more than one, and the term "or" is used to refer to a nonexclusive "or" unless otherwise indicated. In addition, it is to be understood that the phraseology or terminology employed herein, and not otherwise defined, is for the purpose of description only and not of limitation.

A ceramic membrane module system is shown in FIGs. 1A, IB, 1C 2A, 2B, 3A, 3B, 4, 5.

In one or more embodiments, a method for forming a ceramic membrane module system comprises disposing at least one membrane within a housing, where the housing has a first housing end and a second housing end, the membrane has capillaries therein, and the capillaries extend from at least a first end of the membrane. The method further includes disposing at least one sealing pad adjacent to the membrane, disposing at least one drive plate assembly adjacent to the at least one sealing pad, coupling the at least one drive plate assembly with the housing, applying force to the sealing pad with the drive plate assembly, sealing the capillaries of first membrane end with the at least one sealing pad and forming a seal between the at least one sealing pad and the membrane, and disposing potting material into the housing without plugging more than 15% of the capillaries with the potting material.

In one or more embodiments, disposing at least one spacer pad adjacent to the at least one sealing pad, between the drive plate assembly and the at least one sealing pad.

In one or more embodiments, disposing the at least one sealing pad and at least one spacer pad includes disposing at least one sealing pad and at least one spacer pad at each end of the housing.

In one or more embodiments, the method further includes measuring displacement of the at least one sealing pad while force is being applied to the at least one sealing pad.

In one or more embodiments, the method further includes removing the sealing pads and spacer pads from the housing.

In one or more embodiments, the method further includes pre-potting the membrane.

In one or more embodiments, disposing potting material includes disposing potting material through a side port of the housing, and closing the side port after the potting.

In one or more embodiments, disposing potting material includes disposing potting material through the at least one sealing pad.

In one or more embodiments, a filtration assembly formation assembly includes a housing, a membrane extending from a first membrane end to a second membrane end, where the membrane is disposed within the housing, and the membrane has capillaries therein, where the capillaries have capillary ends. The assembly further includes at least one sealing pad disposed adjacent to the membrane, and the drive plate assembly configured to apply force to the sealing pad to seal off the capillary ends.

In one or more embodiments, the method further includes at least one spacer pad disposed adjacent to the at least one sealing pad, where the spacer pad is disposed between the drive plate assembly and the at least one sealing pad.

In one or more embodiments, at least one spacer pad is disposed at each end of the membrane, and at least one sealing pad is disposed at each end of the membrane.

In one or more embodiments, the membrane is a pre-potted membrane.

In one or more embodiments, the method further includes a measurement device configured to measure displacement of the at least one sealing pad while force is being applied to the at least one sealing pad.

In one or more embodiments, the housing includes a potting side port.

In one or more embodiments, the system includes a ceramic membrane module that includes a ceramic monolith or potted segments making up a monolith that is optionally set back from the ends of the housing, and is made using a drive plate. The segments and or monolith of the ceramic membranes are aligned and affixed in from the ends of the housing and are potted in place in a manner that allow fluid to mix in a mixing zone and evenly distribute flow over the face end of the capillary of the ceramic monolith or potted monolith.

In one or more embodiments, the module as described herein, affixes the ceramic membrane to the housing at a recess from the end of the housing, for example, a predetermined distance from either or both ends of the housing. A drive plate assembly is used to provide a predetermined amount of force on the seal to ensure proper sealing.

In one or more embodiments, the drive plate assembly includes a drive plate 180, a retaining plate 188, and plate displacement device 181, including but not limited to, screws, bolts, cams, or similar for moving the drive plate 180. The drive plate assembly is used near the end portions of the membrane 130 in conjunction with a retention member 184. The retention member 184 couples the drive plate assembly with the housing, and holds the drive plate assembly in place when the drive plate assembly is used to apply pressure to the sealing pad. In one or more embodiments, the retention member 184 includes a thrust retainer, swing bolt/Victaulic type couplings, retaining bolts or pins, V- bands, or union closures. A sealing pad 142 and spacer pad is disposed between the drive plate assembly and the membrane 130. In one or more embodiments, the drive plate 180 has an outer shape that is similar to an inner shape of the housing 120 for the membrane, for example, a circular shape. The drive plate 180 has an outer dimension that is smaller than the inner dimensions of the housing. In one or more embodiments, there is a gap of about ½ mm - 5mm between the outer perimeter of the drive plate 180 and the inner dimension of the housing.

In one or more embodiments, the plate displacement device 181 includes a number of screws. In one or more embodiments, there are 1 - 6 screws. In one more embodiments, there are three screws. The screws apply a compressive force to the drive plate 180. In one more embodiments, 5 psi - 100 psi of force is applied.

The retaining plate 188 is mechanically coupled with the housing 120, and a retention member 184, also mechanically coupled with the housing 120, prevents movement of the retaining plate 188 along the longitudinal axis of the housing 120 during use of the drive plate assembly.

The drive plate assembly is further used in conjunction with the sealing pad 142 and spacer pad 150. The sealing pad 142 is disposed directly against the membrane, and the spacer pad 150 is disposed between the sealing pad 142 and the drive plate 180. The drive plate 180 is disposed between the retaining plate 188 and the spacer 150.

The drive plate assembly has an uncompressed state (FIG. 1 A) and a compressed state (FIG. 7). In the compressed state, the drive plate 180 displaces the sealing pad 142 by 3 - 25%. In one or more embodiments, the sealing pad 142 is elastic, and can be formed of elastomeric material, such as a natural r silicone rubber. In one or more embodiments, the sealing pad 142 is formed of rubber that is about 30 - 90 durometer, Shore A.

The drive plate 180 can be made of rigid material, such as durable thermoplastic, composite material, stainless steel or aluminum. In one or more embodiments, the thickness of the drive plate 180 is about 10 mm - 30 mm. In one or more embodiments, the thickness of the drive plate is 5 - 20% of the inner dimension of the housing, such as the inner diameter. This prevents flexing of the drive plate 180, since flexing puts uneven pressure on the sealing pad.

During use of the drive plate assembly, the plate displacement device 181 of the drive plate assembly is moved. For instance, screws are turned to compress the drive plate 180 against the spacer pad 150 and the sealing padl42. As the drive plate 180 applies force to the spacer pad 150, the spacer pad 150 forces the sealing pad 142 against the membrane and substantially seals the end of the membrane. In one or more embodiments, a measurement device 190, such as a sensor, is included with the drive plate assembly to measure the amount of displacement as force is applied with the drive plate assembly. In one or more embodiments, a measurement device, such as a dial indicator, is coupled with the drive plate assembly to measure the amount of displacement of the sealing pad 142. The measurement device is configured to measure displacement of the at least one sealing pad while force is being applied to the at least one sealing pad.

The distance of the ceramic membrane and potting from the end of the module housing provides for protection of the face end seal from accidental mechanical damage, while the distance from the end cap 140 provides for mixing and uniform distribution of fluids to be processed. Since the housing contains the pressure, a variety of end cap designs can be used interchangeably and be made of various materials to optimize performance in a given installation. For instance, in applications where a high salinity stream is used a plastic end cap may be used to minimize corrosion, while in a high temperature application a metal end cap may be replaced. Recessing the ceramic membrane decreases the range of approaches which could cause damage, and thus the risk of damage to the membrane.

This module is commonly used in a vertical orientation, and can be supported by the edges of the base of the housing, while leaving the center region with clearance to remove the end cap 140 and access the membrane. The module could also be supported around the circumference.

The material used for the end cap 140 can be chosen from a variety of materials.

Thermoset or thermoplastics may be used, and the may be used with or without reinforcement materials. These may include ABS, Acetal, PPE resin, Nylon, PEEK, PET, PPSU, CPVC, PVC, PP, PE, PVDF, PTFE, PEI, epoxies, urethanes, or other plastics. These end caps 140 may also be reinforced by the use of an external plate, preferably metal such as steel or aluminum. The end cap 140 may also be made of metals, which may optionally be coated or modified to improve stability to the fluids and cleaning agents used during use.

A variety of methods have been devised as a means to affix the end cap 140 to the module. For instance thrust snap rings can be used to hold the end cap 140 in place internal to the vessel. Alternately, swing bolt/Victaulic type couplings, retaining bolts or pins, V- bands, union closures, or other similar closure styles can be used.

In an example of a method for forming a ceramic membrane module system, and referring to FIGs. 1 A, IB, and 1C, the method includes disposing a membrane 130 within a housing 120, where the housing 120 has a first housing end 122 and a second housing end 124, and the membrane 130 has capillaries 136 (FIG. 6) therein, where the capillaries 136 extend from at least a first end 132 of the membrane 130. In one or more embodiments, the capillaries 136 extend from the first end 132 to the second end 134 of the membrane. The membrane 130 is recessed from at least one of the first or second housing ends 122, 124.

The method further includes disposing a resistant spacer pad 150 and sealing pad 142 near the first end of the membrane and sealing the capillaries 136, disposing at least one end cap 140 in the housing near the spacer pad.

The method still further includes sealing the first housing end 122 with the sealing pad and forming a seal, applying force to the sealing pad with a drive plate assembly. Plate displacement device 181 of the drive plate assembly are used to move the drive plate 180 along the longitudinal axis of the housing, where the screws are thrust from the retaining plate 188 to provide the force to the drive plate 180. The drive plate 180 provides force to the spacer pad 150, which in turn provides pressure to the sealing pad 142.

The method further includes disposing potting material into the housing 120 without plugging the capillaries 136, for example without plugging more than 15% of the capillaries with the potting material. The sealing pad 142 keeps the potting in place during potting and curing, and then removed. Once the module is potted and cured, the sealing pad 142 is removed. In a further option, the method includes sealing and potting both ends of the housing using the above method. The drive plate assembly can be used to perform the pre-potting. After the potting has occurred, the end cap can be added.

A variety of materials can be used for the housing. In one or more embodiments, the materials include, but are not limited to, thermoplastics, FRP including ABS, Acetal, PPE resin, Nylon, PEEK, PET, PPSU, PEI, CPVC, PVC, PP, PE, PVDF, PTFE, or combinations thereof. Thermoplastics may also include reinforcement materials such as carbon fiber, glass or ceramic particles or fibers to improve thermal and mechanical stability. Metals such as steel, stainless steel, aluminum, and titanium may also be used as a housing material. These metals may optionally be coated or modified to improve stability to the fluids and cleaning agents used during use. In one or more embodiments, the housing material includes fiber reinforced plastics (FRP), for instance glass fiber or carbon fibers reinforced with thermosets such as epoxy.

In one or more embodiments, the housing includes side ports 126. These side ports provide an exit connection for purified fluids, and a means to clean the membrane surface by pressurizing the filtrate and causing the flow direction to temporarily reverse. The port materials can be adjusted for the application and its temperature and chemical requirements, various metals allows and sealing pad systems or other housing materials as indicated earlier may be used for these ports. Modules as described herein can be made by potting the ceramic plates within the housing. To do this the ceramic membrane is placed within the housing, for example, in a vertical orientation. A support is used with a sealing pad material that seals the channels preventing the potting material from sealing the channels of the ceramic membrane. The uncured potting material is added through the side port 126, through the opposite end, or through a hole in the sealing pad so that the potting material completely seals the ceramic to the internal housing wall. The depth of this potting material is chosen to maximize the mechanical integrity of the module, while minimizing the amount of potting material used. Preferred amounts give a depth of potting material between 0.1 and 20cm, preferably between 0.5 and 5cm, and more preferably between 1 and 3 cm. After the first side is potted, and sufficiently cured, the module can be inverted and the process repeated to pot the second end. In this instance the potting material may be applied in a similar manner to the first side, through the side port or sealing pad.

If a ceramic monolith is used, it can be potted directly into the housing. If a segmented monolith is to be used, it can be either placed into the vessel with a series of spacers or a fixturing device, either of which end up being encapsulated in potting material. Alternatively the segments may be first potted into a prepot. In a prepot concept both ends of the ceramic are first potted together at both ends with a disc of potting material. Gaskets can be used to prevent potting material from entering the channels and a mold is used to prepare the disc shape which is slightly smaller than the internal diameter of the housing.

To improve the adhesion of the potting material to the vessel, the surface of the vessel may be modified prior to potting. This may include cleaning, for instance with solvent, acids, or bases, mechanical roughening of the surface, for instance by sanding, or chemical modification for instance by functionalization or plasma or corona treatment.

Recessed potting allows a mixing zone for uniform entry into the feed side of the membrane. The extension of the housing walls leads to a mechanical protection of the face end seal and ceramic membrane from damage. The recessed potting allows a closure type that enables the use of a thrust snap ring closure type, a flat or domed inward or outward end cap, a swing bolt type enclosure, a v-band type closure, and other grooved type closure methods.

These are cost advantages over other types of closure thus reducing the housing cost and the product cost. These methods can be used in FRP, metallic and other plastic type housings and or endcaps. In addition, the ceramic module described herein allows for less expensive and more chemically resistant endcaps and closure types such as inward domed or flat endcaps secured by thrust ring 192/ grooved closures, V-band swing bolts, screwed union or other similar methods. It is to be understood that the above description is intended to be illustrative, and not restrictive. Many other embodiments will be apparent to those of skill in the art upon reading and understanding the above description. It should be noted that embodiments discussed in different portions of the description or referred to in different drawings can be combined to form additional embodiments of the present application. The scope should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.