New membrane technologies are often invented in labs, but most of them fail to be commercialized. In many cases this is due to issues that arise during technology scale-up. Scaling up membrane technology from the lab to pilot-scale and from pilot-scale to the commercial production scale are two crucial steps on the path to commercialization with very different challenges. The scale-up of membrane technology involves three main technical areas:
1. New membrane chemistries
Fundamental understanding of membrane formation via interfacial polymerization and how different reactants behave at the interface
The reaction mechanism and function of chemical additives in the membrane formulation
How the chemistry impacts the final membrane's physical and chemical properties and stability, particularly during the separation process (i.e., testing)
Fate and potential safety concerns of any chemical compounds used
2. Membrane manufacturing process
Process design decisions to accommodate the transition from batch operation in the lab to continuous production
Fluid management considerations in wetting and drying steps of the processes
Proper make-up solution strategies to prevent formula drift to ensure a stable manufacturing process
Key considerations for operational safety protections
How to keep the operation economical and environmentally friendly
3. Manufacturing equipment
Integration of process technology into equipment via special design of the machine
Selection criteria for coating methods and their associated required equipment
Incorporation of automation to streamline daily production and minimize waste and maintenance for stable long-term operation
In summary, scaling up is not a simple matter of copying over the lab-scale parameters or multiplying them by a factor. There are many factors to consider, with the ultimate goal of producing high quality membranes in a consistent manner. In this talk, we will discuss some key parameters that need to be evaluated and addressed for a successful scale-up process.
