This presentation will outline the critical steps and pitfalls in the scale-up pathway for CPMs. At the laboratory level, techniques such as interfacial polymerization and dip coating are commonly used to fabricate dense, selective layers. While effective at small scale, these methods face reproducibility issues and throughput limitations when extended to continuous production formats like roll-to-roll (R2R) and slot-die coating. Maintaining nanoscale uniformity and strong adhesion between layers at high production speeds requires a re-engineering of both the chemistry and the process mechanics. Case studies, including recent advances in scalable polyamide thin-film formation (ElSherbiny et al., Membranes, 2020) and Ardent’s own Optiperm™ platform, will be discussed.
Defect control is a central barrier to full-scale deployment. Defects such as pinholes, delamination, or interfacial voids can critically undermine membrane performance. To address this, inline monitoring systems and data-driven process control—leveraging real-time imaging and machine learning—are being explored to improve consistency and minimize waste (Liu et al., AIChE J., 2022).
Beyond materials and fabrication, module integration imposes mechanical and chemical durability constraints. CPMs must survive long-term operational stresses, including compaction, cleaning cycles, and solvent exposure. The transition from flat-sheet prototypes to full-scale spiral-wound or hollow-fiber modules requires co-optimization of membrane structure and module architecture to prevent failure under industrial conditions (Freeman et al., Chem. Rev., 2019).
Finally, the lack of standardized performance benchmarks and regulatory pathways for emerging CPM technologies (especially in solvent-resistant or gas separation applications) presents an ongoing commercialization bottleneck. Engagement with certification bodies and deployment at pilot scale is crucial for risk reduction and customer validation.
Key Takeaways:
This talk aims to provide a comprehensive view of the engineering, materials science, and systems-level challenges in scaling up CPMs and to propose actionable strategies for researchers and manufacturers navigating the bench-to-plant transition.
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