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EP-4741043-A2 - MEMBRANE MODULE

EP4741043A2EP 4741043 A2EP4741043 A2EP 4741043A2EP-4741043-A2

Abstract

A membrane module for separating a fluid feed stream (14) which comprises permeate material and retentate material into a permeate stream (18, 18a, 18b, 18c, 18d) and a retentate stream (16, 16a) comprises at least one pressure vessel (2) extending along a longitudinal axis (4) from a first end (5) towards a second end (6) and having a cylindrical wall (7) enclosing an internal space (8). The first end (5) of the pressure vessel (2) is closed by a first end cap (11) and the second end (6) of the pressure vessel (2) is closed by a second end cap (12). At least one of the first end cap (11) and the cylindrical sidewall (7) comprises a fluid inlet (13) for receiving the fluid feed stream (14). The second end cap (12) comprises a retentate outlet (15) for discharging the retentate stream (16, 16a). At least one of the first end cap (11) and the second end cap (12) comprises one or more permeate outlets (17, 17a, 17b, 17c) for discharging the permeate stream (18, 18a, 18b, 18c, 18d). The membrane module further comprises at least one membrane cartridge (9, 9a) arranged inside the pressure vessel (2) each of said membrane cartridges comprising multiple membrane envelopes arranged in the form of a stack. The membrane envelopes each comprise two membranes each arranged on a carrier material and one or more first spacers between the membranes, which keep the membranes spaced apart from each other, in order to allow a free flow cross-section for a through-flow of the permeate stream (18, 18a, 18b, 18c, 18d) through the membrane envelopes. The membranes comprise edges along which the membranes of a membrane envelope are connected to each other, in order to prevent the fluid feed stream (14) and the retentate stream (16, 16a) from penetrating into the membrane envelopes. Each of the membrane cartridges (9, 9a) further comprise second spacers between the membrane envelopes, which keep the membrane envelopes spaced apart, in order to allow a free flow cross-section for a throughflow of the fluid feed stream (14) and/or the retentate stream (16, 16) in a flow direction. The membrane cartridges (9, 9a) further comprise one or more permeate tubes (19), which extend, transversely to the flow direction of the fluid feed stream (14) and are in fluid connection with the at least one permeate outlet (17, 17a, 17b, 17c. The one or more permeate tubes (19) comprise one or more radial openings, through which the permeate material from the membrane envelopes arrives in the one or more permeate tubes (19).

Inventors

  • NOTZKE, HEIKO
  • WOLFF, THORSTEN
  • BRINKMANN, TORSTEN
  • Corner, Andrew
  • Gorringe, Simon

Assignees

  • Helmholtz-Zentrum hereon GmbH
  • Cool Planet Technologies Ltd

Dates

Publication Date
20260513
Application Date
20240508

Claims (15)

  1. Membrane module for separating a fluid feed stream (14) which comprises permeate material and retentate material into a permeate stream (18, 18a, 18b, 18c, 18d) and a retentate stream (16, 16a), wherein the membrane module (1) is adapted for the large-scale capture of carbon dioxide from industrial flue gas emissions such as in cement, iron and steel and coal-fired and waste to energy power generation plants, and wherein the membrane module is configured to be operated at a pressure range of the fluid feed stream (14) from 100 kPa to 1.5 MPa, wherein the membrane module comprises: at least one pressure vessel (2) extending along a longitudinal axis (4) from a first end (5) towards a second end (6) and having a cylindrical wall (7) enclosing an internal space (8), wherein the first end (5) of the pressure vessel (2) is closed by a first end cap (11) and the second end (6) of the pressure vessel (2) is closed by a second end cap (12), wherein at least one of the first end cap (11) and the cylindrical sidewall (7) comprises a fluid inlet (13) for receiving the fluid feed stream (14), wherein the second end cap (12) comprises a retentate outlet (15) for discharging the retentate stream (16, 16a) and, wherein at least one of the first end cap (11) and the second end cap (12) comprises one or more permeate outlets (17, 17a, 17b, 17c) for discharging the permeate stream (18, 18a, 18b, 18c, 18d), wherein the membrane module (1, 1') further comprises at least one membrane cartridge (9, 9a) arranged inside the pressure vessel (2) each membrane cartridge (9, 9a) comprising multiple membrane envelopes (24) arranged in the form of a stack, wherein the membrane envelopes (24) each comprise two membranes (25) each arranged on a carrier material and one or more first spacers (26) between the membranes (25), which keep the membranes (25) spaced apart from each other, in order to allow a free flow cross-section for a through-flow of the permeate stream (18, 18a, 18b, 18c, 18d) through the membrane envelopes (24), wherein the membranes (25) comprise edges along which the membranes (25) of a membrane envelope (24) are connected to each other, in order to prevent the fluid feed stream (14) and the retentate stream (16, 16a) from penetrating into the membrane envelopes (24), second spacers (27) between the membrane envelopes (24), which keep the membrane envelopes (24) spaced apart, in order to allow a free flow cross-section for a throughflow of the fluid feed stream (14) and/or the retentate stream (16, 16a) in a flow direction, and one or more permeate tubes (19), which extend, transversely to the flow direction of the fluid feed stream (14) and are in fluid connection with the at least one permeate outlet (17, 17a, 17b, 17c), wherein the one or more permeate tubes (19) comprise one or more radial openings, through which the permeate material from the membrane envelopes (24) arrives in the one or more permeate tubes (19), wherein the at least one membrane cartridge (9, 9a) has a cuboid housing (10), wherein each pressure vessel (2) comprises an annulus (20) located radially inward between the cylindrical wall (7) of the pressure vessel (2) and the cuboid housing (10) of the at least one membrane cartridge (9, 9a), and that the fluid inlet (13) is fluidically connected with the annulus (20) such that the pressure at the fluid inlet (13) and the annulus (20) is equalized, characterized in that the membrane cartridges (9, 9a) are arranged in two cartridge rows (28) each cartridge row (28) comprising multiple membrane cartridges (9, 9a) arranged in series, wherein the two cartridge rows (28) are arranged in parallel such that the fluid feed stream (14) simultaneously flows through both of the cartridge rows (28), and the two cartridge rows (28) are arranged along the longitudinal axis (4) with a gap (29) in between the two cartridge rows (28), wherein the fluid inlet (13) at the first end cap (11) or the cylindrical sidewall (4) of the pressure vessel (2) is fluidically connected with the gap (29) between the two cartridge rows (28) and, wherein the two cartridge rows (28) are further arranged such that the fluid feed stream (14) is divided at the gap (29) and flows in opposite directions along the longitudinal axis (4) through both of the cartridge rows (28) towards the first end cap (11) and the second end cap (12), respectively.
  2. Membrane module according to claim 1, characterized in, that the membrane module (1, 1') is configured to be operated at a pressure range of the fluid feed stream (14) from 150 kPa to 1.0 MPa.
  3. Membrane module according to any of the preceding claims, characterized in, that the pressure vessel (2) further comprises a first end piece (21) and a second end piece (22), each sealing the at least one membrane cartridge (9, 9a) against the first end cap (11) and the second end cap (12), respectively.
  4. Membrane module according to any of the preceding claims, characterized in, that the membrane module (1, 1') comprises multiple membrane cartridges (9, 9a) which are arranged in series inside the pressure vessel (2) along the longitudinal axis (4) and, wherein the cuboid housings (10) of the membrane cartridges (9, 9a) are sealed to each other, such that the fluid feed stream (14) streams through the multiple membrane cartridges (9, 9a) before exiting the membrane module (1, 1') as retentate stream (16).
  5. Membrane module according to any of the preceding claims, characterized in, that up to 12 membrane cartridges (9, 9a), preferably up to 10 membrane cartridges (9, 9a), more preferably up to 8 membrane cartridges (9, 9a), most preferably 4 membranes cartridges (9, 9a) are arranged in series inside the pressure vessel (2).
  6. Membrane module according to any of the preceding claims, characterized in, that the pressure vessel (2) comprises a detachment mechanism which upon actuation allows detachment of the at least one membrane cartridge (9, 9a) out of the pressure vessel (2).
  7. Membrane module according to claim 6, characterized in, that the detachment mechanism comprises rails arranged inside the pressure vessel (2) parallel to the longitudinal axis (4) thereof and the at least one membrane cartridge (9, 9a) comprises pulleys configured to roll on the rails such that the at least one membrane cartridge (9, 9a) is movable along the rails out of the pressure vessel (2).
  8. Membrane module according to any of the preceding claims, characterized in, that membrane module (1, 1') comprises multiple pressure vessels (2), preferably up to 10 pressure vessels (2), more preferably up to 6 pressure vessels (2), most preferably 4 pressure vessels (2) and further comprises a 20', 40', 45' High-Cube, 45' Pallet Wide or 53' High-Cube ISO standardized and derivative intermodal shipping container (3) in which the pressure vessels (2) are housed.
  9. Method for separating a fluid feed stream (14) which comprises permeate material and retentate material into a permeate stream (18, 18a, 18b, 18c, 18d) and a retentate stream (16, 16a), in which f. a membrane module (1, 1') according to any of claims 1 to 11 is provided; g. a fluid feed stream (14) is guided through the fluid inlet (13) into the at least one pressure vessel (2); h. the fluid feed stream (14) flows in the direction of the retentate outlet (15) through the at least one membrane cartridge (9, 9a) inside the pressure vessel (2), wherein, during the throughflow through the at least one membrane cartridge (9, 9a), the permeate material flows through the membranes (25) into the membrane envelopes (24), thereby separating the fluid feed stream (14) into a permeate stream (18, 18a, 18b, 18c, 18d) in the membrane envelopes (24) and a retentate stream (16, 16a) between the membrane envelopes (24); i. the permeate stream (18, 18a, 18b, 18c, 18d) flows from the membrane envelopes (25) through the one or more radial openings into the one or more permeate tubes (19), flows through the one or more permeate tubes (19) to the one or more permeate outlets (17, 17a, 17b, 17c) and is discharged there; j. the retentate stream (16, 16a) flows between the membrane envelopes (24) and, having passed the at least one membrane cartridge (9, 9a), is discharged through the retentate outlet (15), wherein each pressure vessel (2) comprises an annulus (20) located radially inward between the cylindrical wall (7) of the pressure vessel (2) and a cuboid housing (10) of the at least one membrane cartridge (9, 9a), wherein the fluid inlet (13) is fluidically connected with the annulus (20) and, wherein the fluid feed stream (14) entering the at least one pressure vessel (2) partially streams towards the annulus thereby equalizing the pressure at the fluid inlet (13) and the annulus (20).
  10. Method according to claim 9, wherein the membrane module (1, 1') comprises multiple membrane cartridges (9, 9a) arranged in series inside the pressure vessel (2) along the longitudinal axis (4) and, wherein in step e. the retentate stream (16, 16a) flows between the membrane envelopes (24) to the subsequent membrane cartridge (9, 9a) of the multiple membrane cartridges (9, 9a) arranged in series and enters the subsequent membrane cartridges (9, 9a) as a stripped fluid feed stream (14) and, having passed the membrane cartridges (9, 9a) arranged in series, the retentate stream (16, 16a) is discharged through the retentate outlet (15).
  11. Method according to any of claims 9 or 10, in which the fluid feed stream (14) and the permeate stream (18, 18a, 18b, 18c, 18d) at least partially flow past each other in a countercurrent manner through the at least one membrane cartridge (9, 9a).
  12. Method according to any of claims 9 to 11, wherein the pressure vessel (2) further comprises a first end piece (21) and a second end piece (22), each sealing the at least one membrane cartridge (9, 9a) against the first end cap (11) and the second end cap (12), respectively.
  13. Method according to any of claims 9 to 12, wherein the first end piece (21) comprises an equalization port (23) which is configured to fluidically connect the fluid inlet (13) at the first end cap (11) and the annulus (20).
  14. Method according to any of claims 9 to 13, in which the fluid feed stream (14) has a pressure range from 100 kPa to 2 MPa, preferably from 100 kPa to 1.5 MPa, more preferably from 150 kPa to 1.0 MPa.
  15. Method according to any of claims 9 to 14, in which the membrane cartridges (9, 9a) are arranged in two cartridge rows (28) with a gap (29) in between, each cartridge row (28) comprising multiple membrane cartridges (9, 9a) arranged in series, wherein the two cartridge rows (28) are arranged in parallel and, wherein the fluid feed stream (14) simultaneous flows through both of the cartridge rows (28) in opposite directions along the longitudinal axis (4) from the gap (29) through both of the cartridge rows (28) towards the first end cap (11) and the second end cap (12), respectively.

Description

The present invention relates to a membrane module for separating a fluid feed stream into a permeate stream and a retentate stream, in particular to a membrane module which can be operated at a high pressure. BACKGROUND OF THE INVENTION Membrane-based separation processes have found numerous applications in various industries over the past decades. They find their application in fields such as water, energy, chemical, petro-chemical and pharmaceutical industries. Their increasing degree of application is due to the ability to produce high permeability and essentially defect-free membranes on a large scale, and the ability to assemble these membranes into compact, efficient and economical membrane modules with a high membrane surface-area. Industrial membrane separation requires large areas of membrane surface to be economically and effectively packaged. These packages are referred-to as membrane modules. Generally, there are four basic types of membrane module: plate-and-frame, spiral wound, tubular and hollow fibre membrane modules. Effective module design is one of the critical qualities which determine the commercial success of membrane-based separation units. Membrane modules separate a fluid feed stream into a permeate stream and a retentate stream. The stream which penetrates the membrane and is separated from the feed material is referred-to as permeate stream, and the stream stripped of the permeate, which does not penetrate the membrane and is dispensed from the separation unit, is referred-to as retentate stream. Some industrial applications benefit - in addition to a large surface area - from the application of high pressure. Such processes include, for example, the separation of carbon dioxide from flue gases of industrial and power generation CO2 emitters. Using renewable energy, the carbon dioxide separated off as permeate can be converted into usable, carbon-based products such as fuels or polymers, or can be stored underground or used as nutrient for algae. The use of membrane technology for the large-scale capture of carbon dioxide from major industrial flue gas emissions requires extremely large membrane areas. Generally, membrane modules in the form of plate-and-frame modules are preferred for large membrane area applications. The membranes to be packed into plate-and-frame modules are readily available. However, one disadvantage is that up to now plate-and-frame modules cannot be operated at above ambient pressures of e.g. 120 kPa or more. In addition to the large membrane area the membranes and the space required to house such large membrane areas, it would thus be desirable to operate membrane separation also at high pressures, such as at an absolute pressure of 120 kPa or more. EP 3 227 004 A1 for example is directed to a membrane module whose components are housed in a 20', 40', 45' HC, 45' PW or 53' HC container. The membrane module provides a large membrane area, by means of which the number of individual membrane modules required in practical applications can be reduced. However, the membrane module does not allow operation at an elevated pressure above approximately 120 kPa as the container housing is not able to withstand such operating pressures. Alternatively, membranes also be arranged in the form of flat sheet membranes which are spirally wound and contained within tubular housings (spiral wound modules), typically containing 40-80 m2 of membrane area. The tubular housings are able to withstand an absolute operating pressure in excess of 1 MPa. However, this approach is prohibitively expensive due to the large number (thousands) of tubular housings that would be required for large-scale capture of carbon dioxide. Spiral wound modules are both expensive to manufacture and difficult to interconnect for adapting them to the use in large scale operations. Another, alternative, option for arranging gas phase separation membranes in membrane modules is the use of hollow fibre membranes. Hollow fibre membranes utilize thousands of long, porous filaments ranging from 0.1 - 3.5 mm wide, that are potted in place in a shell. Each filament is very narrow in diameter and flexible. Hollow fibres can find uses in various types of membrane processes, ranging from microfiltration to reverse osmosis and gas separation. However, the geometry of hollow fibre membranes is not suitable for the type of membrane used in this invention for carbon dioxide separation from flue gases, as it would cause a large pressure drop throughout the length of the membrane and thin polymer film required for carbon dioxide separation cannot be applied. DESCRIPTION OF THE INVENTION It is therefore the object of the present invention to provide and operate a membrane module which has large membrane areas, is readily available, and is able to operate at an absolute pressure of 120 kPa or more. The above object is achieved by a membrane module according to claim 1. Preferred embodiments are set out in the dependent cl