USOO6685832B2

(12) United States Patent (10) Patent No.: US 6,685,832 B2

Mahendran et al. (45) Date of Patent: *Feb. 3, 2004

(54) METHOD OF POTTING HOLLOW FIBER (56) References Cited

MEMBRANES
U.S. PATENT DOCUMENTS
(75) Inventors: Mailvaganam Mahendran, Hamilton 3,339,341 A 9/1967 Maxwell et al.
(CA); Steven Pedersen, Burlington 3,708,071 A 1/1973 Crowley
(CA) 3,730.959 A 5/1973 Horres et al.
3,734,989 A 5/1973 Leonard et al.
(73) Assignee: Zenon Environmental Inc., Oakville 5,174.900 A 12/1992 Nichols et al.
(CA) 5.248,424 A 9/1993 Cote et al.
5,480,553 A 1/1996 Yamamori et al.
(*) Notice: Subject to any disclaimer, the term of this 5,554,283 A 9/1996 Brinda et al.
patent is extended or adjusted under 35 5,639,373 A 6/1997 Mahendran et al.
U.S.C. 154(b) by 11 days. (List continued on next page.)
This patent is Subject to a terminal dis FOREIGN PATENT DOCUMENTS
claimer.
CH 528347 9/1972
EP O 931582 7/1999
(21) Appl. No.: 10/167,699 JP O1-151906 6/1989
JP 2174915 * 7/1990
(22) Filed: Jun. 13, 2002 JP O3-131324 6/1991
(65) Prior Publication Data JP OS-269354 10/1993
JP O7-O24272 1/1995
US 2002/0153299 A1 Oct. 24, 2002 JP 10572O6 * 4/1996
JP OO-334271 12/2000
Related U.S. Application Data WO WO OO/06357 2/2000

(63) Continuation of application No. 09/849,573, filed on May 4, Primary Examiner Ana Fortuna
2001, which is a continuation of application No. 09/507,438, (74) Attorney, Agent, or Firm-Bereskin & Parr
filed on Feb. 19, 2000, now Pat. No. 6.294,039, which is a (57) ABSTRACT
division of application No. 09/258.999, filed on Feb. 26,
1999, now Pat. No. 6,042,677, which is a division of
application No. 08/896,517, filed on Jun. 16, 1997, now Pat. A method of potting a plurality of hollow fiber membranes
No. 5,910,250, which is a continuation-in-part of application into a mass of Solidified potting liquid is described. Open
No. 08/690,045, filed on Jul. 31, 1996, now Pat. No. ends of a plurality of hollow fiber membranes are enclosed
5,783,083, and a continuation-in-part of application No.
08/514,119, filed on Aug. 11, 1995, now Pat. No. 5,639,373. in a first material held in a container which may be a part of
(60) Provisional application No. 60/012,921, filed on Mar. 5, a permeate collection means, for example, a permeate pan or
1996. header enclosure. A potting liquid is flowed into the con
tainer over the first material. The potting liquid Surrounds
(51) Int. Cl. ................................................ B01D 63/00 each hollow fiber membrane and then becomes a Solid mass
that provides a fluid-tight seal to the outside of the hollow
(52) U.S. Cl. .............................. 210/321.8; 210/321.78; fiber membranes. The first material prevents the potting
156/242; 156/245; 156/246; 24.4/DIG. 48 liquid or Solid mass from closing the ends of the membranes.
The first material is later removed from the ends of the
(58) Field of Search .............................. 210/636, 321.8, hollow fiber membranes.
210/321.78, 321.69; 156/242, 245, 246;
264/DIG. 48 18 Claims, 13 Drawing Sheets
 US 6,685,832 B2
Page 2

U.S. PATENT DOCUMENTS 6,042,677 A * 3/2000 Mahendran et al.

6.294,039 B1 * 9/2001 Mahendran et al.
5,695,702 A 12/1997 Niermeyer 6,303,035 B1 * 10/2001 Cote et al.
5,783,083 A * 7/1998 Henshaw et al.
5,922.201 A 7/1999 Yamamori et al. * cited by examiner
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 US 6,685,832 B2
1 2
METHOD OF POTTING. HOLLOW FIBER Solidifying the first liquid. Upon removing the fugitive
MEMBRANES header, what is left is the “finished” or “final’ header formed
by the Second potting material. Of course, leSS preferably,
any prior art method may be used for forming finished
FIELD OF THE INVENTION headers in which opposed terminal end portions of fibers in
a Stack of arrays are Secured in proximately Spaced-apart
This application is a continuation of Ser. No. 09/849,573 relationship with each other.
filed May 4, 2001; which is a continuation of Ser. No. The 424 patent required potting the opposed ends of a
09/507,438 filed Feb. 19, 2000 issued as U.S. Pat. No. frameless array of fibers and dispensed with the shell of a
6,294,039; which is a division of Ser. No. 09/258,999, filed module; it was an improvement on two preceding configu
Feb. 26, 1999, issued as U.S. Pat. No. 6,042,677; which is rations disclosed in U.S. Pat. Nos. 5,182,019, and 5,104,535,
a division of Ser. No. 08/896,517, filed Jun. 16, 1997, issued each of which used frameless arrays and avoided potting the
as U.S. Pat. No. 5,910,250; which is a continuation-in-part fibers. The efficiency of gas-Scrubbing a 424 array was
application of Ser. No. 08/690,045, filed Jul. 31, 1996, believed to be due, at least in large part, to a Substantial
issued as U.S. Pat. No. 5,783,083 which is a non-provisional 15 portion of the fibers of the fibers in the array lying in
of provisional application Serial No. 60/012,921 filed Mar. transverse relationship to a mass of rising bubbles, referred
5, 1996 and a continuation-in-part of Ser. No. 08/514,119, to herein as a “column of rising bubbles', So as to intercept
filed Aug. 11, 1995, issued as U.S. Pat. No. 5,639,373. The the bubbles. Specific examples are illustrated in FIGS. 9,
disclosure of all the patents and applications listed above are 9A, 10 and 11 of the 424 patent.
hereby incorporated by reference thereto as if fully set forth A 424 “array' referred to a bundle of arcuate fibers the
herein.
geometry of which array was defined by the position of a
BACKGROUND OF THE INVENTION pair of transversely spaced headers in which the fibers were
potted. In the 424 array, as in the array of this invention,
This invention relates to a membrane device which is an each fiber is free to move independently of the others, but the
improvement on a frameless array of hollow fiber mem 25 degree of movement in the 424 is unspecified and arbitrary,
branes and a method of maintaining clean fiber Surfaces while in the vertical skein of this invention, movement is
while filtering a Substrate to withdraw a permeate, which is critically restricted by the defined length of the fibers
also the subject of U.S. Pat. No. 5,248,424; and, to a method between opposed headers. Except for their opposed ends
of forming a header for a skein of fibers. The term “vertical being potted, there is no physical restraint on the fibers of a
skein” in the title (hereafter “skein” for brevity), specifically skein. To avoid confusion with the term “array' as used for
refers to an integrated combination of Structural elements the 424 bundle of arcuate fibers, the term "skein fibers” is
including (i) a multiplicity of vertical fibers of substantially used herein to refer to plural arrayS. An "array' in this
equal length; (ii) a pair of headers in each of which are invention refers to plural, essentially vertical fibers of Sub
potted the opposed terminal portions of the fiberS So as to Stantially equal lengths, the one ends of each of which fibers
leave their ends open; and, (iii) permeate collection means 35 are closely Spaced-apart, either linearly in the transverse
held peripherally in fluid tight engagement with each header (y-axis herein) direction to provide at least one row, and
So as to collect permeate from the ends of the fibers. typically plural rows of equidistantly spaced apart fibers.
The term “fibers” is used for brevity, to refer to “hollow LeSS preferably, a multiplicity of fiberS may be spaced in a
fiber membranes' of porous or Semipermeable material in random pattern. Typically, plural arrays are potted in a
the form of a capillary tube or hollow fiber. The term 40 header and enter its face in a generally x-y plane (see FIG.
“substrate” refers to a multicomponent liquid feed. A “mul 5). The width of a rectangular parallelpiped header is
ticomponent liquid feed” in this art refers, for example, to measured along the X-axis, and is the relatively shorter
fruit juices to be clarified or concentrated; wastewater or dimension of the rectangular upper Surface of the header;
water containing particulate matter, proteinaceous liquid and, the header's length, which is its relatively longer
dairy products Such as cheese whey, and the like. The term 45 dimension, is measured along the y-axis.
"particulate matter is used to refer to micron-sized (from 1 This invention is particularly directed to relatively large
to about 44 um) and Submicron sized (from about 0.1 um to Systems for the microfiltration of liquids, and capitalizes on
1 um) filterable matter which includes not only particulate the Simplicity and effectiveness of a configuration which
inorganic matter, but also dead and live biologically active dispenses with forming a module in which the fibers are
microorganisms, colloidal dispersions, Solutions of large 50 confined. AS in the 424 patent, the novel configuration
organic molecules Such as fulvic acid and humic acid, and efficiently uses a cleansing gas, typically air, discharged near
oil emulsions. the base of a skein to produce bubbles in a specified size
The term header is used to specify a solid body in which range, and in an amount large enough to Scrub the fibers, and
one of the terminal end portions of each one of a multiplicity to cause the fibers to Scrub themselves against one another.
of fibers in the Skein, is Sealingly Secured to preclude 55 Unlike in the 424 system the fibers in a skein are vertical
Substrate from contaminating the permeate in the lumens of and do not present an arcuate configuration above a hori
the fibers. Typically, a header is a continuous, generally Zontal plane through the horizontal center-line of a header.
rectangular parallelpiped of Solid resin (thermoplastic or AS a result, the path of the rising bubbles is generally parallel
thermosetting) of arbitrary dimensions formed from a natu to the fibers and is not crossed by the fibers of a vertical
ral or Synthetic resinous material. In the novel method 60 skein. Yet the bubbles scrub the fibers. The restrictedly
described hereinbelow, the end portions of individual fibers Swayable fibers, because of their defined length, do not get
are potted in Spaced-apart relationship in cured resin, most entangled, and do not abrade each other excessively, as is
preferably by “potting the end portions Sequentially in at likely in the 424 array. The defined length of the fibers
least two Steps, using first and Second potting materials. The herein minimizes (i) Shearing forces where the upper fibers
Second potting material (referred to as “fixing material”) is 65 are held in the upper header, (ii) excessive rotation of the
Solidified or cured after it is deposited upon a “fugitive upper portion of the fibers, as well as (iii) excessive abrasion
header” (so termed because it is removable) formed by between fibers. The fibers of this invention are confined so
 US 6,685,832 B2
3 4
as to sway in a “Zone of confinement” (or “bubble Zone') Skein, and the accessibility of those Surfaces by air bubbles,
through which bubbles rise along the outer surfaces of the the fiberS may be densely arranged in a header to provide a
fibers. The Side-to-side displacement of an intermediate large membrane surface of up to 1000 m and more.
portion of each fiber within the bubble Zone is restricted by One header of a skein is displaceable in any direction
the fiber's length. The bubble Zone, in turn, is determined by relative to the other, either longitudinally (X-axis) or trans
one or more columns of Vertically rising gas bubbles, versely (y-axis), only prior to the headers being vertically
preferably of air, generated near the base of a skein. fixed in Spaced apart parallel relationship within a reservoir,
Since there is no module in the conventional Sense, the for example, by mounting one header above another, against
main physical considerations which affect the operation of a a vertical wall of the reservoir which functions as a Spacer
Vertical Skein in a reservoir of Substrate relate to intrinsic
considerations, namely, (a) the fiber chosen, (b) the amount means. This is also true prior to spacing one header above
of air used, and (c) the substrate to be filtered. Such another with other Spacer means Such as bars, rods, Struts,
considerations include the permeability and rejection prop I-beams, channels, and the like, to assemble plural Skeins
erties of the fiber, the process flow conditions of substrate into a “bank of skeins” (“bank” for brevity), in which bank
Such as pressure, rate of flow across the fibers, temperature, a row of lower headers is directly beneath a row of upper
etc., the physical and chemical properties of the Substrate
15 headers. After assembly into a bank, a Segment intermediate
and its components, the relative directions of flow of the the potted ends of each individual fiber is displaceable along
Substrate (if it is flowing) and permeate, the thoroughness of either the X- or the y-axis, because the fibers are loosely held
contact of the Substrate with the outer Surfaces of the fibers, in the Skein. There is essentially no tension on each fiber
and Still other parameters, each of which has a direct effect because the opposed faces of the headers are spaced apart at
on the efficiency of the skein. The goal is to filter a slow a distance less than the length of an individual fiber.
moving or captive Substrate in a large container under By operating at ambient pressure, mounting the headers
ambient or elevated preSSure, but preferably under essen of the Skein within a reservoir of Substrate, and by allowing
the fibers restricted movement within the bubble Zone in a
tially ambient pressure, and to maximize the efficiency of a
Skein which does so (filters) practically and economically. 25
Substrate, we minimize damage to the fibers. Because, a
In the skein of this invention, all fibers in the plural rows header secures at least 10, preferably from 50 to 50,000
of fibers, Staggered or not, rise generally vertically while fibers, each generally at least 0.5 m long, in a skein, it
fixedly held near their opposed terminal portions in a pair of provides a high Surface area for filtration of the Substrate.
opposed, Substantially identical headers to form the Skein of The fibers divide a reservoir into a “feed Zone' and a
Substantially parallel, Vertical fibers. This Skein typically withdrawal Zone referred to as a “permeate Zone”. The feed
includes a multiplicity of fibers, the opposed ends of which of substrate is introduced externally (referred to as “outside
are potted in closely-spaced-apart profusion and bound by in” flow) of the fibers, and resolved into “permeate” and
potting resin, assuring a fluid-tight circumferential Seal “concentrate” streams. The Skein, or a bank of Skeins of this
around each fiber in the header and presenting a peripheral invention is most preferably used for microfiltration with
boundary around the outermost peripheries of the Outermost 35
“outside-in” flow. Typically a bank is used in a relatively
fibers. The position of one fiber relative to another in a skein large reservoir having a volume in excess of 10 L (liters),
is not critical, So long as all fibers are Substantially codirec preferably in excess of 1000 L, Such as a flowing Stream,
tional through one face of each header, open ends of the more typically a reservoir (pond or tank). Most typically, a
fibers emerge from the opposed other face of each header, bank or plural banks with collection means for the permeate,
and Substantially no terminal end portions of fibers are in 40
are mounted in a tank under atmospheric pressure, and
fiber-to-fiber contact. We found that the skein of fibers, permeate is withdrawn from the tank.
deployed to be restrictedly Swayable, were as ruggedly Where a bank or plural banks of skeins are placed within
durable as they were reliable in operation. a tank or bioreactor, and no liquid other than the permeate
The fibers are stated to be “restrictedly Swayable”, is removed the tank is referred to as a “dead end tank”.
because the extent to which they may Sway is determined by 45 Alternatively, a bank or plural banks may be placed within
the free length of the fibers relative to the fixedly spaced a bioreactor, permeate removed, and Sludge disposed of; or,
apart headers, and the turbulence of the Substrate. When a in a tank or clarifier used in conjunction with a bioreactor,
large number of fiberS is used in a skein, as is typically the permeate removed, and sludge disposed of.
case herein, the movement of a fiber adjacent to otherS may Operation of the System relies upon positioning at least
be modulated by the movement of the others, but the 50 one skein, preferably a bank, close to a Source of Sufficient
movement of fibers within a skein is constricted. This air or gas to maintain a desirable flux, and, to enable
system is therefore limited to the use of a skein of fibers permeate to be collected from at least one header. A desir
having a critically defined length relative to the vertical able flux is obtained, and provides the appropriate trans
distance between headers of the skein. The defined length membrane pressure differential of the fibers under operating
limits the side-to-side movement of the fibers in the Sub 55 process conditions. “Transmembrane pressure differential”
Strate in which they are deployed, except near the headers refers to the pressure difference acroSS a membrane wall,
where there is negligible movement. resulting from the process conditions under which the mem
In the prior art, a vertical Skein of fibers in a Substrate is brane is operating.
typically avoided due to expected problems relating to The relationship of flux to permeability and transmem
channelling of the feed. However, because the fibers are 60 brane preSSure differential is Set forth by the equation:
restrictedly Swayable in a “bubble Zone” as described J-kAP
herebelow, the fibers are substantially evenly contacted over
their individual surfaces with substrate and provide filtration where in, J = flu X; k = per me ability constant;
performance based on a maximized Surface which is Sub AP=transmembrane pressure differential; and k=1/u.Rm
Stantially the Sum of the Surface areas of all fibers in contact 65 where u=Viscosity of water and, Rm=membrane resistance.
with the Substrate. Moreover, because of the ease with which The transmembrane pressure differential is preferably
the Substrate coats the Surfaces of the vertical fibers in a generated with a conventional non-vacuum pump if the
 US 6,685,832 B2
S 6
transmembrane pressure differential is sufficiently low in the banks which may be deployed in a tank, pond or lake, the
range from 0.7 kPa (0.1 psi) to 101 kPa (1 bar), provided the number to be determined by the size of the body of water,
pump generates the requisite Suction. The term “non the rate at which permeate is to be withdrawn, and, the cost
Vacuum pump' refers to a pump which generates a net of doing So.
Suction Side pressure difference, or, net positive Suction head Typically, a relatively large number of long fibers, at least
(NPSH), adequate to provide the transmembrane pressure 100, is used in a skein of restrictedly Swayable fibers, the
differential generated under the operating conditions. By fiberS operate under a relatively low transmembrane pres
“vacuum pump' we refer to one capable of generating a Sure differential, and permeate is withdrawn with a non
Suction of at least 75 cm of Hg. A pump which generates Vacuum pump. If the liquid head, measured as the Vertical
minimal Suction may be used if an adequate “liquid head' is distance between the level of Substrate and the level from
provided between the surface of the substrate and the point which permeate is to be withdrawn, is greater than the
at which permeate is withdrawn; or, by using a pump, not a transmembrane pressure differential under which the fiber
Vacuum pump. A non-vacuum pump may be a centrifugal, operates, the permeate will be separated from the remaining
rotary, crossbow, flow-through, or other type. Moreover, as Substrate, due to gravity.
explained in greater detail below, once the permeate flow is 15 Irrespective of whether a non-vacuum pump, Vacuum
induced by a pump, the pump may not be necessary, the pump, or other type of pump is used, or permeate is
permeate continuing to flow under a "siphoning effect”. withdrawn with a siphoning effect, it is essential that the
Clearly, operating with fiberS Subjected to a transmembrane fibers in a skein be positioned in a generally vertical attitude,
pressure differential in the range up to 101 kPa (14.7 psi), a rising above the lower header. An understanding of how a
non-vacuum pump will provide adequate Service in a res Vertical skein operates will make it apparent that, Since fibers
ervoir which is not pressurized; and, in the range from 101 in a skein are anchored at the base of the Skein by the lower
kPa to about 345 kPa (50 psi), by Superatmospheric pressure header, the specific gravity of the fibers relative to that of the
generated by a high liquid head, or, by a pressurized Substrate is immaterial and will not affect their vertical
reservoir. disposition.
The fibers are not required to be subjected to a narrowly 25 The unique method of forming a header disclosed herein
critical transmembrane pressure differential though fibers allows one to position a large number of fibers, in closely
which operate under a Small transmembrane pressure dif Spaced apart relationship, randomly relative to one another,
ferential are preferred. A fiber which operates under a Small or, in a chosen geometric pattern, within each header of
transmembrane pressure differential in the range from about Synthetic resinous material. It is preferred to position the
0.7 kPa (0.1 psi) to about 70 kPa (10 psi) may produce fibers in arrays before they are potted to ensure that the fibers
permeate under gravity alone, if appropriately positioned are Spaced apart from each other precisely, and, to avoid
relative to the location where the permeate is withdrawn. In wasting Space on the face of a header; it is essential, for
the range from 3.5 kPa (0.5 psi) to about 206 kPa (30 psi) greatest reliability, that the fibers not be contiguous. By
a relatively high liquid head may be provided with a Sequentially potting the terminal portions of fibers in Stages
preSSurized vessel. The longer the fiber, which greater the 35 as described herein, the fibers may be cut to length in an
area and the more the permeate. array, either after, or prior to being potted. The use of a
In the Specific instance where a bank is used in combi razor-sharp knife, or Scissors, or other cutting means to do
nation with a Source of cleansing gas Such as air, both to So, does not decrease the open cross-sectional area of the
Scrub the fibers and to oxygenate a mixed liquor Substrate, fibers bores (“lumens”). The solid resin forms a circumfer
most, if not all of the air required, is introduced either 40 ential Seal around the exterior terminal portions of each of
continuously or intermittently, near the base of the fibers the fibers, open ends of which protrude through the
near the lower header. The perforations through which the permeate-discharging face of each header, referred to as the
gas is discharged near the header are located close enough “aft face.
to the fiberS So as to provide columns of relatively large Further, one does not have to cope with the geometry of
bubbles, preferably larger than about 1 mm in nominal 45 a frame, the specific function of which is to hold fibers in a
diameter, which codirectionally contact the fibers and flow particular arrangement within the frame. In a skein, the Sole
Vertically along their outer Surfaces Scrubbing them. The function of the header Spacing means is to maintain a fixed
outer periphery of the columns of bubbles define the Zone of Vertical distance between headers which are not otherwise
confinement in which the scrubbing force exerted by the Spaced apart. In a skein of this invention, there is no frame.
bubbles on the fibers, keeps their surfaces sufficiently free of 50 The skein of this invention is most preferably used to treat
attached microorganisms and deposits of inanimate particles wastewater in combination with a Source of an oxygen
to provide a relatively high and Stable flow of permeate over containing gas which is bubbled within the Substrate, near
many weeks, if not months of operation. The Significance of the base of a lower header, either within a skein or between
this improvement will be better appreciated when it is adjacent Skeins in a bank, for the Specific purpose of
realized that the Surfaces of fibers in conventional modules 55 Scrubbing the fibers and oxygenating the mixed liquor in
are cleaned nearly every day, and Sometimes more often. activated sludge, Such as is generated in the bioremediation
Because this System, like the 424 System, does away with of wastewater. It was found that, as long as enough air is
using a shell, there is no void space within a shell to be introduced near the base of each lower header to keep the
packed with fibers, and, because of gas being introduced fibers awash in bubbles, and the fibers are restrictedly
proximately to, and near the base of Skein fibers, there is no 60 Swayable in the activated Sludge, a build-up of growth of
need to maintain a high Substrate Velocity acroSS the Surface microbes on the Surfaces of the fibers is inhibited while
of the fibers to keep the surfaces of the fibers clean. As a permeate is directly withdrawn from activated Sludge, and
result, there is virtually no limit to the number of restrictedly excellent flow of permeate is maintained over a long period.
Swayable fibers which may be used in a skein, the practical Because essentially all Surface portions of the fibers are
limit being set by (i) the ability to pot the ends of the fibers 65 contacted by Successive bubbles as they rise, whether the air
reliably; (ii) the ability to provide sufficient air to the is Supplied continuously or intermittently, the fibers are Said
surfaces of essentially all the fibers, and (iii) the number of to be “awash in bubbles.
 US 6,685,832 B2
7 8
The use of an array of fibers in the direct treatment of It has also been discovered that permeate may be effi
activated Sludge in a bioreactor, is described in an article ciently withdrawn from a Substrate for a Surprisingly long
titled “Direct Solid-Liquid Separation Using Hollow Fiber period, in a single stage, essentially continuous filtration
Membrane in an Activated Sludge Aeration Tank” by Kazuo process, by mounting a pair of headers in Vertically spaced
Yamamoto et al in Wat. Sci. Tech. Vol. 21, Brighton pp apart relationship, one above another, within the Substrate
43-54, 1989, and discussed in the 424 patent, the disclosure which directly contacts a multiplicity of long vertical fibers
of which is incorporated by reference thereto as if fully set in a "gas-Scrubbed assembly' comprising a Skein and a
forth herein. The relatively poor performance obtained by gas-distribution means. The Skein has a Surface area which
Yamamoto et all was mainly due to the fact that they did not is at least >1 m, and opposed spaced-apart ends of the fibers
realize the critical importance of maintaining flux by aerat are Secured in Spaced-apart headers, So that the fibers, when
ing a skein of fibers from within and beneath the skein. They deployed in the Substrate, acquire a generally vertical profile
did not realize the necessity of thoroughly Scrubbing Sub therewithin and Sway within the bubble Zone defined by at
stantially the entire surfaces of the fibers by flowing bubbles least one column of bubbles. The length of fibers between
through the skein to keep the fibers awash in bubbles. This opposed Surfaces of headers from which they extend, is in a
requirement becomes more pronounced as the number of 15 critical range from at least 0.1% (percent) longer than the
fibers in the Skein increases.
AS will presently be evident, Since most Substrates are distance Separating those opposed faces, but less than 5%
contaminated with micron and Submicron size particulate longer. Usually the length of fiberS is less than 2% longer,
material, both organic and inorganic, the Surfaces of the and most typically, less than 1% longer, So that Sway of the
fibers in any practical membrane device must be maintained fibers is confined within a vertical Zone of movement, the
in a clean condition to obtain a desirable Specific flux. To do periphery of which Zone is defined by Side-to-side move
this, the most preferred use of the Skein as a membrane ment of outer fibers in the Skein, and, the majority of the
device is in a bank, in combination with a gas-distribution fibers near the periphery move in a slightly larger Zone than
means, which is typically used to distribute air, or oxygen one defined by the projected area of one header upon the
enriched air between the fibers, from within the skein, or other. Though the distance between headers is fixed during
25 operation, the distance is preferably adjustable to provide an
between adjacent Skeins, at the bases thereof. optimum length of fibers, within the aforesaid ranges,
Tests using the device of Yamamoto et al indicate that between the headers. It has been found that for no known
when the air is provided outside the Skein the flux decreases reason, fibers which are more than 5% but less than 10%
much faster over a period of as little as 50 hr, confirming the longer than the fixed distance between the opposed faces of
results obtained by them. This is evident in FIG. 1 described the headers of a skein, tend to shear off at the face; and those
in greater detail below, in which the graphs show results 10% longer tend to clump up in the bubble Zone.
obtained by Yamamoto et al, and the 424 array, as well as The terminal end portions of the fibers are secured non
those with the vertical skein, all three assemblies using contiguously in each header, that is, the Surface of each fiber
essentially identical fibers, under essentially identical con is Sealingly Separated from that of another adjacent fiber
ditions.
The investigation of Yamamoto et all with downwardly 35 with cured potting resin. Preferably, for maximum utiliza
Suspended fibers was continued and recent developments tion of Space on a header, the fibers are deliberately Set in a
were reported in an article titled “Organic Stabilization and geometrically regular pattern. Typically permeate is with
Nitrogen Removal in Membrane Separation Bioreactor for drawn from the open ends of fibers which protrude from the
Domestic Wastewater Treatment” by C. Chiemchaisri et al permeate-discharging aft (upper) face of a header. The
delivered in a talk to the Conference on Membrane Tech 40 overall geometry of potted fibers is determined by a fiber
nology in Wastewater Management, in Cape Town, South setting form used to set individual fibers in an array. The
Africa, Mar. 2–5, 1992, also discussed in the 424 patent. Skein operates in a Substrate held in a reservoir at a preSSure
The fibers were suspended downwardly and highly turbulent in the range from 1 atm to an elevated preSSure up to about
flow of water in alternate directions, was essential. 10 atm in a pressurized vessel, without being confined
It is evident that the disclosure in either the Yamamoto et 45 within the shell of a module.
al or the Chiemchaisri et all reference indicated that the flow It is therefore a general object of this invention to provide
of air across the surfaces of the suspended fibers did little or a novel, economical and Surprisingly trouble-free membrane
nothing to inhibit the attachment of microorganisms from device, for providing alternative to both, a conventional
the Substrate. module having plural individual arrays there within, and also
50 to a frameless array of arcuate fibers, the novel device
SUMMARY OF THE INVENTION includes, (i) a vertical skein of a multiplicity of restrictedly
It has been discovered that bubbles of a fiber-cleansing Swayable fibers, together having a Surface area in the range
gas (“scrubbing gas”) flowing parallel to fibers in a vertical from 1 m to 1000 mi, preferably from 10 m to 100 m”,
skein are more effective than bubbles which are intercepted Secured only in spaced-apart headers; and (ii) a gas
by arcuate fibers crossing the path of the rising bubbles. 55 Scrubbing means which produces at least one column of
Bubbles of an oxygen-containing gas to promote growth of bubbles engulfing the Skein. A Skein includes permeate pans
microbes unexpectedly fails to build-up growth of microbes disposed, preferably non-removably, within a Substrate held
on the Surfaces of the fibers because the Surfaces are in a reservoir of arbitrary proportions, the reservoir typically
“vertically air-scrubbed”. Deposits of animate and/or inani having a volume in excess of 100 L (liters), generally in
mate particles upon the Surfaces of fibers are minimized 60 excess of 1000 L A fluid component is to be selectively
when the restrictedly Swayable fibers are kept awash in removed from the Substrate.
codirectionally rising bubbles which rise with sufficient It is a specific object of this invention to provide a
Velocity to exert a physical Scrubbing force (momentum membrane device having hollow fibers for removing per
provides the energy) to keep the fibers Substantially free of meate from a Substrate, comprising, a skein of a multiplicity
deleterious deposits. Thus, an unexpectedly high flux is 65 of fibers restrictedly Swayable in the Substrate, the opposed
maintained over a long period during which permeate is terminal end portions of which fibers in Spaced-apart
produced by outside-in flow through the fibers. relationship, are potted in a pair of headers, one upper and
 US 6,685,832 B2
9 10
one lower, each adapted to be mounted in Vertically spaced ate, means for withdrawing the permeate; and, Sufficient air
apart generally parallel relationship, one above the other, is flowed through the Shaped gas-distribution means to
within the substrate; essentially all the ends of fibers in both generate enough bubbles flowing upwardly through the
headers are open So as to pass permeate through the headers, Skein, between and parallel to the fiberS So as to keep the
the fibers in a skein have a length in the range from at least surfaces of the fibers substantially free from deposits of live
0.1% greater, but less than 5% greater than the direct microorganisms as well as Small inanimate particles which
distance between opposed faces of the upper and lower may be present in the Substrate.
headers, So as to present the fibers, when they are deployed, It has still further been discovered that a system utilizing
in an essentially vertical configuration; permeate is collected a bank of vertical skeins of fibers potted in headers vertically
in a collection means, Such as a permeate pan; and, permeate Spaced-apart by Spacer means, and deployed in a Substrate
is withdrawn through a ducting means including one or more containing particulate material, in combination with a proxi
conduits and appropriate valves. mately disposed gas-distribution means to minimize fouling
It has also been discovered that Skein fibers are main of the membranes, may be operated to withdraw permeate
tained Sufficiently free from particulate deposits with Sur under gravity alone, So that the cost of any pump to
prisingly little cleansing gas, So that the Specific flux at 15 withdraw permeate is avoided, provided the net positive
equilibrium is maintained over a long period, typically from Suction head corresponding to the vertical height between
50 hr to 1500 hr, because the skein is immersed so as to the level of Substrate, and the location of withdrawal of
present a generally vertical profile, and, the Skein is main permeate, provides the transmembrane pressure differential
tained awash in bubbles either continuously or intermittently under which the fibers function in the skein.
generated by a gas-distribution means ("air-manifold'). The It is therefore a general object of this invention to provide
air-manifold is disposed adjacent the Skein's lower header to the foregoing System in which opposed terminal end por
generate a column of rising bubbles within which column tions of skein fibers are essentially free from fiber-to-fiber
the fibers are awash in bubbles. A bank of skeins is “gas contact after being potted in upper and lower headers kept
scrubbed” with plural air-tubes disposed between the lower Vertically Spaced-apart with Spacer means, the Skein being
headers of adjacent Skeins, most preferably, also adjacent the 25 unconfined in a shell of a module and deployed in the
outermost array of the first and last skeins, so that for “n” Substrate without the fibers being Supported during operation
headers there are “n+1 air-manifolds. Each header is pref except by the Spacer means which Support only the headers,
erably in the shape of a rectangular parallelpiped, the upper the headers being mounted So that the fibers present a
and lower headers having the same transverse (y-axis) generally vertical profile yet are restrictedly Swayable in a
dimension, So that plural headers are longitudinally Stack Zone of confinement defined by rising bubbles, means for
able (along the X-axis). Common longitudinally positioned mounting each header in open fluid communication with
linear air-tubes, or, individual, longitudinally spaced apart collection means for collecting permeate, and, means for
vertically rising air-tubes, Service the bank and one or more withdrawing the permeate; and, shaped gas-distribution
permeate tubes withdraw permeate. means adapted to generate bubbles from micron-size to 25
It is therefore a general object of this invention to provide 35 mm in nominal diameter, most preferably in the size range
a gas-scrubbed assembly of fibers for liquid filtration, the from 1 mm to 20 mm, the bubbles flowing upwardly through
assembly comprising, (a) bank of gas-Scrubbed Skeins of and parallel to the fibers at a flow rate chosen from the range
fibers which Separate a desired permeate from a large body specified hereabove; whereby the fibers are scrubbed with
of multicomponent Substrate having finely divided particu bubbles and resist the attachment of growing microorgan
late matter in the range from 0.1 um-44 um dispersed 40 isms and any other particulate matter to the Surfaces of the
therein, (b) each skein comprising at least 20 fibers having fibers, So as to maintain a desirable specific flux during
upper and lower terminal portions potted Spaced-apart, in operation.
upper and lower headers, respectively, the fibers being Still further, a low cost process has been discovered for
restrictedly Swayable in a bubble Zone, and (c) a shaped treating a multi-component Substrate under pressure ranging
gas-distribution means adapted to provide a profusion of 45 from 1-10 atm in a preSSurizable vessel, particularly for
Vertically ascending bubbles near the lower header, the example, an aqueous Stream containing finely divided inor
length of the fibers being from at least 0.1% but less than 5% ganic matter Such as Silica, Silicic acid, or, activated Sludge,
greater than the distance between the opposed faces of the when the Substrate is confined in a large tank or pond, by
headers. The gas-distribution means has through-passages using a bank of Vertical Skeins each comprising restrictedly
therein through which gas is flowed at a flow rate which is 50 Swayable unsupported fiberSpotted in headers in open fluid
proportional to the number of fibers. The flow rate is communication with a means for withdrawing permeate, in
generally in the range from 0.47-14 cm/sec per fiber combination with a Source of air which generates bubbles
(0.001-0.03 scfm/fiber) (standard ft per minute per fiber), near the lower header.
typically in the range from 1.4-4.2 cm/sec/fiber It is therefore a general object of this invention to provide
(0.003–0.009 scfm/fiber). The surface area of the amount of 55 a process for maintaining relatively clean fiber Surfaces in an
air used because the air travels Substantially vertically along array of a membrane device while Separating a permeate
the length of each fiber. The gas generates bubbles having an from a Substrate, the proceSS comprising, Submerging a
average diameter in the range from about 0.1 mm to about skein of restrictedly Swayable substantially vertical fibers
25 mm, or even larger. within the substrate so that upper and lower headers of the
It is a specific object of this invention to provide the 60 Skein are mounted one above the other with a multiplicity of
aforesaid novel gas-Scrubbed assembly comprising, a bank fibers secured between said headers, the fibers having their
of Vertical Skeins and a shaped gas-distribution means for opposed terminal portions in open fluid communication with
use with the bank, in a Substrate in which microorganisms permeate collecting means in fluid-tight connection with
grow, the assembly being used in combination with verti Said headers; the fiberS operating under a transmembrane
cally adjustable Spacer means for mounting the headers in 65 pressure differential in the range from about 0.7 kPa (0.1 psi)
Vertically Spaced apart relationship, and in open fluid com to about 345 kPa (50 psi), and a length from at least 0.1%
munication with collection means for collecting the perme to about 2% greater than the direct distance between the
 US 6,685,832 B2
11 12
opposed faces of upper and lower headers, So as to present, unsupported during operation of the device, with the ends of
when the fibers are deployed, a generally vertical Skein of the fibers potted in a lower header, along with a permeate
fibers, maintaining an essentially constant flux Substantially collection pan, and a permeate withdrawal conduit. By
the same as the equilibrium flux initially obtained, indicating "unsupported” is meant not Supported except for Spacer
that the surfaces of the fibers are substantially free from means to Space the headers.
further build-up of deposits once the equilibrium flux is FIG. 2A is an enlarged detail side elevational view of a
attained; collecting the permeate; and, withdrawing the Side wall of a collection pan showing the profile of a
permeate. header-retaining Step atop the periphery of the pan.
It has still further been discovered that the foregoing FIG. 2B is a bottom plan view of the header showing a
proceSS may be used in the operation of an anaerobic or random pattern of open ends protruding from the aft face of
aerobic biological reactor which has been retrofitted with the a header when fibers are potted after they are Stacked in rows
membrane device of this invention. The anaerobic reactor is
a closed vessel and the Scrubbing gas is a molecular oxygen and glued together before being potted.
free gas, Such as nitrogen. FIG. 3 is a perspective view of a Single array, Schemati
It is therefore a general object of this invention to provide 15 cally illustrated, of a row of Substantially coplanarly dis
an aerobic biological reactor retrofitted with at least one posed parallel fiberS Secured near their opposed terminal
gas-Scrubbed bank of Vertical skeins, each Skein made with ends between Spaced apart cards. Typically, multiple arrayS
from 500 to 5000 fibers in the range from 1 m to 3 m long, are assembled before being Sequentially potted.
in combination with a permeate collection means, and to FIG. 4 illustrates a side elevational view of a stack of
provide a process for the reactor's operation without being arrays near one end where it is together, showing that the
encumbered by the numerous restrictions and limitations individual fibers (only the last fiber of each linear array is
imposed by a Secondary clarification System. Visible, the remaining fibers in the array being directly
A novel composite header is provided for a bundle of behind the last fiber) of each array are separated by the
hollow fiber membranes or “fibers”, the composite header thickness of a Strip with adhesive on it, as the Stack is held
comprising a molded, laminated body of arbitrary shape, 25 Vertically in potting liquid.
having an upper lamina formed from a "fixing” (potting) FIG. 5 is a perspective view Schematically illustrating a
material which is laminated to a lower lamina formed from Skein with its integral finished header, its permeate collec
a “fugitive' potting material. The terminal portions of the tion pan, and twin air-tubes feeding an integral air distribu
fibers are potted in the fugitive potting material when it is tion manifold potted in the header along an outer edge of the
liquid, preferably forming a generally rectangular paral skein fibers.
lelpiped in which the open ends of the fibers (until potted) FIG. 6 is a side elevational view of an integral finished
are embedded and plugged, keeping the fibers in closely header Showing details of a permeate pan Submerged in
Spaced-apart Substantially parallel relationship. The plugged Substrate, the walls of the header resting on the bottom of a
ends of the fibers fail to protrude through the lower (aft) face reservoir, and multiple air-tubes feeding integral air distri
of the lower lamina, while the remaining lengths of the fibers 35 bution manifolds potted in the header along each outer edge
extend through the upper face of the lower lamina. The of the skein fibers.
upper lamina extends for a height along the length of the FIG. 7A is a perspective view schematically illustrating
fiberS Sufficient to maintain the fibers in the same Spaced an air-manifold from which vertical air-tubes rise.
apart relationship relative to one and another as their spaced FIG. 7B is a perspective view schematically illustrating a
apart relationship in the lower portion. If desired, the com 40
tubular air-manifold having a transverse perforated portion,
posite header may include additional laminae, for example, positioned by opposed terminal portions.
a “cushioning lamina overlying the fixing lamina, to cush FIG. 8 is a perspective view of an integral finished header
ion each fiber around its embedded outer circumference; having plural Skeins potted in a common header molded in
and, a “gasketing lamina to provide a Suitable gasketing an integral permeate collection means with air-tubeS rising
material against which the permeate collection means may 45
Vertically through the header between adjacent Skeins, and
be mounted.
along the Outer peripheries of the Outer Skeins.
BRIEF DESCRIPTION OF THE DRAWINGS FIG. 9 is a detail, not to Scale, illustratively showing a gas
The foregoing and additional objects and advantages of distribution means discharging gas between arrays in a
the invention will best be understood by reference to the 50 header, and optionally along the Sides of the lower header.
following detailed description, accompanied by Schematic FIG. 10 is a perspective view schematically illustrating a
illustrations of preferred embodiments of the invention, in pair of Skeins in a bank in which the upper headers are
which illustrations like reference numerals refer to like mounted by their ends on the vertical wall of a tank. The
elements, and in which: Skeins in combination with a gas-distribution means form a
FIG. 1 is a graph in which the variation of flux is plotted 55 "gas-Scrubbing assembly deployed within a Substrate, with
as a function of time, showing three curves for three runs the fiberS Suspended essentially vertically in the Substrate.
made with three different arrays, in each case, using the Positioning the gas-distribution means between the lower
Same amount of air, the identical membranes and the same headers (and optionally, on the outside of skein fibers)
membrane surface area. The results obtained by Yamamoto generate masses (or “columns”) of bubbles which rise
et al are plotted as curve 2 (under conditions modified to 60 vertically, codirectionally with the fibers, yet the bubbles
give them the benefit of doubt as to the experimental Scrub the outer Surfaces of the fibers.
procedure employed, as explained below); the flux obtained FIG. 11 is a perspective view of another embodiment of
using the gas-Scrubbed assembly of the 424 patent is shown the Scrubbing-assembly showing plural skeins (only a pair is
as curve 1; and the flux obtained using the gas-Scrubbed shown) connected in a bank with gas-distribution means
assembly of this invention is shown as curve 3. 65 disposed between Successive skeins, and, optically, with
FIG. 2 is a perspective exploded view Schematically additional gas-distribution means fore and aft the first and
illustrating a membrane device comprising a skein of fibers, last Skeins, respectively.
 US 6,685,832 B2
13 14
FIG. 12 is an elevational view schematically illustrating a poly(ethylene terephthalate), and the like disclosed in U.S.
bank of Skeins mounted against the wall of a bioreactor, Pat. No. 4,230,463 the disclosure of which is incorporated
showing the convenience of having all piping connections by reference thereto as if fully set forth herein. Preferred
outside the liquid. ceramic fibers are made from alumina, by E. I. duPont
FIG. 13 is a plan view of the bioreactor shown in FIG. 12 deNemours Co. and disclosed in U.S. Pat. No. 4,069,157.
showing how multiple banks of Skeins may be positioned Typically, there is no croSS flow of Substrate across the
around the circumference of the bioreactor to form a large surface of the fibers in a “dead end” tank. If there is any flow
permeate extraction Zone while a clarification Zone is of Substrate through the Skein in a dead end tank, the flow
formed in the central portion with the help of baffles. is due to aeration provided beneath the Skein, or to Such
FIG. 14 illustratively shows another embodiment of the mechanical mixing as may be employed to maintain the
Skein in which the permeate tube is concentrically disposed Solids in Suspension. There is more flow through the Skein in
within the air Supply tube and both are potted, near their a tank into which Substrate is being continuously flowed, but
lower ends in the lower header. Ports in the lower end of the the velocity of fluid across the fibers is generally too
air Supply tube provide air near the base of the Skein fibres. insignificant to deter growing microorganisms from attach
15 ing themselves, or Suspended particles, e.g. microscopic
DETAILED DESCRIPTION OF PREFERRED Siliceous particles, from being deposited on the Surfaces of
EMBODIMENTS the fibers.
The Skein of this invention may be used in a liquid-liquid For hollow fiber membranes, the outside diameter of a
Separation process of choice, and more generally, in various fiber is at least 20 um and may be as large as about 3 mm,
Separation processes. The Skein is specifically adapted for typically being in the range from about 0.1 mm to 2 mm. The
use in microfiltration processes used to remove large organic larger the outside diameter the leSS desirable the ratio of
molecules, emulsified organic liquids and colloidal or SuS surface area per unit volume of fiber. The wall thickness of
pended Solids, usually from water. Typical applications are a fiber is at least 5 um and may be as much as 1.2 mm,
(i) in a membrane bioreactor, to produce permeate as puri 25
typically being in the range from about 15% to about 60%
fied water and recycle biomass; for (ii) tertiary filtration of of the outside diameter of the fiber, most preferably from 0.5
wastewater to remove Suspended Solids and pathogenic mm to 1.2 mm.
bacteria; (iii) clarification of aqueous streams including AS in a 424 array, but unlike in a conventional module,
filtration of Surface water to produce drinking water the length of a fiber in a skein is essentially independent of
(removal of colloids, long chain carboxylic acids and the Strength of the fiber, or its diameter, because the Skein is
pathogens); (iv) separation of a permeable liquid component buoyed both by bubbles and the substrate in which it is
in biotechnology broths, (v) de-watering of metal hydroxide deployed. The length of fibers in the skein is preferably
Sludges; and, (vi) filtration of oily wastewater, inter alia. determined by the conditions under which the skein is to
The problem with using a conventional membrane mod operate. Typically fibers range from 1 m to about 5 m long,
ule to Selectively Separate one fluid from another, particu 35 depending upon the dimensions of the body of Substrate
larly using the module in combination with a bioreactor, and (depth and width) in which the skein is deployed.
the attendant costs of operating Such a System, have been The fixing material to fix the fibers in a finished header is
avoided. In those instances where an under-developed coun most preferably either a thermosetting or thermoplastic
try or distressed community lacks the resources to provide Synthetic resinous material, optionally reinforced with glass
membrane modules, the most preferred embodiment of this 40 fibers, boron or graphite fibers and the like. Thermoplastic
invention is adapted for use without any pumps. In those materials may be crystalline, Such as polyolefins, polya
instances where a pump is conveniently used, a vacuum mides (nylon), polycarbonates and the like, Semi-crystalline
pump is unnecessary, adequate driving force being provided such as polyetherether ketone (PEEK), or substantially
by a simple centrifugal pump incapable of inducing a amorphous, such as poly(vinyl chloride) (PVC), polyure
vacuum of 75 cm Hg on the Suction side. 45 thane and the like. Thermosetting resins commonly include
The fibers used to form the skein may be formed of any polyesters, polyacetals, polyethers, cast acrylates, thermo
conventional membrane material provided the fibers are Setting polyurethanes and epoxy resins. Most preferred as a
flexible and have an average pore croSS Sectional diameter “fixing material (so termed because it fixes the locations of
for microfilitration, namely in the range from about 1000 A the fibers relative to each other) is one which when cured is
to 10000 A. Preferred fibers operate with a transmembrane 50 Substantially rigid in a thickness of about 2 cm, and referred
pressure differential in the range from 7 kPa (1 psi)–69 kPa to generically as a "plastic' because of its hardness. Such a
(10 psi) and are used under ambient pressure with the plastic has a hardness in the range from about Shore D 50 to
permeate withdrawn under gravity. The fibers are chosen Rockwell R 110 and is selected from the group consisting of
with a view to perform their desired function, and the epoxy resins, phenolics, acrylics, polycarbonate, nylon,
dimensions of the Skein are determined by the geometry of 55 polystyrene, polypropylene and ultra-high molecular weight
the headers and length of the fibers. It is unnecessary to polyethylene (UHMWPE). Polyurethane such as is com
confine a skein in a modular shell, and a skein is not. mercially available under the brand names Adiprene(R) from
Preferred fibers are made of organic polymers and Uniroyal Chemical Company and Airthane(R) from Air
ceramics, whether isotropic, or anisotropic, with a thin layer Products, and commercially available epoxy resins Such as
or “skin' on the outside Surface of the fibers. Some fibers 60 Epon 828 are excellent fixing materials.
may be made from braided cotton covered with a porous The number of fibers in an array is arbitrary, typically
natural rubber lateX or a water-insoluble cellulosic poly being in the range from about 1000 to about 10000 for
meric material. Preferred organic polymers for fibers are commercial applications, and the preferred Surface area for
polysulfones, poly(styrenes), including styrene-containing a skein is in the range from 10 m to 100 m.
copolymerS Such as acrylonitrile-styrene, butadiene-Styrene 65 The particular method of securing the fibers in each of the
and Styrene-Vinylbenzylhalide copolymers, polycarbonates, headers is not narrowly critical, the choice depending upon
cellulosic polymers, polypropylene, poly(Vinyl chloride), the materials of the header and the fiber, and the cost of using
 US 6,685,832 B2
15 16
a method other than potting. However, it is essential that high-speed diamond blade, tends to damage the fibers and
each of the fibers be secured in fluid-tight relationship within initiate the collapse of the circumferential wall. In another
each header to avoid contamination of permeate. This is conventional method of potting fibers, described in U.S. Pat.
effected by potting the fibers essentially vertically, in No. 5,202,023, bundled fibers have their ends dipped in resin
closely-spaced relationship, either linearly in plural equally or paint to prevent potting resin penetration into the bores of
Spaced apart rows across the face of a header in the X-y the fibers during the potting process. The ends of the bundle
plane, or alternatively, randomly, in non-linear plural rows. are then placed in molds and uncured resin added to Saturate
In the latter, the fibers are displaced relative to one another the ends of the fiber bundle and fill the spaces between the
in the lateral direction. individual fibers in the bundle and the flexible tubing in
FIG. 1 presents the results of a comparison of three runs which the bundle is held. The cured molded ends are
made, one using the teachings of Yamamoto in his 89 removed from the molds and the molded ends cut off (see,
publication (curve 2), but using an aerator which introduced bridging cols 11 and 12). In each art method, Sectioning the
air from the Side and directed it radially inwards, as is shown mold damages the embedded fibers.
in Chiemchaisri et al. A second run (curve 1) uses the Therefore a novel method is used to form a header 11 in
gas-Scrubbed assembly of the 424 patent, and the third run 15 the form of a rectangular prism. The method requires
(curve 3) uses the gas-scrubbed skein of this invention. The forming a composite header with two liquids. A first liquid
specific flux obtained with an assembly of an inverted fugitive material, when Solidified (cured), forms a “fugitive
parabolic array with an air distributor means (Yamamoto et lamina” of the composite header; a Second liquid of non
al), as disclosed in Wat. Sci. Tech. Vol. 21, Brighton pp fugitive fixing material forms a "fixing lamina'. By a
43-54, 1989, and, the parabolic array by Cote et al in the “fugitive material” we refer to a material which is either (i)
424 patent, are compared to the Specific flux obtained with soluble in a medium in which the fibers and fixing material
the vertical skein of this invention. are not soluble, or (ii) fluidizable by virtue of having a
The comparison is for the three assemblies having fibers melting point (if the material is crystalline) below that which
with nominal pore size 0.2 um with essentially identical might damage the fibers or fixing material; or, the material
bores and Surface area in 80 L tanks filled with the same 25 has a glass transition temperature Tg (if the material is
activated sludge Substrate. The differences between the non-crystalline), below that which might damage the fibers
stated experiment of Yamamoto et al, and that of the 424 or material(s) forming the non-fugitive header; or (iii) both
patent are of record in the 424 patent, and the conditions of Soluble and fluidizable.
the comparison are incorporated by reference thereto as if The first liquid is poured around terminal portions of
fully set forth herein. The vertical skein used herein differs fibers, allowed to cool and Solidify into a fugitive lamina; the
from the 424 skein only in the vertical configuration of the fibers in the fugitive lamina are then again potted, this time
280 fibers each of which was about 1% longer than the by pouring the Second liquid over the Solid fugitive lamina.
distance between the spaced apart headers during operation. In greater detail, the method for forming a finished header
The flow rate of air for the vertical skein is 1.4 m/hr/m 35
for Skein fibers comprises,
using a coarse bubble diffuser. forming a Stack of at least two Superimposed essentially
It will be evident from FIG. 1 in which the specific flux, coplanar and Similar arrays, each array comprising a
liters/meter hr/kPa (conventionally written as (lmh/kPa), is chosen number of fiberS Supported on a Support means
plotted as a function of operating time for the three having a thickness corresponding to a desired lateral
assemblies, that the curve, identified as reference numeral 3 40 spacing between adjacent arrays,
for the flux for the vertical skein, provides about the same holding the Stack in a first liquid with terminal portions of
Specific flux as the parabolic skein, identified as reference the fiberS Submerged, until the liquid Solidifies into a
numeral 1. AS can be seen, each specific flux reaches an first shaped lamina, provided that the first liquid is
equilibrium condition within less than 50 hr, but after about unreactive with material of the fibers;
250 hr, it is seen that the specific flux for the inverted 45 pouring a Second liquid over the first shaped lamina to
parabolic array keeps declining but the other two assemblies embed the fibers to a desired depth, and solidifying the
reach an equilibrium. Second liquid to form a fixing lamina upon the first
Referring to FIG. 2 there is illustrated, in exploded view shaped lamina, the Second liquid also being Substan
a portion of a membrane device referred to as a “vertical tially unreactive with either the material of the fibers or
Skein’ 10, comprising a lower header 11 of a pair of headers, 50 that of the first shaped lamia;
the other upper header (not shown) being Substantially whereby a composite header is formed in which terminal
identical; a collection pan 20 to collect the permeate; and, a portions of the fibers are potted, preferably in a geo
permeate withdrawal conduit 30. The header shown is a metrically regular pattern, the composite header com
rectangular prism Since this is the most convenient shape to prising a laminate of a fugitive lamina of fugitive
make, if one is going to pot fiberS 12 in a potting resin Such 55 material and a contiguous finished header of fixing
as a polyurethane or an epoxy. Though the fiberS 12 are not lamina; and thereafter,
shown as close together as they would normally be, it is removing the first shaped lamina without removing a
essential that the fibers are not in contact with each other but portion of the fixing lamina So as to leave the ends of
that they be spaced apart by the cured resin between them. the fibers open and protruding from the aft face of the
As illustrated, the open ends of the terminal portion 12" of 60 header, the open ends having circular cross-section.
the fibers are in the same plane as the lower face of the The step-wise procedure for forming an array “A” with
header 11 because the fibers are conventionally potted and the novel header is described with respect to an array
the header Sectioned to expose the open ends. A specific illustrated in FIG. 3, as follows:
potting procedure in which the trough of a U-shaped bundle A desired number of fibers 12 are each cut to about the
of fibers is potted, results in forming two headers. This 65 Same length with a sharp blade So as to leave both opposed
procedure is described in the 424 patent (col 17, lines ends of each fiber with an essentially circular cross-section.
44-61); however, even cutting the potted fibers with a thin, The fibers are coplanarly disposed Side-by-side in a linear
 US 6,685,832 B2
17 18
array on a planar Support means Such as Strips or cards 15 ensure that both the intermediate portions 12" on the strips
and 16. Preferably the Strips are coated with an adhesive, e.g. and terminal portions 12" will be held spaced apart when
a commercially available polyethylene hot-melt adhesive, So the first liquid solidifies and plugs all the fibers.
that the fibers are glued to the Strips and opposed terminal (2) The Second liquid, a curable, water-insoluble liquid
portions 12" respectively of the fibers, extend beyond the 5 potting resin, or reactive components thereof, is poured
strips. Intermediate portions 12" of the fibers are thus secured over the Surface of the fugitive lamina to Surround the
on the Strips. Alternatively, the Strips may be grooved with fibers, until the second liquid rises to a level L2. It is
parallel Spaced-apart grooves which Snugly accommodate solidified to form the fixing lamina (which will be the
the fibers. The strips may be flexible or rigid. If flexible, finished header) having a thickness measured from the
Strips with fibers adhered thereto, are in turn, also adhered to level L1 to the level L2 (the thickness is written
each other Successively So as to form a progressively Stiffer “L1-L2”). The thickness L1-L2 of the fixing lamina,
Stack for a header having a desired geometry of potted fibers. typically from about 1 cm to about 5 cm, is sufficient to
To avoid gluing the Strips, a regular pattern of linear rows maintain the relative positions of the vertical fibers. A first
may be obtained by Securing multiple arrays on rigid Strips composite header is thus formed having the combined
in a Stack, with rubber bands 18 or other clamping means. 15 thicknesses of the fugitive and fixing laminae.
The terminal portions 12" are thus held in Spaced-apart (3) In a manner analogous to that described immediately
relationship, with the center to center distance of adjacent hereinabove, a Stack is potted in a Second composite
fibers preferably in the range from 1.2 (1.2d) to about 5 header.
times (5d) the outside diameter “d of a fiber. Spacing the (4) The composite headers are demolded from their potting
fibers further apart wastes Space and Spacing them closer pans and hot air blown over them to melt the fugitive
increases the risk of fiber-to-fiber contact near the terminal laminae, leaving only the finished headers, each having a
end portions when the ends are potted. Preferred center-to thickness L1-L2. The fugitive material such as the PEG
center Spacing is from about 1.5d to 2d. The thickness of a wax, is then reused. Alternatively, a water-Soluble fugitive
Strip and/or adhesive is Sufficient to ensure that the fibers are material may be placed in hot water to dissolve the wax,
kept Spaced apart. Preferably, the thickness is about the same 25 and the material recovered from its water Solution.
as, or relatively Smaller than the outside diameter of a fiber, (5) The adhered strips and terminal portions of the fibers
preferably from about 0.5d to 1d thick, which becomes the which were embedded within the fugitive lamina are left
spacing between adjacent outside Surfaces of fibers in Suc protruding from the permeate-discharging aft faces of the
cessive linear arrayS. headers with the ends of the fibers being not only open,
Having formed a first array, a Second array (not shown but essentially circular in croSS Section. The fibers may
because it would appear essentially identical to the first) is now be cut above the strips to discard them and the
prepared in a manner analogous to the first, Strip 15 of the terminal portions of the fibers adhered to them, yet
Second array is overlaid upon the intermediate portions 12 maintaining the circular open ends. The packing density
on strip 15 of the first array, the strip 15 of the second array of fibers, that is, the number of fibers per unit area of
resting on the upper Surfaces of the fiberS Secured in Strip 15 35 header preferably ranges from 4 to 50 fibers/cm depend
of the first array. Similarly, strip 16 of the second array is ing upon the diameters of the fibers.
overlaid upon the intermediate portions 12" on strip 16 of the B. Illustrated Second is the potting of Skein fibers in upper
first array. and lower headers from which the strips will not be
A third array (essentially identical to the first and Second) removed, to avoid the Step of cutting the fibers.
is prepared in a manner analogous to the first, and then 40 (1) The first liquid is poured to a level L1' below the cards,
overlaid upon the Second, with the Strips of the third array to a depth in the range from about 1-2.5 cm, and
resting on the upper Surfaces of the fibers of the Second Solidified, forming fugitive lamina L1'.
array. (2) The Second liquid is then poured over the fugitive lamina
Additional arrays are overlaid until the desired number of to depth L2 and Solidified, forming a composite header
arrays are Stacked in rows forming a Stack of arrays with the 45 with a fixing lamina having a thickness L1-L2.
adhesive-coated Strips forming the Spacing means between (3) The composite header is demolded and the fugitive
Successive rows of fibers. The Stack of arrays on Strips is lamina removed, leaving the terminal portions 12" pro
then held vertically to present the lower portion of the stack truding from the aft face of the finished header, which aft
to be potted first. face is formed at what had been the level L1'. The finished
Referring to FIG. 4, there is schematically illustrated a 50 header having a thickness L1-L2 embeds the strips 15
rectangular potting pan 17 the length and width dimensions (along with the rubber bands 18, if used).
of which correspond Substantially to the longitudinal C. Illustrated third is the potting of skein fibers to form a
(X-axis) and transverse (y-axis) dimensions respectively, of finished headers with a cushioning lamina embedding the
the desired header. The lower Stack is Submerged in a first fibers on the opposed (fore) faces of the headers from which
liquid which rises to a level indicated by L1, in the pan 17. 55 the strips will be removed.
Most preferred is a liquid wax, preferably a water-soluble The restricted Swayability of the fibers generates some
wax having a melting point lower than 75 C., Such as a intermittent Snapping motion of the fibers. This motion has
polyethylene glycol (PEG) wax. been found to break the potted fibers around their
The depth to which the first liquid is poured will depend circumferences, at the interface of the fore face and Sub
upon whether the strips 15 are to be removed from, or left 60 strate. The hardness of the fixing material which forms a
in the finished header. "fixing lamina” was found to initiate excessive shearing
A. First illustrated is the potting of Skein fibers in upper and forces at the circumference of the fiber. The deleterious
lower headers from which the strips will be removed. effects of Such forces is minimized by providing a cushion
(1) A first shaped lamina having a thickness L1 ing lamina of material Softer than the fixing lamina. Such a
(corresponding to the depth to which the first liquid was 65 cushioning lamina is formed integrally with the fixing
poured) is formed to provide a fugitive lamina from about lamina, by pouring cushioning liquid (So termed for its
5-10 cm thick. The depth of the first liquid is sufficient to function when cured) over the fixing lamina to a depth L3 as
 US 6,685,832 B2
19 20
shown in FIG. 4, which depth is sufficient to provide enough and the ends 104 and 105 protrude from through-passages in
give around the circumferences of the fibers to minimize the vertical walls on either Side of the permeate pan.
the risk of Shearing. Such cushioning liquid, when cured is Permeate withdrawal nipple 106 (FIG. 6) is first temporarily
rubbery, having a hardneSS in the range from about Shore A plugged. The Stack of StripS 15 is positioned between
30 to Shore D 45, and is preferably a polyurethane or 5 air-tubes 103, vertically in the pan 120 which is filled to
silicone or other rubbery material which will adhere to the level L1 to form a fugitive lamina, the level being just
fixing lamina. Upon removal of the fugitive lamina, the beneath the lower edges of the strips 15 which will not be
finished header thus formed has the combined thicknesses of removed. When solidified, the fugitive lamina embeds the
the fixing lamina and the cushioning lamina, namely L1-L3 terminal portions of the fibers 12 and also fills permeate tube
when the strips 15 are cut away. 106. Then the second liquid is poured over the upper surface
D. Illustrated fourth is the formation a finished header with of the fugitive lamina until the liquid covers the strips 15 but
a gasketing lamina embedding the fibers on the headers aft leaves the upper ends of the air-tubes 103 open. The second
face, and a cushioning lama embedding the fibers on the liquid is then cured to form the fixing lamina of the com
header's fore face; the Strips are to be removed. posite header which is then heated to remove the fugitive
Whichever finished header is made, it is preferably fitted 15 material through the permeate nozzle 106 after it is
into a permeate pan 20 as illustrated in FIG. 2 with a unplugged.
peripheral gasket. It has been found that it is easier to Seal FIG. 7A schematically shows in perspective view, an
the pan against a gasketing lamina, than against a peripheral air-manifold 107 having vertical air-tubes 103 rising from a
narrow gasket. A relatively Soft gasketing material having a transverse header-tube which has longitudinally projecting
hardness in the range from Shore A 40 to Shore D 45, is feeder air-tubes 104 and 105. The bore of the air-tubes which
desirable to form a gasketing lamina integrally with the aft may be either “fine bubble diffusers”, or “coarse bubble
face of the finished header. In the embodiment in which the diffusers”, or “aerators', is chosen to provide bubbles of the
Strips are cut away, the fugitive lamina is formed as before, desired diameter under operating conditions, the bore typi
and a gasketing liquid (So termed because it forms the gasket cally being in the range from 0.1 mm to 5 mm. Bubbles of
when cured) is poured over the Surface of the fugitive lamina 25 Smaller diameter are preferably provided with a perforated
to a depth L4. The gasketing liquid is then cured. Upon transverse tube 103' of an air-manifold 107" having feeder
removal of the fugitive lamina, when the strips 15 are cut air-tubes 104" and 105", illustrated in FIG. 7B. In each case,
away, the finished header thus formed has the combined the bubbles function as a mechanical brush.
thicknesses of the gasketing lamina (L1-L4), the fixing The skein fibers for the upper header of the skein are
lamina (LA-L2) and the cushioning lamina (L2-L3), namely potted in a manner analogous to that described above in a
an overall L1-L3. Similar permeate pan to form a finished header, except that
In another embodiment, to avoid Securing the pan to the no air manifolds are inserted.
header With a gasketing means, and, to avoid positioning one Referring to FIG. 8 there is Schematically illustrated, in a
or more gas-distribution manifolds in an optimum location croSS-Sectional perspective view, an embodiment in which a
near the base of the Skein fibers after a skein is made, the 35 bank of two skeins is potted in a Single integral finished
manifolds are formed integrally with a header. Referring to header enclosure, referred to generally by reference numeral
FIG. 5 there is illustrated in perspective view an “integral 120b. The term "header enclosure' is used because its side
single skein” referred to generally by reference numeral 100. walls 121 and 122, and end walls (not shown) enclose a
The integral Single Skein is So termed because it includes an plenum in which air is introduced. Instead of a permeate pan,
integral finished header 101 and permeate pan 102. The pan 40 permeate is collected from a permeate manifold which
102 is provided with a permeate withdrawal nipple 106, and Serves both Skeins. Another similar upper enclosure 120u
fitted with vertical air-tubes 103 which are to be embedded (not shown), except that it is a flat-bottomed channel-shaped
in the finished header. The air-tubes are preferably mani pan (inverted for use as the upper header) with no air-tubes
folded on either side of the skein fibers, to feeder air-tubes molded in it, has the opposed terminal portions of all the
104 and 105 which are snugly inserted through grommets in 45 skein fibers potted in the pan. For operation, both the lower
the walls of the pan. The permeate nipple 106 is then and upper enclosures 120b and 120u, with their skein fibers
plugged, and a Stack of arrays is held vertically in the pan in are lowered into a reservoir of the Substrate to be filtered.
which a fugitive lamina is formed embedding both the ends The side walls 121 and 122 need not rest on the bottom of
of the fibers and the lower portion of the vertical air-tubes the reservoir, but may be mounted on a side wall of the
103. A fixing lamina is then formed over the fugitive lamina, 50 reservoir.
embedding the fibers to form a fixing lamina through which The side walls 121 and 122 and end walls are part of an
protrude the open ends of the air-tubes 103. The fugitive integrally molded assembly having a platform 123 connect
lamina is then melted and withdrawn through the nipple 106. ing the walls, and there are aligned multiple risers 124
In operation, permeate collects in the permeate pan and is molded into the platform. The risers resemble an inverted
withdrawn through nipple 106. 55 test-tube, the diameter of which need only be large enough
FIG. 6 illustrates a croSS-Section of an integral Single to have an air-tube 127 inserted through the top 125 of the
skein 110 with another integral finished header 101 having inverted test-tube. As illustrated, it is preferred to have
a thickneSS L1-L2, but without a cushioning lamina, formed “n+1 rows of air-tubes for “n” stacks of arrays to be potted.
in a procedure Similar to that described hereinabove. A Crenelated platform 123 includes risers 124 between which
permeate pan 120 with outwardly flared sides 120' and 60 lie channels 128 and 129. Channels 128 and 129 are each
transversely spaced-apart through-apertures therein, is pre wide enough to accept a Stack of arrays of fibers 12, and the
fabricated between side walls 111 and 112 so the pan is risers are wide enough to have air-tubes 127 of sufficient
spaced above the bottom of the reservoir. length inserted therethrough So that the upper open ends 133
A pair of air-manifolds 107 Such as shown in FIG. 7A or of the air-tubes protrude from the upper Surface of the fixing
7B, is positioned and held in mirror-image relationship with 65 material 101. The lower ends 134 of the air-tubes are
each other adjacent the permeate pan 120, with the vertical Sectioned at an angle to minimize plugging, and positioned
air-tubes 103 protruding through the apertures in sides 120, above the Surface S of the Substrate. The channel 129 is
 US 6,685,832 B2
21 22
formed so as to provide a permeate withdrawal tube 126 in Skeins of non-rectangular croSS-Section than a vertical
integrally formed with the platform 123. Side wall 122 is air-tube which discharges air radially along its vertical
provided with an air-nipple 130 through which air is intro length and which vertical air-tube concurrently Serves as the
duced into the plenum formed by the walls of the enclosure spacing means. Such Skeins with a generally circular or
120b, and the surface S of Substrate under the platform 123. elliptical cross-section with Vertical air-tubes are leSS pre
Each stack is potted as described in relation to FIG. 6 above, ferred to form a bank, but provide a more efficient use of
most preferably by forming a composite header of fugitive available Space in a reservoir than a rectangular Skein.
PEG wax and epoxy resin around the Stacks of arrayS Referring further to FIG. 2, the header 11 has front and
positioned between the rows of risers 124, making Sure the rear walls defined by Vertical (Z-axis) edges 11" and longi
open ends of the air-tubes are above the epoxy fixing tudinal (X-axis) edges 13'; side walls defined by edges 11
material, and melting out the wax through the permeate and transverse (y-axis) edges 13"; and a base 13 defined by
withdrawal tube 126. When air is introduced into the enclo edges 13' and 13".
sure the air will be distributed through the air-tubes between The collection pan 20 is sized to Snugly accommodate the
and around the Skeins. base 13 above a permeate collection Zone within the pan.
Referring to FIG. 9 there is shown a schematic illustration 15 This is conveniently done by forming a rectangular pan
of a skein having upper and lower headers 41u and 41b having a base 23 of Substantially the same length and width
respectively, and in each, the protruding upper and lower dimensions as the base 13. The periphery of the pan 20 is
ends 12u" and 12b" are evidence that the face of the header provided with a peripheral Step as shown in FIG. 2A, in
was not cut to expose the fibers. The height of the contiguous which the wall 20' of the pan terminates in a step section 22,
intermediate portions 12u' and 12b' respectively, corre having a Substantially horizontal shoulder 22" and a vertical
sponds to the cured depth of the fixing material. retaining wall 22".
It will now be evident that the essential feature of the FIG.2B is a bottom plan view of the lower face of header
foregoing potting method is that a fugitive lamina is formed 13 showing the open ends of the fibers 12" prevented from
which embeds the openings of the terminal portions of the touching each other by potting resin. The geometrical dis
fibers before their contiguous intermediate portions 12u' and 25 tribution of fibers provides a regular peripheral boundary 14
12u" and 12b' and 12b" respectively are fixed in a fixing (shown in dotted outline) which bounds the peripheries of
lamina of the header. An alternative choice of materials is the open ends of the outermost fibers.
the use of a fugitive potting compound which is Soluble in Permeate flows from the open ends of the fibers onto the
a non-aqueous liquid in which the fixing material is not base 23 of the pan 20, and flows out of the collection Zone
Soluble. Still another choice is to use a water-insoluble through a permeate withdrawal conduit 30 which may be
fugitive material which is also insoluble in non-aqueous placed in the bottom of the pan in open flow communication
liquids typically used as Solvents, but which fugitive mate with the inner portion of the pan. When the skein is
rial has a lower melting point than the final potting material backwashed, backwashing fluid flows through the fibers and
which may or may not be water-soluble. into the substrate. If desired, the withdrawal conduit may be
The fugitive material is inert relative to both, the material 35 positioned in the side of the pan as illustrated by conduit 30'.
of the fibers as well as the final potting material to be cast, Whether operating under gravity alone, or with a pump to
and the fugitive material and fixing material are mutually provide additional Suction, it will be apparent that a fluid
insoluble. Preferably the fugitive material forms a substan tight Seal is necessary between the periphery of the header
tially smooth-Surfaced solid, but it is critical that the fugitive 11 and the peripheral step 22 of the pan 20. Such a seal is
material be at least partially cured, Sufficiently to maintain 40 obtained by using any conventional means Such as a Suitable
the shape of the header, and remain a Solid above a tem Sealing gasket or Sealing compound, typically a polyure
perature at which the fixing material is introduced into the thane or Silicone resin, between the lower periphery of the
header mold. The fugitive lamina is essentially inert and header 11 and the step 22. As illustrated in FIG. 2, permeate
insoluble in the final potting material, So that the fugitive drains downward, but it could also be withdrawn from upper
lamina is removably adhered to the fixing lamina. 45 permeate port 45u in the upper permeate pan 43u (see FIG.
The demolded header is either heated or solvent extracted 9).
to remove the fugitive lamina. Typically, the fixing material It will now be evident that a header with a circular
is cured to a firm Solid mass at a first curing temperature no periphery may be constructed, if desired. Headers with
higher than the melting point or Tg of the fugitive lamina, geometries having still other peripheries (for example, an
and preferably at a temperature lower than about 60° C.; the 50 ellipse) may be constructed in an analogous manner, if
firm Solid is then post-cured at a temperature high enough to desired, but rectangular headers are most preferred for ease
melt the fugitive material but not high enough to adversely of construction with multiple linear arrayS.
affect the curing of the fixing material or the properties of the Referring to FIGS. 9 and 2A, six rows of fibers 12 are
fibers. The fugitive material is removed as described shown on either side of a gas distribution line 52 which
hereinafter, the method of removal depending upon the 55 traverses the length of the rows along the base of the fibers.
fugitive material and the curing temperature of the final The potted terminal end portions 12b" open into permeate
potting material used. pan 43b. Because portions 12u' and 12b' of individual fibers
Since, during operation, a high flux is normally main 12 are potted, and the fibers 12 are preferably from 1% to 2%
tained if cleansing air contacts Substantially all the fibers, it longer than the fixed distance between upper and lower
will be evident that when it is desirable to have a skein 60 headers 41u and 41b, the fibers between opposed headers are
having a cross-section which is other than generally generally parallel to one another, but are particularly parallel
rectangular, for example elliptical or circular, or having a near each header. Also held parallel are the terminal end
geometrically irregular periphery, and it is desired to have a portions 12u" and 12b" of the fibers which protrude from the
large number of skein fibers, it will be evident that the headers with their open ends exposed. The fibers protrude
procedure for Stacking consecutive peripheral arrayS 65 below the lower face of the bottom header 41b, and above
described above will be modified. Further, the transverse the upper face of the upper header 41.u. The choice of fiber
central air-tube 52 (see FIG. 9) is found to be less effective spacing in the header will determine packing density of the
 US 6,685,832 B2
23 24
fibers near the headers, but fiber Spacing is not a Substantial The skein fibers (only one array of which is shown for
consideration because Spacing does not Substantially affect clarity) shown in this perspective view have an elongated
Specific flux during operation. It will be evident however, rectangular parallelpiped shape the Sides of which are
that the more fibers, the more tightly packed they will be, irregularly shaped when immersed in a Substrate, because of
giving more Surface area. the random Side-to-side displacement of fibers as they Sway.
Since the length of fibers tends to change while in Service, An elongated rectangular parallelpiped shape is preferred
the extent of the change depending upon the particular Since it permits a dense packing of fibers, yet results in
composition of the fibers, and the Spacing between the upper excellent scrubbing of the surfaces of the fibers with
and lower headers is critical, it is desirable to mount the bubbles. With this shape, a skein may be formed with from
headers So that one is adjustable in the vertical direction 1O 10 to 50 arrays of fibers across the longitudinal width 'w of
relative to the other, as indicated by the arrow V. This is the headers 41u, 41b, and 41u', 41b' with each array having
conveniently done by attaching the pan 43u to a plate 19 fibers extending along the transverse length 1 of each
having vertically Spaced apart through-passages 34 through
which a threaded stud 35 is inserted and secured with a nut header. Air-tubes on either Side of a Skein effectively cleanse
36. Threaded stud 35 is in a fixed mounting block 37. the fibers if there are less than about 30 arrays between the
The density of fibers in a header is preferably chosen to 15 air-tubes. A Skein having more than 30 arrayS is preferably
provide the maximum membrane Surface area per unit also centrally aerated as illustrated by the air-tube 52 in FIG.
Volume of Substrate without adversely affecting the circu 9.
lation of Substrate through the Skein. A gas-distribution Thus, if there are about 100 fibers closely spaced-apart
means 52 Such as a perforated air-tube, provides air within along the transverse length 1 of an array, and there are 25
the skein so that bubbles of gas (air) rise upwards while arrays in a skein in a header of longitudinal width w, then
clinging to the Outer Surfaces of the fibers, thus efficiently the opposed terminal end portions of 2500 fibers are potted
scrubbing them. If desired, additional air-tubes 52' may be in headers 41u and 41b. The open ends of all fibers in
placed on either side of the skein near the lower header 41b, headers 41b and 41b' point downwards into collection zones
as illustrated in phantom outline, to provide additional in collection pans 43b and 43b' respectively, and those of all
air-scrubbing power. Whether the permeate is withdrawn 25 fibers in headers 41u and 41u point upwards into collection
from the upper header through port 45u or the lower header Zones in collection pans 43u and 43u' respectively. With
through port 45b, or both, depends upon the particular drawal conduits 45u and 45u' are manifolded to permeate
application, but in all instances, the fibers have a Substan manifold 46u through which permeate collecting in the
tially vertical orientation. upper collection pans 43u and 43u' is typically continuously
The vertical Skein is deployed in a Substrate to present a withdrawn. If the permeate flow is high enough, it may also
generally vertical profile, but has no structural shape. Such be withdrawn from the collection pans 43b and 43b' through
shape as it does have changes continuously, the degree of withdrawal conduits 45b and 45b' which are manifolded to
change depending upon the flexibility of the fibers, their
lengths, the overall dimensions of the skein, and the degree permeate manifold 46b. When permeate is withdrawn in the
of movement imparted to the fibers by the substrate and also same plane as the permeate withdrawal conduits 45u, 45u
by the oxygen-containing gas from the gas-distribution 35 and manifold 46.u., and the transmembrane preSSure differ
CS. ential of the fibers is in the range from 35-75 kPa (5-10 psi),
Referring to FIG. 10 there is illustrated a typical assembly manifold 46u may be connected to the Suction side of a
referred to as a “wall-mounted bank' which includes at least centrifugal pump which will provide adequate NPSH.
two Side-by-Side Skeins. indicated generally by reference In general, the permeate is withdrawn from both the upper
numerals 40 and 40' with their fibers 42 and 42", fibers 42 are 40 and lower headers, until the flux declines to so low a level
potted in upper and lower headers 41u and 41b respectively; as to require that the fibers be backwashed. The Skeins may
and fibers 42 in headers 41 u' and 41b'; headers 41u and 41b be backwashed by introducing a backwashing fluid through
are fitted with permeate collecting means 46u and 46b the upper permeate collection manifold 46u, and removing
respectively; headers 41u and 41b' are fitted with permeate the fluid through the lower manifold 46b. Typically, from 3
collecting means 46.u' and 46b' respectively; and, the Skeins 45 to 30 skeins may be coupled together for internal fluid
share a common gas-distribution means 50. A “bank” of communication with one and another through the headers,
Skeins is typically used to retrofit a large, deep tank from permeate withdrawal means and the fibers, and, for external
which permeate is to be withdrawn using a vacuum pump. fluid communication with one another through an air mani
In a large reservoir, Several banks of Skeins may be used in fold. Since the permeate withdrawal means is also used for
Side-by-side relationship within a tank. Each Skein includes 50 backflushing it is generally referred to as a liquid circula
multiple rows (only one row is shown) of fibers 42 and 42 tion means, and as a permeate withdrawal means only when
in upper headers 41u and 41 u', and lower headers 41b and it is used to withdraw permeate.
41b' respectively, and arms 51 and 51" of gas-distribution When deployed in a Substrate containing Suspended and
means 50 are disposed between the lower headers 41b and dissolved organic and inorganic matter, most fibers of
41b', near their bases. The upper headers 44u and 44u are 55 organic polymers remain buoyant in a vertical position. The
mounted by one of their ends to a vertical interior Surface of fibers in the skein are floatingly buoyed in the Substrate with
the wall W of a tank, with mounting brackets 53 and 53' and the ends of the fibers anchored in the headers. This is
suitable fastening means such as bolts 54. The wall W thus because (i) the permeate is essentially pure water which has
functions as a Spacer means which fixes the distance a specific gravity leSS than that of the Substrate, and most
between the upper and lower headers. Each upper header is 60 polymers from which the fibers are formed also have a
provided with a permeate collection pan 43u and 43u', Specific gravity less than 1, and, (ii) the fibers are buoyed by
respectively, connected to permeate withdrawal conduits bubbles which contact them. Fibers made from ceramic, or,
45u and 45u' and manifolded to permeate manifold 46u glass fibers are heavier than water.
through which permeate being filtered into the collection Adjacent the skeins, an air-distribution manifold 50 is
pans is continuously withdrawn. Each header is Sealingly 65 disposed below the base of the bundle of fibers, preferably
bonded around its periphery, to the periphery of each col below the horizontal plane through the horizontal center
lection pan. lines of the headers. The manifold 50 is preferably split into
 US 6,685,832 B2
25 26
two foraminous arms 51 and 51' adjacent the bases of pans 63u and 63u' respectively, and each pan has withdrawal
headers 41b and 41b' respectively, so that when air is conduits 65u and 65u' which are manifolded to longitudinal
discharged through holes in each portion 51 and 51", col liquid conduits 81 and 81'. Analogously, headers 61b and
umns of bubbles rise adjacent the ends of the fibers and 61b' are each secured in fluid-tight relationship with collec
thereafter flow along the fibers through the skeins. If desired, tion Zones in collection pans 63b and 63b' respectively, and
additional portions (not shown) may be used adjacent the each pan has withdrawal conduits 65b and 65b' which are
bases of the lower headers but located on the outside of each, manifolded to longitudinal conduits 82 and 82". As
So as to provide additional columns of air along the outer illustrated, withdrawal conduits are shown for both the
Surfaces of the fibers. upper and the lower headers, and both fore and aft the
The type of gas (air) manifold is not narrowly critical headers. In many instances, permeate is withdrawn from
provided it delivers bubbles in a preferred size range from only an upper manifold which is provided on only one side
about 1 mm to 25 mm, measured within a distance of from of the upper headers. A lower manifold is provided for
1 cm to 50 cm from the through-passages generating them. backwashing. Backwashing fluid is typically flowed through
If desired, each portion 51 and 51' may be embedded in the the upper manifold, through the fibers and into the lower
upper Surface of each header, and the fibers potted around 15 manifold. The additional manifolds on the aft ends of the
them, making Sure the air-passages in the portions 51 and 51 upper and lower headers not only provides more uniform
are not plugged with potting compound. If desired, addi distribution of backwashing fluid but support for the inter
tional arms of air-tubes may be disposed on each Side of each connected headers. It will be evident that, absent the aft
lower header, so that fibers from each header are scrubbed interconnecting upper conduit 81, an upper header Such as
by columns of air rising from either transverse side. 61u will require to be spaced from its lower header by some
The air may be provided continuously or intermittently, other interconnection to header 61 u' or by a Spacer Strut
better results generally being obtained with continuous air between headers 61u and 61b.
flow. The amount of air provided depends upon the type of In the best mode illustrated, each upper header is provided
Substrate, the requirements of the type of microorganisms, if with rigid PVC tubular nipples adapted to be coupled with
any, and the susceptibility of the surfaces of the fibers to be 25 fittings such as ells and tees to the upper conduits 81 and 81
plugged, there always being Sufficient air to produce desired respectively. Analogously, each lower header is connected to
growth of the microorganisms when operated in a Substrate lower conduits 82 and 82 (not shown) and/or spacer struts
where maintaining Such growth is essential. are provided to provide additional rigidity, depending upon
Referring to FIG. 11, there is schematically illustrated the number of headers to be interconnected. Permeate is
another embodiment of an assembly, referred to as a “stand withdrawn through an upper conduit, and all piping
alone bank” of skeins, two of which are referenced by connections, including the air connection, are made above
numeral 60. The bank is referred to as being a “stand-alone” the liquid level in the reservoir.
because the Spacer means between headers is Supplied with The length of fibers (between headers) in a skein is
the Skeins, usually because mounting the Skeins against the generally chosen to obtain efficient use of an economical
wall of a reservoir is less effective than placing the bank in 35 amount of air, So as to maintain optimum flux over a long
Spaced-apart relationship from a wall. In other respects, the period of time. Other considerations include the depth of the
bank 60 is analogous to the wall-mounted bank illustrated in tank in which the bank is to be deployed, the positioning of
FIG 10. the liquid and air manifolds, and the convection patterns
Each bank 60 with fibers 62 (only a single row of the within the tank inter alia.
multiple, regularly Spaced apart generally vertical arrays is 40 In another embodiment of the invention, a bioreactor is
shown for the sake of clarity) is deployed between upper and retrofitted with plural banks of skeins schematically illus
lower headers 61u and 61b in a Substrate 'S'. The lower trated in the elevational view shown in FIG. 12, and the plan
headers rest on the floor of the reservoir. The upper headers view shown in FIG. 13. The clarifier tank is a large circular
are secured to rigid vertical air tubes 71 and 71" through tank 90 provided with a vertical, circular outer baffle 91, a
which air is introduced into a tubular air manifold identified 45 vertical circular inner baffle 92, and a bottom 93 which
generally by reference numeral 70. The manifold 70 slopes towards the center (apex) for drainage of accumulat
includes (i) the vertical tubular arms 71 and 71"; (ii) a lower ing sludge. Alternatively, the baffles may be individual,
transverse arm 72 which is perforated along the length of the closely Spaced rectangular plates arranged in Outer and inner
lower header 61b' and secured thereto; the arm 72 commu circles, but continuous cylindrical baffles (shown) are pre
nicates with longitudinal tubular arm 73, and optionally 50 ferred. Irrespective of which baffles are used, the baffles are
another longitudinal arm 73' (not shown) in mirror-image located So that their bottom peripheries are located at a
relationship with arm 73 on the far side of the headers; and chosen vertical distance above the bottom. Feed is intro
(iii) transverse arms 74 and 74 in open communication with duced through feed line 94 in the bottom of the tank 90 until
72 and 73; arms 74 and 74" are perforated along the visible the level of the Substrate rises above the outer baffle 91.
transverse faces of the headers 61b an 61b', and 74 and 74 55 A bank 60 of plural skeins 10, analogous to those in the
may communicate with tubular arm 73" if it is provided. The bank depicted in FIG. 10, each of which skeins is illustrated
vertical air-tubes 71 and 71' conveniently provide the addi in FIG. 9, is deployed against the periphery of the inner wall
tional function of a Spacer means between the first upper of the bioreactor with Suitable mounting means in an outer
header and the first lower header, and because the remaining annular permeate extraction Zone 95" (FIG. 13) formed
headers in the bank are also similarly (not shown) intercon 60 between the circular outer baffle 91 and the wall of the tank
nected by rigid conduits, the headers are maintained in 90, at a depth sufficient to submerge the fibers. A clarifica
Vertically and transversely spaced-apart relationship. Since tion Zone 91" is defined between the outer circular baffle 91
all arms of the air manifold are in open communication with and inner circular baffle 92. The inner circular baffle 92
the air Supply, it is evident that uniform distribution of air is provides a vertical axial passage 92 through which Substrate
facilitated. 65 is fed into the tank 90. The skeins form a dense curtain of
AS before, headers 61u and 61 u" are each secured in fibers in radially extending, generally planar vertical arrayS
fluid-tight relationship with collection Zones in collection as illustrated in FIG. 9, potted between upper and lower
 US 6,685,832 B2
27 28
headers 41u and 41b. Permeate is withdrawn through mani about 20 Shore D, and most preferred to use a polyurethane
fold 46u and air is introduced through air-manifold 80, having a hardness in the range from 50 Shore A to about 20
extending along the inner wall of the tank, and branching out Shore D, measured as set forth in ASTM D-790, Such as
with air-distribution arms between adjacent headers, includ PTU-921 available from Canadian Poly-Tech Systems. To
ing outer distribution arms 84 on either side of each lower form the upper finished header 183 the air supply tube is
header 41b at each end of the bank. The air manifold 80 is Snugly inserted through an O-ring held in a central bore in
positioned between Skeins in the permeate extraction Zone a plate Such as used in FIG. 5, to avoid loSS of potting resin
95" in such a manner as to have bubbles contact essentially from the ring 120, and the fugitive resin and finishing resins
the entire Surface of each fiber which is continuously awash poured and cured, first one then the other, in the ring. Lower
with bubbles. Because the fibers are generally vertical, the finished header 184 is formed with intermediate portions
air is in contact with the Surfaces of the fibers longer than if 112b' embedded, and terminal portions 112b" protruding
they were arcuate, and the air is used most effectively to from the header's aft face. Upper finished header 183 is
maintain a high flux for a longer period of time than would formed with intermediate portions 112u' embedded, and
otherwise be maintained. terminal portion 112u" protruding from the header's fore
It will be evident that if the tank is at ground level, there 15 face. After the finished headers 183 and 184 are formed and
will be insufficient liquid head to induce a desirable liquid the fibers checked for defects, the upper end 186u of the air
head under gravity alone. Without an adequate Siphoning supply tube 186 is inserted through a central bore 188 in
effect, a centrifugal pump may be used to produce the upper end-cap 181 and Sealed within the bore with Sealing
necessary Suction. Such a pump should be capable of compound or a collar 189. Preferably the permeate tube 185,
running dry for a short period, and of maintaining a vacuum the air supply tube 186 and the collar 189 are all made of
on the suction side of from cm (10")-51 cm (20") of Hg, or PVC so that they are easily cemented together to make
-35 kPa (-5 psi) to -70 kPa (-10 psi). Examples of such leak-proof connections.
pumps rated at 18.9 L/min (5 gpm)(a)15" Hg, are (i) flexibly AS shown, permeate may be withdrawn through the
impeller centrifugal pumps, e.g. Jabsco #30510-2003; (ii) air permeate tube 185 from the permeate collection Zone in the
operated diaphragm pumps, e.g. Wilden M2, (iii) progress 25 lower end-cap 182, and Separately from the upper end-cap
ing cavity pumps, e.g. Ramoy 3561; and (iv) hose pumps, 181 through permeate withdrawal port 181p which may be
e.g. Waukesha SP 25. threaded for attaching a pipe fitting. Alternatively, the per
The Skein may also be potted in a header which is not a meate port 181p may be plugged and permeate withdrawn
rectangular prism, preferably in cylindrical upper and lower from both end-caps through the permeate tube 185.
headers in which Substantially concentric arrays of fibers are Upper end 185u of permeate tube 185 and upper end 186u
non-removably potted in cylindrical permeate pans, and the of air supply tube 186 are inserted through a T-fitting 201
beaders are spaced apart by a central gas tube which through which air is supplied to the air supply tube 186. The
functions as both the spacer means and the gas-distribution lower end of 201b of one of the arms of the T 201 is
means which is also potted in the headers. AS before, the Slip-fitted and Sealed around the air Supply tube. The upper
fibers are restrictedly Swayable, but permeate is withdrawn 35 end 201u of the other arm is inserted in a reducing bushing
from both upper and lower headers through a single perme 202 and Sealed around the permeate tube. Air Supplied to
ate pan So that all connections for the Skein, when it is intake 203 of the T 201 travels down the annular Zone
Vertically Submerged, are from above. Permeate is prefer between the permeate tube and the air Supply tube and exits
ably withdrawn from the lower permeate pan through a through opposed ports 204 in the lower portion of the air
central permeate withdrawal tube which is centrally axially 40 supply tube, just above the upper face 184u of the lower
held within the central gas (air) tube. The concentric arrays header 184. It is preferred to thread ports 204 to threadedly
are formed by wrapping Successive sheets of flat arrayS Secure the ends of arms 141 to form a Sparger which
around the central air-tube, and gluing them together before distributed air substantially uniformly across and above the
they are potted. This configuration permits the use of more surface 184u. Additional ports may be provided along the
filtration Surface area per unit volume of a reservoir, com 45 length of the Vertical air Supply tube, if desired.
pared to Skeins with rectangular prism headers, using the EXAMPLE
Same diameter and length of fibers.
Referring to FIG. 14 there is schematically illustrated Microfiltration of an activated sludge at 30° C. having a
another embodiment of skein 180 in which rigid permeate concentration of 25 uL (2.5% TSS) is carried out with a
tube 185 is held concentrically within a rigid air-supply tube 50 skein of polysulfone fibers in a pilot plant tank. The fibers
186 which is potted axially within skein fibers 112 held are “air scrubbed” at a flow rate of 12 CFM (034 m/min)
between opposed upper and lower headers 183 and 184 in with a coarse bubble diffuser generating bubbles in the range
upper and lower rings 120u and 120b which are in turn from about 5 mm to 25 mm in nominal diameter. The air is
sealed in end-caps 181 and 182 respectively. For ease of Sufficient not only for the oxidation requirements of the
manufacture, the lower end 185b of permeate tube 185 is 55 biomass but also for adequate Scrubbing. The fibers have an
snugly fitted and sealed in a bushing 187. The bushing 187 outside diameter of 1.7 mm, a wall thickness of about 0.5
and end 185b are then inserted in the lower end 86b of the mm, and a Surface porosity in the range from about 20% to
air supply tube 186 and sealed in it so that the annular Zone 40% with pores about 0.2 um in diameter, both latter
between the outer surface of permeate tube 185 and the inner physical properties being determined by a molecular weight
surface of air supply tube 186 will duct air to the base of the 60 cut off at 200,000 Daltons. The skein which has 1440 fibers
fibers but not permit permeate to enter the annular Zone. The with a surface area of 12 m is wall-mounted in the tank, the
air Supply tube is then placed on an array and the array is Vertical Spaced apart distance of the headers being about 1%
rolled into a spiral which is held at each end with rubber less than the length of a fiber in the Skein. The opposed ends
bands. The lower end of the roll is placed in a ring 120b and of the fibers are potted in upper and lower headers
a lower ring header is formed with a finished header 184 as 65 respectively, each about 41 cm long and 10 cm wide. The
described above. It is preferred to use a relatively stiff fixing material of the headers is an epoxy having a hardneSS
elastomer having a hardneSS in the range from 50 Shore A to of about 70 Shore D with additional upper an lower laminae
 US 6,685,832 B2
29 30
of softer polyurethane (about 60 Shore A and 30 Shore D d) removing the first material from Said ends and terminal
respectively) above and below the epoxy lamina, and the portions of the hollow fiber membranes.
fibers are potted to a depth Sufficient to have their open ends 2. The process of claim 1 wherein the container is at least
protrude from the bottom of the header. The average trans part of a permeate collection means.
membrane pressure differential is about 34.5 kPa (5 psi). 3. The process of claim 1 wherein the container is a
Permeate is withdrawn through lines connected to the col permeate pan or header enclosure.
lection pan of each header with a pump generating about 4. The process of claim 1 wherein the potting liquid
34.5 kPa (5 psi) Suction. Permeate is withdrawn at a specific Sealingly attaches to the container as it Solidifies.
flux of about 0.7 lmh/kPa yielding about 4.8 l/min of 5. The process of claim 1 wherein the plurality of hollow
permeate which has an average turbidity of <0.8 NTU, fiber membranes are glued in a fixed relationship relative to
which is a turbidity not discernible to the naked eye. each other at a portion of their lengths which will become
It will now be evident that the membrane device and basic
Separation processes of this invention may be used in the fixed in the Solid mass of potting material prior to step (b)
of claim 1.
recovery and Separation of a wide variety of commercially 6. The process of claim 1 wherein terminal portions of the
Significant materials, Some of which, illustratively referred 15
to, include the recovery of water from ground water con hollow fiber membranes protrude from a face of the Solidi
taining micron and Submicron particles of Siliceous fied potting liquid.
materials, preferably "gas Scrubbing with carbon dioxide; 7. The process of claim 1 wherein the first material is
or, the recovery of Solvent from paint-contaminated Solvent. removed by dissolving it.
In each application, the choice of membrane will depend 8. The process of claim 1 wherein the first material is a
upon the physical characteristics of the materials and the liquid when the membranes are inserted into the first mate
Separation desired. The choice of gas will depend on rial but is Solidified before the potting liquid is placed over
whether oxygen is needed in the Substrate. it.
In each case, the Simple process comprises, disposing a 9. The process of claim 1 wherein the first material is
skein of a multiplicity of hollow fiber membranes, or fibers 25 removed by flowing it away from the membranes.
each having a length >0.5 meter, together having a Surface 10. The process of claim 1 wherein the first material is
area >1 m, in a body of Substrate which is unconfined in a Soluble in a Solvent and the potting liquid upon Solidification
modular shell, so that the fibers are essentially restrictedly is insoluble in the Solvent.
Swayable in the substrate. The substrate is typically not 11. A process of potting a plurality of hollow fiber
under pressure greater than atmospheric. The fibers have a membranes into a mass of Solidified potting liquid fixed to
low transmembrane pressure differential in the range from a permeate pan or other header enclosure of a filtration
about 3.5 kPa (0.5 psi) to about 350 kPa (50 psi), and the module comprising the Steps of,
headers, the terminal portions of the fibers, and the ends of a) providing a plurality of hollow fiber membranes, the
the fibers are disposed in Spaced-apart relationship as 35
membranes having terminal portions adjacent open
described hereinabove, So that by applying a Suction on the ends,
aft face of at least one of the headers, preferably both, b) enclosing the open ends and terminal portions of the
permeate is withdrawn through the collection means in hollow fiber membranes in a first material held in the
which each header is mounted in fluid-tight communication. permeate pan or other header enclosure;
Having thus provided a general discussion, and Specific 40 c) flowing a potting liquid into the permeate pan or other
illustrations of the best mode of constructing and deploying header enclosure over the first material, which potting
a membrane device comprising a skein of long fibers in a liquid Surrounds each hollow membrane and then
Substrate from which a particular component is to be pro Solidifies becoming a Solid mass which provides a
duced as permeate, how the device is used in a gas-Scrubbed fluid-tight seal to the outside of the hollow fiber mem
Skein, and having provided specific illustrative Systems and 45 branes and which attaches and Seals to the permeate
processes in which the Skein is used, it is to be understood pan or other header enclosure, the first material pre
that no undue restrictions are to be imposed by reason of the venting the potting liquid or Solid mass from closing
Specific embodiments illustrated and discussed, and particu Said ends of the membranes, and,
larly that the invention is not restricted to a slavish adher d) removing the first material from Said ends and terminal
ence to the details set forth herein.
We claim:
50 portions of the hollow fiber membranes and the per
1. A process of potting a plurality of hollow fiber mem meate pan or other header enclosure.
branes into a mass of Solidified potting liquid comprising the 12. The process of claim 11 wherein terminal portions of
Steps of, the hollow fiber membranes protrude from a face of the
Solidified potting liquid.
a) providing a plurality of hollow fiber membranes, the 55 13. The process of claim 11 wherein the first material is
membranes having terminal portions adjacent open removed by dissolving it.
ends, 14. The process of claim 11 wherein the first material is
b) enclosing the open ends and terminal portions of the a liquid when the membranes are inserted into the first
hollow fiber membranes in a first material held in a material but is Solidified before the potting liquid is placed
container; 60 over it.
c) flowing a potting liquid in the container over the first 15. The process of claim 11 wherein the first material is
material, which potting liquid Surrounds each hollow removed by flowing it away from the membranes.
membrane and then becomes a Solid mass which pro 16. The process of claim 11 wherein the first material is
vides a fluid-tight seal to the outside of the hollow fiber Soluble in a Solvent and the potting liquid upon Solidification
membranes, the first material preventing the potting 65 is insoluble in the Solvent.
liquid or Solid mass from closing Said ends of the 17. A header incorporating potted hollow fiber
membranes, and, membranes, the header having,
 US 6,685,832 B2
31 32
a) a Solid mass of a potting material having a first face; a) a Solid mass of a potting material having a first face;
and, b) a hollow body sealed to the potting material to provide
b) a plurality of hollow fiber membranes sealed in the a plenum between the first face and the body; and,
potting material, characterized by, c) a plurality of hollow fiber membranes sealed in the
potting material So as to be open to the plenum,
c) parts (a) and (b) being obtainable by the process of any characterized by,
previous claim; and, d) parts (a), (b) and (c) being obtainable by the process of
d) terminal portions of the hollow fiber membranes adja any previous claim; and,
cent open ends of the membranes protruding from the e) terminal portions of the hollow fiber membranes adja
first face of the Solid mass of potting material. cent open ends of the membranes protruding from the
18. Aheader and permeate collection means incorporating first face into the plenum.
potted hollow fiber membranes, the header and permeate
collection means having, k k k k k