METHOD AND APPARATUS FOR THE FILTRATION OF BIOLOGICAL SOLUTIONS

Abstract
A system, method and device are disclosed for bio-processing a feed stream and providing a constant output by operating a continuous single-pass tangential-flow process. The single-pass process provides high conversion concentration while operating at relatively low feed flow rates, and the process can also be used to provide constant output diafiltration.
Description

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other aspects, embodiments, objects, features and advantages of the present teachings can be more fully understood from the following description in conjunction with the accompanying drawings. In the drawings, like reference characters generally refer to like features and structural elements throughout the various figures. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the present teachings. The following drawings are illustrative of embodiments of the invention and are not meant to limit the scope of the invention as encompassed by the claims.



FIG. 1 shows a P&I diagram of prior art TFF process using a recirculation loop;



FIG. 2 shows a P&I diagram of an SPF process according to the invention;



FIG. 3 shows a P&I diagram of a an SPF similar to the process of FIG. 2 in which two pressurized tanks drive and control the process;



FIGS. 4A and 4B show P&I diagrams of an SPF processes according to various embodiments of the present invention in which two pumps are used to drive and control the process;



FIG. 5 is a schematic diagram of a longitudinal section of a flow channel of a hollow fiber module formed with hollow fiber membranes according to the invention;



FIG. 6 is a schematic diagram of a longitudinal section of flow channel of a flat-sheet module formed with flat-sheet membranes according to the invention;



FIG. 7A is a schematic block diagram of a multi-stage system according to the invention;



FIGS. 7B and 7C are schematic diagrams of internally-staged modules according to the invention wherein staging is accomplished by reducing the number of flow channels in each stage along the flow path;



FIG. 7D is a schematic diagram of a multi-stage system having stages with multiple serial flow paths according to the invention;



FIG. 8A is a perspective diagram of a multi-stage system according to the invention having stages including channels with differing specific membrane area;



FIGS. 8B and 8C are schematic diagrams of internally-staged modules according to various embodiments of the present invention, where staging is accomplished by increasing the specific membrane area of channels in each stage along the flow path;



FIGS. 9A and 9B are schematic diagrams of feed and permeate compartments, respectively, of an internally-staged module comprising rectangular channels having decreasing cross-sectional area along the flow path according to the invention;



FIG. 10A is a schematic diagram of a single-leaf spirally-wound module according to the invention;



FIGS. 10B, 10C, 10D and 10E show multiple views of the spiral module of FIG. 10A including rectangular channels having decreasing cross-sectional area along the flow path;



FIG. 11A is a schematic diagram of an exemplary staging plate and cassette system according to the invention;



FIG. 11B is a schematic diagram of a staging plate assembly using the components of FIG. 11A;



FIG. 11C is a schematic diagram of conventional cassette as used in the system of FIG. 11A;



FIG. 11D is a flow schematic of one embodiment of a single pass filtration concentration module in a 3-2-1-1 configuration according to the invention;



FIG. 12 is an exemplary flux profile for a concentration module similar to the module of FIG. 11A;



FIG. 13A is a schematic diagram of an internally staged diafiltration system suitable for diafiltration according to the invention;



FIG. 13B is a schematic diagram of one embodiment of the system of FIG. 13A, including diafiltration hydraulic distributors;



FIG. 14A is a schematic diagram of a diafiltration distributor similar to the distributor in the system of FIG. 13B implemented as a parallel resistance network of hydraulic resistors;



FIG. 14B is a schematic diagram of a diafiltration distributor similar to the distributor in the system of FIG. 13B implemented as a series resistance network of hydraulic resistors;



FIG. 14C is a schematic diagram of a diafiltration distributor similar to the distributor in the system of FIG. 13B implemented as a series-parallel resistance network of hydraulic resistors;



FIG. 15 is a schematic diagram of a counter current diafiltration module according to the invention showing the distributors as a parallel network of resistors coupled to a pump;



FIG. 16A is a schematic diagram of internally staged hollow fiber module according to the invention;



FIG. 16B is a schematic cross section diagram of the internally staged hollow fiber module of FIG. 16A;



FIG. 17 is a schematic cross section diagram of an internally staged hollow fiber module suitable for diafiltration according to the invention;



FIG. 18A is a longitudinal cross section view of an internally staged hollow fiber module suitable for diafiltration according to the invention;



FIG. 18B is an axial cross section view of the internally staged hollow fiber module of FIG. 18A through line 18B;



FIG. 19A is schematic diagram of an internally staged module including a staging plate suitable for cross current diafiltration according to the invention;



FIG. 19B is a flow diagram showing the feed stream in the four-stage module of FIG. 19A;



FIG. 20 is a schematic diagram of a staged module suitable for counter current diafiltration according to the invention; and



FIG. 21 is a schematic diagram of permeate distributor according to the invention.


Claims
  • 1. A filtration system comprising: a plurality of stages, each stage having a plurality of channels providing at least one serial flow path, each stage being in fluid communication with each adjacent stage preceding it and being in fluid communication with each adjacent stage that follows it;each of the plurality of channels comprising an filtration membrane and having a length, a membrane area, a void volume, a specific membrane area expressed as a ratio of the membrane area to the void volume, and a dimensionless length expressed as a product of the channel length and the specific membrane area;wherein a dimensionless length of a stage is the sum of the dimensionless lengths of each channel in the longest serial flow path in the stage and the dimensionless length of the system is the sum of the dimensionless lengths of the plurality of stages; andwherein the specific membrane area of at least one channel is greater than about 40 cm−1, the dimensionless length of the system is greater than about 2,000 and the dimensionless length of at least one of the plurality of stages is less than about 6,000.
  • 2. The system of claim 1 wherein an initial hydraulic permeability of the membrane is greater than about 0.5 lmh/psi.
  • 3. The system of claim 1 wherein the filtration membrane is one of: an ultrafiltration membrane; anda microfiltration membrane.
  • 4. The system of claim 1 wherein the number of stages is greater than two.
  • 5. The system of claim 1 wherein the number of stages is greater than four.
  • 6. The system of claim 1 wherein the channels comprise one of: a hollow fiber membrane;a flat-sheet membrane; anda membrane monolith.
  • 7. The system of claim 1 wherein the plurality of channels in any one of the plurality of stages are substantially identical.
  • 8. The system of claim 7 wherein the dimensionless length of each of the plurality of stages is less than about 3,500.
  • 9. The system of claim 7 further comprising at least one diafiltration distributor in fluid communication with selected ones of the plurality of stages and a diafiltrate source.
  • 10. The system of claim 9 wherein each of the selected ones of the plurality of stages further comprises a feed manifold fluidly coupled to the channels of the selected ones of the plurality of stages and the at least one diafiltration distributor further comprises a plurality of diafiltration flow passages fluidly coupling the feed manifolds to the diafiltrate source.
  • 11. The system of claim 10 further comprising a pressure source and wherein the diafiltrate source is supplied in the selected ones of the plurality of stages at a pressure greater than the feed pressure in the channels.
  • 12. The system of claim 10 wherein a network of hydraulic resistances of the diafiltration flow passages of the at least one diafiltration distributor is provided as one of: a parallel arrangement;a series arrangement; anda series parallel arrangement.
  • 13. The system of claim 9 further comprising: a feed manifold fluidly coupled to the plurality of channels in each stage; andat least one permeate compartment disposed opposite at least one channel, the filtration membrane disposed therebetween, and wherein the at least one diafiltration flow passage fluidly couples the at least one permeate compartment to the feed manifolds in selected preceding stages.
  • 14. The system of claim 13 further comprising a pump disposed between the at least one permeate compartment and the feed manifolds in selected preceding stages.
  • 15. The system of claim 7 further comprising at least one permeate compartment disposed adjacent at least one channel of at least one of the plurality of stages and having at least one permeate distributor fluidly coupled to the at least one permeate compartment.
  • 16. The system of claim 7 further comprising a first stage of the plurality of stages having a greater number of channels than a second stage of the plurality of stages following the first stage.
  • 17. The system of claim 1 wherein the inlet width of at least one channel of at least one of the plurality of stages is 1.2 times greater than the outlet width of the at least one channel of at least one of the plurality of stage.
  • 18. The system of claim 1 further comprising at least one change in a channel property between at least one channel of a first stage and at least one channel of a second stage following the first stage.
  • 19. The system of claim 18 the channels of the first stage and the second stage each further comprising a feed spacer disposed adjacent the filtration membrane and wherein the property change is a change in the hydraulic diameter of the feed spacer.
  • 20. The system of claim 18 wherein the property change is at least one of: a change in the channel cross-sectional area;a change in specific membrane area;a change in dimensionless length;a change in permeate control; anda change in the filtration membrane properties.
  • 21. The system of claim 20 wherein the property change is monotonic between the first stage and a plurality of following stages.
  • 22. The system of claim 20 wherein the change in the filtration membrane properties is at least one of: a change in membrane permeability; anda change in the molecular weight cut off of the membrane.
  • 23. The system of claim 1 wherein the dimensionless length of the system is greater than about 4,000 and the dimensionless length of the at least one of the plurality of stages is less than about 3,500.
  • 24. The system of claim 23 further comprising a first stage having a greater number of substantially identical channels than a second stage following the first stage.
  • 25. The system of claim 1 further comprising a housing and wherein the plurality of stages are disposed within the housing.
  • 26. The system of claim 25 further comprising at least one cassette wherein the housing comprises flat plates for holding the at least one cassette.
  • 27. The system of claim 25 wherein the housing comprises a tubular shell for holding at least one spiral-wound cartridge.
  • 28. The system of claim 25 wherein the housing comprises a hollow fiber assembly.
  • 29. An internally staged filtration system comprising: a housing;a plurality of stages disposed within the housing, each stage having a plurality of channels comprising an filtration membrane, each stage being in fluid communication with each adjacent stage preceding it and being in fluid communication with each adjacent stage that follows it, and at least two stages form a serial flow path; andwherein a filtration property of a first stage and a second stage following the first stage differ to maintain separation performance.
  • 30. The system of claim 29 further comprising at least one permeate compartment disposed adjacent at least one channel of at least one of the plurality of stages and having at least one permeate distributor fluidly coupled to the at least one permeate compartment.
  • 31. The system of claim 29 wherein the filtration property is at least one of the cross-sectional flow area of the stage; the specific membrane area of the stage;the number of channels in the stage;the hydraulic diameter of a feed spacer disposed adjacent the membrane and within at least one channel of a stage; andthe filtration membrane properties.
  • 32. The system of claim 31 wherein the change in the cross-sectional area is provided by a ratio of the cross-sectional area of the first stage to the cross-sectional area of the second stage being greater than about 1.1.
  • 33. The system of claim 31 wherein the change in the cross-sectional area is provided by a ratio of the cross-sectional area of the first stage to the cross-sectional area of the second stage being less than about 0.8.
  • 34. The system of claim 31 wherein a change in the membrane properties comprises a change in the molecular weight cut off of the membrane.
  • 35. The system of claim 29 wherein at least one channel has an inlet and an outlet and has a cross-sectional area which decreases from the inlet to the outlet.
  • 36. The system of claim 29 wherein the specific membrane area of at least one channel is greater than about 40 cm−1 and the dimensionless length of the system is greater than about 2,000 and the dimensionless length of at least one of the plurality of stages is less than about 6,000.
  • 37. The system of claim 29 wherein the plurality of channels comprises a plurality of hollow fiber membranes; and further comprising a plurality of cylindrical flow diverters disposed within the housing substantially parallel to the hollow fiber membranes providing a plurality of stages.
  • 38. The system of claim 37 wherein the plurality of cylindrical flow diverters are disposed to provide a different number of channels per stage.
  • 39. A separation module for the filtration of liquids comprising: a housing; andat least one hollow fiber membrane and having a hydraulic permeability greater than about 2 lmh/psi disposed within the housing forming a flow channel, the flow channel having a membrane area, a void volume, a length, and the dimensionless length of the at least one hollow fiber filtration membrane is greater than about 10,000, and a specific membrane area expressed as a ratio of the membrane area to the void volume wherein the specific membrane area of the at least one hollow fiber is greater than about 50 cm−1.
  • 40. The module of claim 39 wherein the specific membrane area is greater than about 80 cm−1.
  • 41. The module of claim 39 wherein the specific membrane area is greater than about 130 cm−1.
  • 42. A filter module for filtering a fluid mixture comprising: a housing;a membrane disposed within the housing having a first surface;a feed spacer disposed adjacent the first surface of the membrane; andwherein the spacer and the membrane form at least one channel, the at least one channel disposed to establish a tangential flow of the fluid mixture over the first surface of the membrane and the at least one channel having a membrane area, a void volume, a length and a specific membrane area expressed as a ratio of the membrane area to the void volume and a dimensionless length expressed as a product of the channel length and the specific membrane area; andwherein the specific membrane area of the at least one channel is greater than about 40 cm−1, the dimensionless length of the at least one channel is greater than about 3,000, and the at least one channel having a width generally decreasing in the direction of the tangential flow.
  • 43. The module of claim 42 further comprising a plurality of ribs formed adjacent the feed spacer; and wherein the decreasing width is provided by the plurality of ribs.
  • 44. The module of claim 43 wherein the width of the at least one channel decreases by a factor greater than about two from an inlet of the channel to an outlet of the at least one channel.
  • 45. The module of claim 43 wherein the width of the at least one channel decreases by a factor greater than about 4 from an inlet of the at least one channel to an outlet of the at least one channel.
  • 46. The module of claim 45 wherein the at least one channel has a dimensionless length greater than about 4,000.
  • 47. The module of claim 43 further comprising: a center tube disposed within the housing;a second membrane disposed opposite said membrane forming a spirally wound membrane element around the center tube; andwherein the specific membrane area is greater than about 50 cm−1 and the width of the at least one channel decreases by a factor greater than about two from an inlet of the at least one channel to an outlet of the at least one channel.
  • 48. The module of claim 47 wherein the width of the channel decreases by a factor greater than about four from an inlet of the channel to an outlet of the channel.
  • 49. The module of claim 42 wherein the housing comprises a cassette and the specific membrane area of the at least one channel is greater than about 50 cm−1 and the dimensionless length of the at least one channel is greater than about 3,000.
  • 50. The cassette of claim 49 wherein the dimensionless length of the at least one channel is greater than about 4,000.
  • 51. The cassette of claim 49 further comprising a second filtration membrane disposed adjacent to a second surface of the at least one feed spacer and opposite the first filtration membrane.
  • 52. The cassette of claim 49 wherein the feed spacer comprises a turbulence-promoting spacer.
  • 53. An internally staged filter module comprising: a housing;a plurality of stages disposed within the housing, each stage having a plurality of channels comprising a filtration membrane and at least one manifold in fluid communication with the plurality of channels, each stage being in fluid communication with each adjacent stage preceding it and being in fluid communication with each adjacent stage that follows it; andat least one diafiltration distributor disposed within the housing and in fluid communication with the at least one manifold of selected ones of the plurality of stages and having an inlet for supplying a diafiltrate.
  • 54. The module of claim 53 the at least one diafiltration distributor comprising at least one counter current flow passage fluidly coupling the permeate from at least one channel in a first stage as the diafiltrate to at least one channel in a selected preceding stage.
  • 55. The module of claim 53 wherein the at least one diafiltration distributor further comprises a plurality of diafiltration flow passages fluidly coupling the feed manifolds to the diafiltrate inlet.
  • 56. The module of claim 55 wherein each of the plurality of diafiltration flow passages has a hydraulic resistance so as to introduce a predetermined volume of the diafiltrate into the at least one manifold.
  • 57. The module of claim 56 further comprising a channel inlet fluidly coupled to an initial one of the plurality of channels and wherein the diafiltrate flow passage inlet pressure is about twice the channel inlet pressure.
  • 58. The module of claim 55 further comprising a channel inlet fluidly coupled to an initial one of the plurality of channels and a channel outlet fluidly coupled to a last one of the plurality of channels, and wherein the at least one diafiltration distributor has a predetermined hydraulic resistance wherein the diafiltrate flow passage pressure is four times the average pressure difference between the channel inlet and outlet pressure.
  • 59. The module of claim 53 further comprising a diafiltration spacer disposed in the at least one diafiltration flow passage providing a hydraulic resistance predetermined to control the flow rate of a diafiltrate along the at least one diafiltration flow passage.
  • 60. The module of claim 53 wherein the housing is a cylindrical housing comprising and outer shell, an inner annular support ring and a plurality of supports coupled to the inner annular support ring; the diafiltration distributor comprises a diafiltration flow passage disposed within the cylindrical housing and coupled to the plurality of supports; andthe plurality of channels comprise a plurality of hollow fiber membranes disposed within housing between the outer shell and the inner annular support ring
  • 61. The method of claim 53 wherein the specific membrane area of the at least one channel is greater than about 40 cm−1, and the dimensionless length of at least one of the plurality of stages is less than about 3,000.
  • 62. A single pass filter system comprising: a stacked configuration comprising: a first plurality of cassettes, each cassette having a feed manifold, a retentate manifold, at least one permeate channel, and at least one flow channel fluidly coupled to the feed manifold and to the retentate manifold, the flow channels of the plurality of cassettes fluidly coupled in parallel;a staging plate disposed adjacent the first plurality of cassettes;at least one second cassette having a feed manifold and a retentate manifold, the staging plate disposed between the first plurality of cassettes and the at least one second cassette; andwherein the staging plate fluidly couples the retentate manifold of one of the cassettes of the first plurality of cassettes to the feed manifold of the second cassette and blocks the flow from the feed manifold of one of the cassettes of the first plurality of cassettes, thereby serializing the retentate flow through the system.
  • 63. The system of claim 62 further comprising a top plate having a feed port fluidly coupled to at least one of the first plurality of cassettes and a bottom plate having a retentate port in fluid communication with the at least one flow channel of the at least one second cassette.
  • 64. The system of claim 62 wherein the staging plate further comprises a diafiltration port in fluid communication with the feed manifold of one of the cassettes of the first plurality of cassettes.
  • 65. A method for filtering a liquid feed comprising: continuously supplying the feed stream in to at a specific feed flow rate of less than about 200 lmh into a membrane separation module and having at least one channel having specific membrane area greater than about 40 cm−1; andoperating the separation module in a single pass tangential flow filtration mode.
  • 66. The method of claim 65 wherein operating the separation module in a single pass tangential flow filtration mode further comprises controlling at least two of: the feed flow rate;the retentate flow rate;the permeate flow rate;the specific feed rate;the transmembrane pressure (TMP) of the at least one channel; andthe transchannel pressure (TCP) of the at least one channel.
  • 67. The method of claim 66 further comprising selecting a conversion factor and iteratively adjusting at least one of: the feed pressure into the at least one channel; anda retentate pressure of the at least one channel;in response to measuring the conversion.
  • 68. The method of claim 66 further comprising selecting a purification factor and iteratively adjusting a diafiltration volume and at least one of: the feed pressure into the at least one channel; andthe retentate pressure of the at least one channel;in response to measuring the purification.
  • 69. The method of claim 65 further comprising supplying the feed at a specific feed flow rate of less than about 100 lmh.
  • 70. The method of claim 65 further comprising controlling at least one permeate collection channel being at least partially formed by the filtration membrane disposed adjacent the at least one channel, having a permeate port and otherwise sealed.
  • 71. The method of claim 65 wherein the membrane comprises an ultrafiltration membrane.
  • 72. The method of claim 71 further comprising setting the conversion to a predetermined factor by controlling the ratio of the feed stream flow rate to the retentate stream flow rate.
  • 73. The method of claim 72 wherein the ratio of the feed stream flow rate to the retentate stream flow rate is provided by coupling pumps in the feed and retentate streams.
  • 74. The method of claim 71 further comprising setting the conversion to a predetermined factor by controlling the ratio of the feed stream flow rate to the permeate stream flow rate.
  • 75. The method of claim 71 wherein the module further comprises a plurality of stages having a plurality of channels and further comprising controlling the transmembrane pressure in each stage independently of the feed pressures in the stage by using a permeate distributor to control the permeate flow in the stage.
  • 76. The method of claim 75 further comprising operating with a feed pressure of greater than about 60 psi.
  • 77. The method of claim 71 wherein the filtration separation module is at least one of: a hollow fiber cartridge;a plate-and-frame assembly,a cassette, anda spiral wound module.
  • 78. The method of claim 77 further comprising controlling the specific feed flow rate such that the average fluid residence time in the hollow fiber cartridge is greater than about 20 seconds.
  • 79. The method of claim 77 further comprising controlling the specific feed flow rate such that the average fluid residence time in the cassette is greater than about 2 seconds.
  • 80. The method of claim 71 wherein the module further comprises a plurality of stages having a plurality of channels having specific membrane areas greater than about 40 cm−1.
  • 81. The method of claim 71 wherein the module further comprises a plurality of stages having a plurality of channels and at least one diafiltrate distributor having a plurality of diafiltration flow passages, and further comprising adding a diafiltrate through the at least one diafiltrate distributor and distributing the diafiltrate to corresponding ones of the plurality of channels.
  • 82. The method of claim 81 further comprising supplying the diafiltrate in a selected stage, the diafiltrate source pressure greater than about one and one half times the feed pressure in the channel to reduce the effect of varying channel pressures on diafiltrate flow rate.
  • 83. The method of claim 81 further comprising supplying the diafiltrate in a selected stage at a source pressure of about 10 psi greater than the feed pressure in the channel to reduce the effect of varying channel pressures on diafiltrate flow rate.
  • 84. The method of claim 81 further comprising operating the filtration separation module in a counter current diafiltration mode by fluidly coupling the permeate from at least one permeate compartment as the diafiltrate to at least one preceding channel.
  • 85. The method of claim 65 wherein the module is an internally staged filtration separation module.
  • 86. The method of claim 65 wherein the membrane comprises a microfiltration membrane.
  • 87. A method for efficiently using filtration membranes for processing a solute in a feed stream while achieving a high conversion factor and reducing system requirements, hold-up volume and processing time, the method comprising: operating a plurality of stages, at least one stage comprising a plurality of substantially identical, long thin channels comprising the filtration membrane, in SPF mode;maintaining separation performance in at least one of the plurality of stages by varying at least one property of at least one stage relative to a preceding stage; andcontinuously supplying the feed stream at a specific feed flow rate of less than about 200 lmh.
  • 88. The method of claim 87 further comprising serially combining the plurality of stages to provide at least one flow path.
  • 89. The method of claim 87 wherein the channels are characterized by having a specific membrane area greater than about 40 cm−1.
  • 90. The method of claim 89 wherein the sum of the dimensionless lengths of the plurality of stages is greater than about 2,000.
  • 91. The method of claim 87 wherein the dimensionless length of each stage is less than about 6,000.
  • 92. The method of claim 87 wherein varying at least one stage property comprises varying at least one of: the number of channels;the cross-sectional area of the stage along the flow path;the hydraulic diameter of a spacer disposed within the channels;the specific membrane area; andthe filtration membrane properties.
  • 93. The method of claim 87 wherein the separation performance is maintained by affecting in at least one stage at least one of: a transmembrane pressure;a feed stream velocity; anda bulk concentration of the solute.
  • 94. The method of claim 87 wherein continuously supplying the feed stream further comprises operating a feed supply device to provide an inlet pressure greater than about 60 psi.
  • 95. The method of claim 87 further comprising adding a diafiltrate to the feed stream by fluidly coupling at least one channel in the at least one stage to at least one diafiltrate flow passage.
  • 96. The method of claim 95 wherein varying at least one property of the stage comprises adding diafiltrate to the at least one stage at a predetermined rate.
  • 97. The method of claim 96 wherein the predetermined rate is substantially equal for selected ones of the plurality of stages.
  • 98. The method of claim 97 further comprising supplying diafiltrate at a source pressure greater than the feed pressure using a diafiltration distributor.
  • 99. The method of claim 87 wherein maintaining separation performance further comprises controlling the flow of a permeate stream from at least one stage.
  • 100. The method of claim 99 wherein controlling the flow of the permeate stream from at least one stage comprises predetermining the hydraulic resistance of a plurality of permeate flow passages of a permeate distributor.
  • 101. The method of claim 87 wherein maintaining separation performance further comprises controlling transmembrane pressure to substantially equalize the maximum transmembrane pressure in each of the plurality of stages.
  • 102. The method of claim 87 wherein maintaining separation performance further comprises maintaining transmembrane pressure in each of the plurality of stages below a value of about 40 psi using at least one permeate distributor.
  • 103. The method of claim 87 wherein the plurality of stages are disposed in at least one of: a hollow fiber cartridge;a plate-and-frame assembly,a cassette, anda spiral wound module.
Provisional Applications (2)
Number Date Country
60755009 Dec 2005 US
60754813 Dec 2005 US