Scale Up and Validation of Novel Tri-Bore PVDF Hollow Fiber Membranes for Membrane Distillation Application in Desalination and Industrial Wastewater Recycling

Novel tri-bore polyvinylidene difluoride (PVDF) hollow fiber membranes (TBHF) were scaled-up for fabrication on industrial-scale hollow fiber spinning equipment, with the objective of validating the membrane technology for membrane distillation (MD) applications in areas such as desalination, resource recovery, and zero liquid discharge. The membrane chemistry and spinning processes were adapted from a previously reported method and optimized to suit large-scale production processes with the objective of translating the technology from lab scale to pilot scale and eventual commercialization. The membrane process was successfully optimized in small 1.5 kg batches and scaled-up to 20 kg and 50 kg batch sizes with good reproducibility of membrane properties. The membranes were then assembled into 0.5-inch and 2-inch modules of different lengths and evaluated in direct contact membrane distillation (DCMD) mode, as well as vacuum membrane distillation (VMD) mode. The 0.5-inch modules had a permeate flux >10 L m(−2) h(−1), whereas the 2-inch module flux dropped significantly to <2 L m(−2) h(−1) according to testing with 3.5 wt.% NaCl feed. Several optimization trials were carried out to improve the DCMD and VMD flux to >5 L m(−2) h(−1), whereas the salt rejection consistently remained ≥99.9%.