On Demand Treatment of Wastewater Using 3D-Printed Membrane

Executive Summary

This project will demonstrate on-demand separation of multicomponent and multiphase water-oil mixtures using 3D-printed membranes. It is focused on wastewater treatment that is critical to the chemical industry. Application and adoption of intensified process design and 3D-printed membranes offers the prospect of revolutionizing the multicomponent and multiphase water-oil separation. While conventional membranes have been utilized in oil-water separation for some time, demonstration of 3D-printed membranes with well-controlled local structure, which renders the membrane to have multi-selectivity, is still lacking to-date. Moreover, wastewater treatment often involves many steps, and a more intensified process, which is enabled by a single multi-selectivity membrane, is highly desirable. The driving force for the proposed membrane is surface selectivity and topology rather than pressure and has been demonstrated in the laboratory. The present project aims to be a first-of-its-kind demonstration of the validity of the above-mentioned concept for the chemical industry.

Technical Challenge

Wastewater is a multicomponent and multiphase oil-water mixture. The state-of-the-art membrane is made of one material and has one pore size. As a result, each membrane has only one “selectivity” and cannot separate the multicomponent and multiphase mixture in a single processing step. Although membrane technology in general is more energy efficient compared to conventional separation methods, the multi-step processing increases the cost, energy and physical footprint. Although there is no fundamental hurdle to integrate the multiple membrane separation, i.e., each membrane with different selectivity, into a single-step membrane process, this has not yet been demonstrated. 

Potential Impact

Wastewater is a multicomponent and multiphase oil-water mixture. The state-of-the-art membrane is made of one material and has one pore size. As a result, each membrane has only one “selectivity” and cannot separate the multicomponent and multiphase mixture in a single processing step. Although membrane technology in general is more energy efficient compared to conventional separation methods, the multi-step processing increases the cost, energy and physical footprint. Although there is no fundamental hurdle to integrate the multiple membrane separation, i.e., each membrane with different selectivity, into a single-step membrane process, this has not yet been demonstrated.

Resources

In this project, University of Pittsburgh, Lubrizol Corporation and Siemens are working collaboratively. PI Lei Li (Associate Professor, U of Pittsburgh) has extensive expertise in surface science and membrane. Jointly with Lubrizol he has established a state-of-the-art membrane laboratory at the University of Pittsburgh, which incorporates 3D-printing technology and various surface coatings into the membrane. Nanoscale Fabrication and Characterization Facility (NFCF) at the U of Pittsburgh provides a variety of fabrication and characterization tools to support the proposed efforts. Co-PI Cliff Kowall (Senior Technical Fellow, Lubrizol Corp) has 44 years of experience including 21 years at Lubrizol, with deep experience in process development, project management and process innovation. He also is adjunct faculty at Pitt with a weekly presence over the past 5 years to focus collaboration between faculty and corporate interests. Further support is  provided by the Lubrizol Process Technology Leadership Team consisting of Kowall plus other Engineers in process development. Ravi Aglave (Ph.D. (Chemical Engineering), Siemens Software Systems) provides the technical training and support on the SolidEdge and/or NX CAM software throughout the project period.