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Desalination
journal homepage: www.elsevier.com/locate/desal
A R T I C L E I N F O A B S T R A C T
Keywords: Treatment of produced water in the petroleum industry has been a challenge worldwide. In this study, we
Hollow fibers evaluated the use of direct contact membrane distillation (DCMD) for this purpose, removing oil and dissolved
Polyoxadiazole elements and supplying clean water from waste. We synthesized fluorinated polyoxadiazole, a highly hydro-
Produced water phobic polymer, to fabricate hollow fiber membranes, which were optimized and tested for simulated produced
Membrane distillation
water and real produced water treatment. The process performance was investigated under different operating
parameters, such as feed temperature, feed flow velocity and length of the membrane module for 4 days. The
results indicate that by increasing feed temperature and feed flow rate the vapor flux increases. The flux de-
creased with increasing the length of the module due to the decrease of the driving force along the module. The
fouling behavior, which corresponds to flux decline and cleaning efficiency of the membrane, was studied. The
performance of the fabricated hollow fiber membranes was demonstrated for the treatment of produced water,
complying with the industrial reuse and discharge limits.
⁎
Corresponding author.
E-mail address: suzana.nunes@kaust.edu.sa (S.P. Nunes).
1
These authors contributed equally to this work (co–first authors).
https://doi.org/10.1016/j.desal.2017.12.014
Received 29 August 2017; Received in revised form 2 December 2017; Accepted 10 December 2017
0011-9164/ © 2017 Elsevier B.V. All rights reserved.
J. Xu et al. Desalination 432 (2018) 32–39
processes), is a low hydrostatic pressure process (in comparison to 25:75 (vol%) glycerol/water solution overnight, slowly air dried and
pressure driven membrane process like reverse osmosis (RO)), is com- stored in dry environment. Before use, the fibers were extensively wa-
pact (for offshore deployment), simple, and is claimed to be less sus- shed with water to remove the glycerol.
ceptible to fouling than other membrane processes [5-7]. Most of the
published MD works focus on seawater desalination. Only few groups 2.3. Membrane characterization
have explored it for the treatment of produced water by MD [8–12].
Whether desalination or treatment of produced water/wastewater, the 2.3.1. Hollow fiber membrane morphology
membranes for MD should be highly porous and hydrophobic to pre- The membrane morphology was investigated by field emission
vent the feed solution from entering into the pores (high liquid entry scanning electron microscopy (SEM) (FEI Quanta 600 FE or Nova Nano
pressure). Commonly used membranes for MD are polytetra- SEM microscopes) at accelerating voltage of 5 kV. The fibers were dried
fluorethylene (PTFE), polypropylene (PP) and polyvinylidene fluoride overnight and were carefully fractured in liquid nitrogen for cross
(PVDF) with typical pore sizes varying from 0.1 μm to 1 μm sectional SEM analysis. The fibers were sputter coated with Iridium
[5,9,13–22]. The MD membrane performance can be enhanced by dif- (∼ 3 nm-thick, Quorum Q150T ES) to make the polymer surface con-
ferent means, such as incorporation of nanoparticles [23–33], graphene ductive for surface analysis.
oxide [34] or use of alternative solvents such as triethyl phosphate
(TEP) [35] for the membrane manufacture. Few efforts have been 2.3.2. Pore size distribution and membrane liquid entry pressure (LEP)
dedicated to development of new polymers, tailor-made for the needs of The membrane pore size distribution was estimated by using
MD [36–37]. Our group has previously reported polyazole-based Porolux™ 1000 (Porometer.com, Belgium), at the pressure range from 0
membranes for water desalination by MD [38–40]. Polyoxadiazole up to 34.5 bar and using perfluoroether (Porefil) with a surface tension
could be an excellent material comparable to ceramic membrane due to of 16 dynes cm− 1 as pore filler. The same analysis supplied the liquid
its high thermal and oxidative stability and good mechanical strength entry point (LEP), which is the minimum pressure required for liquid to
[41]. pass through the membrane.
In this study, fluorinated polyoxadiazole hollow fiber membranes
have been fabricated, characterized and optimized for produced water 2.4. DCMD experimental set-up
treatment. Synthetic and real produced water samples were in-
vestigated. Various parameters influencing the permeate flux and re- The schematic of the experimental setup for cross-flow DCMD is
jection factors for salts and organic compounds have been investigated shown in Fig. 1.
in DCMD operation. The performance of polyoxadiazole hollow fiber All the experiments were carried out in modules containing 3 to
membranes, as well as their fouling susceptibility, have been in- 4 hollow fibers, using 6 mm polyethylene tube housings, which were
vestigated in long-term separation/operation stability tests. approximately 15 cm long. The fibers were carefully inserted into the
polyethylene tube and sealed with epoxy glue (Devcon, 2 components
2. Materials and methods flow mixture, 5 min epoxy, 1500 psi strength). Fig. 2 shows the hollow
fiber modules. At the beginning and end of the housing, T-junctions
2.1. Materials and chemicals were placed to circulate cold water in the shell side to condense the
permeating water vapor. Before measuring the vapor flux, the fibers
Fluorinated polyoxadiazole (f-POD) was synthesized according to were completely dried to regain their intrinsic hydrophobicity. The
previously reported procedure [40]. N-methyl-2-pyrrolidinone (NMP, vapor flux (JV) through the membrane was measured by pumping
≥ 99.5%, Merck) was used as solvent to prepare hollow fiber spinning (peristatic pumps, Cole Parmer) hot feed (produced water) through the
dope solution. Methanol (HPLC grade, Fischer scientific) and glycerol lumen of the hollow fiber and cold RO water (countercurrent flow)
(≥ 99%, Sigma Aldrich) were used in the process hollow fiber fabri- through the shell side of the module. The change in weight of the
cation and long periods of storage. Produced water was supplied by permeate reservoir over time (10 min interval) at steady state was re-
Saudi Aramco, from one of the drilling locations in Saudi Arabia. corded, using the data acquisition software on to a computer. Si-
multaneously temperatures, pressures and flowrates were recorded. The
2.2. Fiber spinning data presented in this work is an average of at least 3 hollow fiber
modules prepared from different sections of the total fiber spun.
The synthesized polyoxadiazole was washed with methanol to re- The salt rejection (SR) and permeate vapor flux (Jv) were calcu-
move any moisture and dried in vacuum oven at 80 °C overnight, before lated, using the following equations:
using it to prepare dope solution. The dried polymer flakes were added
Cp ⎞
to NMP in small portions to avoid lump formation and stirred at SR% = ⎜⎛1 − ⎟ × 100
600 rpm for 24 h at 70 °C, using overhead mechanical stirrer and hot oil ⎝ Cf ⎠ (1)
bath. The prepared dope solution was loaded into the high-pressure
mp
syringe holder of the spinning machine and degassed to remove any air JV =
At (2)
bubbles entrapped within the solution.
A set-up was built to spin hollow fibers from the laboratory-syn- where Cp and Cf are the salt concentration of permeate and feed solu-
thesized polymers, with capacity for 20 to 30 g polymer. The dope tions, respectively, and mp is the mass of collected permeate, A is the
solution was loaded in a stainless steel syringe and extruded through effective membrane area, and t is the running time.
the spinneret using a high-pressure syringe pump (neMESYS high
pressure syringe pumps, Cetoni GmbH). The extruded polymer solution 2.5. Produced water analysis
was immersed in a water tank to form the hollow fibers by phase in-
version. The bore liquid was pumped through the needle of the spin- The total organic content was analyzed by Dohrmann Series Apollo
neret to form the lumen of the hollow fiber, using HPLC dual head gear 9000 TOC analyzer. Total dissolved solids (TDS) was analyzed, using an
pump (Lab Alliance ™). OAKTON conductivity/TDS meter.
The hollow fibers were washed by replenishing fresh water (purified
by RO) for at least 10 h (at room temperature and a few trials at 50 °C) 2.6. Treatment of produced water by DCMD
and stored in RO water for three days (exchanging the water every day)
to remove any residual solvent. Finally, the hollow fibers were kept in Real produced water supplied by Saudi Aramco was used as feed
33
J. Xu et al. Desalination 432 (2018) 32–39
Fig. 1. Schematic of cross flow hollow fiber membrane based DCMD bench scale experimental set-up (C1, C2 are conductivity sensors; P1, P2 are pressure sensors; T1, T2, T3, T4 are
temperature sensors).
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J. Xu et al. Desalination 432 (2018) 32–39
Fig. 3. SEM images of 19 wt% polyoxadiazole dope solution, fabricated with air gap of 30 cm, bore liquid flow rate of 5 mL/min and 80:20 (vol%) NMP: water mixture as bore liquid.
Table 1
Fluorinated polyoxadiazole hollow fiber membranes fabricated with different bore liquid
compositions and dope flow rates, using a dope solution with 19 wt% polymer, air gap of
30 cm, and 5 mL/min bore liquid flow rate.
POD-1 6 0:100
POD-2 50:50
POD-3 60:40
POD-4 70:30
POD-5 80:20
POD-6 5 80:20
Fig. 5. DCMD permeate flux and salt rejection measured for various fabricated hollow
fibers (feed solution 90 g/L NaCl; feed flow rate: 50 mL/min; permeate flow rate: 50 mL/
min; one fiber per module).
High LEP values indicate that the tendency of pore wetting would be 3.2. Hollow fiber membrane performance for treatment of produced water
less pronounced and higher operational pressure difference could be by DCMD
tolerated. As shown in Fig. 4, POD 4 and POD 5 had the highest LEP
values, when compared to the other fabricated membranes. 3.2.1. MD tests with simulated produced water
The hollow fibers were tested in the DCMD experimental set-up, Before performing the MD experiments with fluorinated poly-
using first 90 g/L NaCl dissolved in deionized (DI) water, as test feed oxadiazole membranes using real samples of produced water as feed,
solution. The feed temperature was kept at 70 °C and the coolant simulated water containing crude oil of 0.1 g/L was used. The
35
J. Xu et al. Desalination 432 (2018) 32–39
Table 2 Table 3
Composition of simulated produced water. DCMD experimental conditions for treatment of produced water.
Fig. 7. Effect of the inlet feed (produced water) temperature on the permeate flux (4 Fig. 8. Effect of the feed (produced water) flow rate on the permeate flux (number of
fibers per module; feed flow rate: 155 mL/min; permeate flow rate: 340 mL/min). fibers per module: 4; feed temperature: 70 °C; permeate temperature: 20 °C).
36
J. Xu et al. Desalination 432 (2018) 32–39
Fig. 10. Experimental results showing hollow fibers long term performance and corre-
Fig. 9. Effect of the hollow fiber module length on the permeate flux (number of fibers
sponding salt rejection (number of fibers per module: 4; feed flow rate: 155 mL/min;
per module: 4; feed flow rate: 155 mL/min; permeate flow rate: 340 mL/min; feed tem-
permeate flow rate: 340 mL/min; feed temperature: 70 °C; permeate temperature: 20 °C).
perature: 70 °C; permeate temperature: 20 °C).
temperature difference and greater permeate flux. The feed flow rate first 100 h of operation (blue line shown in Fig. 11). One reason for the
must be well controlled in order to avoid membrane pore wetting, as flux decline might be fouling caused by salt scale, which could be
the transmembrane hydrostatic pressure (TMP) must be lower than the clearly observed in SEM images (Fig. 12). Fig. 12 shows the SEM images
liquid entry pressure (LEP). Higher flow rates above 250 mL/min were and corresponding elemental analysis performed by EDS, which in-
not tested due to the limitation of liquid entry pressure (LEP) of the dicate the occurrence of salt scaling on the surface of the membrane.
membrane, which was shown in Fig. 4. Once scaling occurs on the membrane surface, the membrane per-
meation can be recovered by effective cleaning. Membrane cleaning is
usually achieved by physical and chemical processes. For chemical
3.2.4. Effect of the length of membrane module on permeate flux
cleaning, a chemical agent should have a good solubility for the scale,
The effect of the module length on the performance was in-
while not causing a substantial damage to the membrane. In this study,
vestigated and the results are shown in Fig. 9. The flux significantly
only a physical method, deionized (DI) water flushing, was in-
decreased with the increase of the length of the membrane module.
vestigated, as we didn't observe severe fouling.
This is attributed to the increase of residence time as the length of
The efficiency of cleaning with DI water is shown in Fig. 11. The
the module increases. We assume that the cross-sectional area of the
results clearly indicate that the flux can be recovered to the initial
fluid channel is constant along the module, and then the following
value. The flux was stable (17–16 kg m− 2 h− 1) for about 90 h. Salt
equation can be used to calculate the residence time, which relates to
rejection was also higher than 99.5% after cleaning. The SEM images
flow rate and membrane length (module effective length):
(Fig. 12) and the results of EDS show that DI water cleaning is effective
Effective length of module to remove salt scale formed on the inner surface (lumen) of hollow
residence time(τ ) =
fluid velocity (4) fiber.
The increase of the effective length of module provides enough time 4. Conclusion
for the fluids to exchange mass and heat across the membrane. It causes
the decrease of temperature at the outlet of the membrane in the hot Nanoporous hydrophobic hollow fiber membranes were fabricated
side, which will cause the temperature difference across the membrane using fluorinated polyoxadiazole. Their performance was investigated
(the driving force of mass transfer) to decrease. This behavior is de- for treatment of produced water by DCMD. The influence of the bore
monstrated by the experimental results shown in Fig. 9. liquid composition during the hollow fiber fabrication on their perfor-
mance was clearly demonstrated. The vapor flux through the mem-
3.2.5. Long term experiment for real produced water branes increased with the increase of the NMP concentration in the bore
After the operational conditions optimization shown above, the fluid during the fiber fabrication. Furthermore, various operating
long-term performance stability was tested. The experiments were parameters, like feed inlet temperature, feed flow rate and module
performed with POD-5 hollow fibers, using real produced water (with length, were tested for the optimization. The permeate flux increased
84 g/L TDS, 41 mg/L TOC and 82 mS/cm conductivity). Long-term with the increase of the feed flow rate and significantly decreased with
experiments were carried out with feed and permeate inlet temperature the increase of the length of the membrane module.
of 70 °C and 20 °C, respectively. The feed and permeate flow rates were A stable water vapor flux of at least 12 kg m− 2 h− 1 and very high
maintained at 155 mL/min and 340 mL/min, respectively. The con- total dissolved solid (TDS) rejection of > 99.5% (conductivity of
ductivity of the produced water feed increased from 82 to 129 mS/cm, 194.7 μS/cm, corresponding to a salt concentration of 88 ppb) have
after 100 h DCMD operation, due to continuous recirculation of the been achieved during 100 h of continuous operation. Although this
retentate. The conductivity of the permeate was about 195 μS/cm, would be an acceptable value of salt content for many applications, a
which corresponds to salt rejection larger than 99.7% or salt con- continuous decrease of rejection could indicate that an undesirable
centration of condensed permeate water ≈0.088 mg/L or 88 ppb (the wetting is taking place or the substantial scaling on the membrane
minimum allowable standard for discharging produced water by China surface is locally increasing the salt concentration much higher levels.
environmental ministry is 10 mg/L). As shown in Fig. 10, the permeate Both factors could compromise extended long-term operation. Taking
flux for POD-5 membrane was stable during experiments, lasting for this concern into consideration, mild cleaning tests, consisting of
100 h. The permeate flux was maintained at 12.5–11.8 kg m− 2·h− 1. washing the membranes with DI water, were performed, and the flux
The permeate had 1.6 mg/L TOC and 197 TDS. could be recovered to the initial value.
The achieved results indicate that the DCMD process using fluori-
3.2.6. Fouling and cleaning study nated polyoxadiazole hollow fibers could be a viable solution for
A slight gradual decrease of the permeate flux occurred during the treatment of produced water with compositions similar to those
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J. Xu et al. Desalination 432 (2018) 32–39
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