Method for sealing a hollow fiber membrane module in a case

Claim 2

A process for sealing a hollow fiber membrane separation module into a case in which the hollow fiber membrane separation module comprises a plurality of hollow fibers arranged in a bundle surrounding a core and having tubesheets surrounding each end of the bundle which bind the hollow fibers together, the process comprising: A. positioning the hollow fiber separation module within a case, while the case is in a substantially vertical position; B. providing first and second protective tubesheet caps adjacently disposed upon the tubesheets defining first and second protected and unprotected portions of the tubesheets, respectively, each protected portion and adjacently disposed protective tubesheet cap defining a space overlying the ends of the hollow fibers; C. introducing a resin through an opening into the first end of the case in an amount sufficient to substantially fill the region defined by the first protective tubesheet cap, the first unprotected portion, and the interior of the case such that said resin encompasses a substantial portion of the first tubesheet; D. curing the resin; E. reversing the position of the case; F. introducing a resin through an opening into the second end of the case in an amount sufficient to fill the regions defined by the second protective tubesheet cap, the second unprotected portion, and the interior of the case such that said resin encompasses a substantial portion o the second tubesheet; G. curing the resin; and H. providing openings at each end of the case through the cured resin, penetrating to the space overlying the ends of the hollow fibers, thereby providing flow paths for introducing and/or withdrawing fluids through said hollow fiber membrane separation module.

Claim 3

The process of claim 1 wherein the hollow fiber separation module comprises: A. a plurality of hollow fiber membranes, wherein the hollow fiber membranes are arranged in a bundle and are adapted for the separation of one or more fluids from one or more other fluids in a feed fluid mixture: B. a first tubesheet comprised of a thermoset or thermoplastic polymeric material located at the first end of the bundle, arranged such that the hollow fiber membranes are embedded in the first tubesheet and communicate through the first tubesheet and are open on the opposite face of the first tubesheet: C. a second tubesheet comprised of a thermoset or thermoplastic polymeric material located at the second end of the bundle opposite the first end of the bundle, arranged such that the hollow fiber membranes are embedded in the second tubesheet and communicate through the second tubesheet and are open on the opposite face of the second tubesheet: D. a core about which is arranged the hollow fiber membrane bundle, further arranged such that the core extends through and is bonded to the first tubesheet and the second tubesheet: and E. one or more means for channeling flow of fluid which permeates through the hollow fiber membranes to the region between the two tubesheets which is outside of the hollow fiber membranes, such means for channeling flow arranged to channel flow of fluid which permeates through the hollow fiber membranes in the longitudinal direction parallel to the core, wherein the means for channeling flow have one end embedded in or attached to the second tubesheet and the second end located at a distance from the first tubesheet, said distance between the second end of the means for channeling flow and the first tubesheet being sufficient to withdraw the fluid which permeates through the hollow fiber membranes and flows along the means for channeling flow.

Claim 4

The process of claim 2 wherein the hollow fiber membrane separation module further comprises: F. a means for introducing a sweep fluid into the core, wherein the core is adapted to introduce the sweep fluid into the portion of the module between the first and second tubesheets which is outside of the hollow fiber membranes.

Claim 5

The process of claim 3 wherein the hollow fiber membrane separation module comprises an exterior means of channeling flow encircles the exterior of the hollow fiber bundle, wherein the first end of said exterior means for channeling flow is attached to or embedded in the second tubesheet, and the second end of said exterior means for channeling flow is located a distance from the first tubesheet, wherein the distance between the second end of said exterior means for channeling flow and the first tubesheet is sufficient to withdraw the permeate fluid and sweep fluid: and the module has at least one interior means for channeling flow in the interior of the hollow fiber bundle, wherein the first end of such interior means for channeling flow is located near the second tubesheet, wherein the distance between the second tubesheet and the interior means for channeling flow is sufficient to allow the sweep fluid to flow into flow channels created by the interior means for channeling flow, and the second end of the interior means for channeling flow is located near the first tubesheet, wherein the distance between the second end of the interior means for channeling flow and the first tubesheet is sufficient to withdraw the permeate fluid and sweep fluid.

Claim 6

The process of claim 2 wherein the hollow fiber membrane separation module comprises an exterior means of channeling flow encircles the exterior of the hollow fiber membrane bundle, wherein the first end of said exterior means for channeling flow is attached to or embedded in the second tubesheet, and the second end of said exterior means for channeling flow is located a distance from the first tubesheet, wherein the distance between the second end of said exterior means for channeling flow and the first tubesheet is sufficient to withdraw the permeate fluid and the device has at least one interior means for channeling flow in the interior of the hollow fiber membrane bundle, wherein the first end of such interior means for channeling flow is located near the second tubesheet, wherein the distance between the second tubesheet and the interior means for channeling flow is sufficient to allow the permeate fluid to flow into flow channels created by the interior means for channeling flow, and the second end of the interior means for channeling flow is located near the first tubesheet, wherein the distance between the second end of the interior means for and the first tubesheet is sufficient to withdraw the permeate fluid.

Claim 7

The process of claim 1 wherein the hollow fiber membranes have a dense discriminating region which separates one or more fluids from one or more other fluids.

Claim 8

The process of claim 6 wherein the hollow fiber membranes are comprised of at least one polymeric material selected from the group consisting of polysulfone, polyethersulfone, polyimide, polyestercarbonate, and polycarbonate.

Claim 9

The process of claim 7 wherein the hollow fiber membranes are comprised of at least one polymeric material selected from the group consisting of polyestercarbonate and polycarbonate.

Claim 10

The process of claim 1 wherein the membranes are microporous.

Claim 11

The process of claim 9 wherein the membranes are comprised of at least one polymeric material selected from the group consisting of polyolefins, fluorinated polyolefins, polystyrene, polyetherketone, and polyetheretherketone.

Claim 12

The process of claim 10 wherein the membranes are comprised of at least one polyolefin selected from the group consisting of polyethylene, polypropylene, and poly-4-methylpentene.

Claim 13

The process of claim 2 wherein the hollow fiber membrane separation module comprises means for channeling flows which comprise impermeable baffles which extend about 50 to about 95 percent of the bundle length between the two tubesheets.

Claim 14

The process of claim 1 wherein the hollow fiber membrane bundle is bias wrapped.

Claim 15

The process of claim 1 wherein the hollow fiber membrane bundle is parallel wrapped.

Claim 16

The process of claim 1 wherein the case comprises a pressure vessel.

Claim 17

The process of claim 1 wherein the resin comprises an epoxy resin.

Claim 18

The process of claim 1 wherein the resin comprises a polyurethane resin.

Claim 19

The process of claim 2 wherein the core is adapted to return fluid which does not permeate through the hollow fiber membranes in the vicinity of the second tubesheet to the vicinity of the first tubesheet.