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Enhancement of Hydrodynamic Conditions for Ultrafiltration Fouling Mitigation Using 3D Printed Elements

Year: 2026
Type: dissertation
Abstract: This Ph.D. study presents a sustainable strategy to enhance hydrodynamics and mitigate membrane fouling in ultrafiltration (UF) systems through the integration of 3D printed turbulence promoters (dead-end UF) and spacers (cross-flow vibratory shear enhanced processing, VSEP). The approach aims to intensify shear forces at the membrane surface, thereby improving filtration performance and reducing reliance on chemical cleaning. Prior to integrating the 3D printed elements, several pretreatment methods were evaluated to decrease fouling. Coagulation and coagulation-flocculation proved most effective among chemical approaches, while microfiltration outperformed ultrasonic treatment among physical methods. Operational parameters were optimized to establish baseline conditions. For dead-end UF, a membrane cut-off of 20 kDa, transmembrane pressure (TMP) of 0.3 MPa, and stirring speed of 400 rpm were identified as optimal. In the cross-flow VSEP system, 0.6 MPa and 2.54-cm vibration amplitude provided the best balance between flux, rejection, and resistance. In the dead-end system, the prototype turbulence promoter reduced filtration time by up to 2.7 times, tripled permeate flux, and decreased total resistance (Rt) by approximately 78%. Increased stirring enhanced flux and fouling mitigation, while higher TMP increased flux but also Rt. Among promoter geometries, PLA-UE and PLA-S achieved ~15% flux improvement, while PLA-S reduced Rt by 36.5%. Material selection influenced performance: resin promoters delivered the best results (22.5% flux increase, 21% Rt reduction), followed by TPU and stainless steel. In the VSEP system, four spacer geometries were evaluated. PETG and PCTG were identified as optimal materials due to superior mechanical durability under vibration. The conical spacer design, combined with vibration, achieved up to 300% flux enhancement and over 85% reduction in Rt, with modest improvements in COD rejection. CFD simulations revealed improved pressure distribution, altered velocity fields, and increased wall shear stress beneath promoters and spacers, confirming localized turbulence enhancement. Membrane surface analyses (SEM, AFM) showed severe fouling in control cases, while spacer- and vibration-assisted configurations exhibited cleaner and more homogeneous surfaces. These findings validate 3D printed hydrodynamic modifiers as an effective, scalable solution for fouling mitigation and performance enhancement in UF systems treating dairy wastewater.
Language: English
Open Access status: green
OpenAlex ID: W7172370768
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