3D CFD study of the effect of multi-layer spacers on membrane performance under steady flow

• Published in: Journal of membrane science 2019-06, Vol.580, p.256-267
• Main Authors: Liang, Y.Y., Toh, K.Y., Fimbres Weihs, G.A.
• Format: Article
• Language: English
• Subjects: CFD; Economic analysis; Mass transfer enhancement; Multi-layer spacer; Spiral wound module
• ISSN: 0376-7388; 1873-3123
• DOI: 10.1016/j.memsci.2019.02.015

Multi-layer feed channel spacers have shown superior mass transfer enhancement than conventional dual-layer spacers used in reverse osmosis (RO) spiral wound membrane modules. However, mass transfer indicators do not directly address the economic advantages of multi-layer spacers. To allow for a direct economic comparison of spacer designs, a simplified multi-scale techno-economic model is proposed which can provide useful cost trends. A total of 8 feed spacer geometries with different attack angles (α = 0–60°) and filament sizes (df/hch = 0.4–0.6) are first investigated using 3D-CFD. Multi-layer spacers typically increase both Sherwood number (~12%) and friction factor (~140%). The techno-economic model is then used to assess the impact of these changes on the total processing cost for RO. The latter analysis found that larger pressure drops associated with multi-layer spacers in long channels have little impact on total water processing cost for RO, with multi-layer spacers showing lower total processing costs (by 2–4%) than the dual-layer spacer for both seawater and brackish water RO. Novel spacer designs should therefore emphasise flux enhancement. The importance of including energy recovery for a more accurate economic analysis is highlighted, especially for systems with low recovery ratio. •CFD based multi-scale techno-economic model for evaluating RO feed spacers.•8 feed spacer geometries with different attack angles and sizes are simulated.•Total RO cost evaluated for seawater (3.5%) and brackish water (0.2%) salinity.•Flux enhancement is more important than pressure loss for economic performance.•Multi-layer feed spacers result in 2–4% lower cost than conventional spacers for RO.