Solvent resistant nanofiltration membranes

Description

Field

[0001] The present invention relates to a method of making a solvent resistant membrane. More particularly it relates to a method of making an organic solvent resistant nanofiltration membrane.

Background of the Invention

[0002] Nanofiltration (NF) membranes have retention characteristics in the range between ultrafiltration and reverse osmosis. Nanofiltration membranes are used to remove multivalent ions and small organic molecules in the molecular weight range of approximately 200-1000 Daltons. The ability to remove small organic molecules has led to much interest for applications in pharmaceutical industries. In particular, there is an interest in operating in organic solvent streams to separate small molecules such as synthetic antibiotics and peptides from organic solutions. In these types of applications, a high permeability is required for economical operation.

[0003] Polar organic solvents, such as dipolar aprotic solvents, particularly solvents such as N-methyl pyrrolidone (NMP), dimethylacetamide (DMAC), and dimethylsulfoxide (DMSO) are used as solvents or media for chemical reactions to make pharmaceuticals and agrochemicals (for example, pyrethroid insecticides) industry. These powerful solvents will cause severe damage to commonly used polymeric membrane filters made from polysulfone, polyethersulfone, polyacrylonitrile or polyvinylidene fluoride polymers.

[0004] In many applications, it would be useful for the membrane to operate with aqueous mixtures of solvents or with both aqueous solutions and solvent based solutions in series. For such uses, hydrophobic membranes are not useful as they have very low permeabilities for aqueous solutions. Low aqueous permeability in hydrophobic NF membranes is shown in Advances in Solvent-Resistant Nanofiltration Membranes, Ann. N.Y. Acad. Sci. 984, pp 159-177, 2003.

[0005] A typical use for these membranes is to concentrate products in organic or aqueous/organic solutions prior to a crystallization step. In other applications, process operators are able to remove low molecular weight impurities and salts by diafiltration, which cannot be done with an evaporation step. Operators are also able to exchange solvents during this type of filtration process. Nanofiltration of organic solutions can replace vacuum flash evaporators or rotovaps, providing a lower capital cost process.

[0006] In the processing of peptides and other low molecular weight organic solutes, the capacity of the membrane to be non-binding is an important attribute. Solutes bound to the membrane lower permeability and reduce yield by irreversibly holding solute. Cellulose is well-known as having a very low binding surface for such molecules, whereas hydrophobic and the typical polyamide NF membranes are known to be highly binding.

[0007] Cellulose is solvent stable, being soluble only in strong solvents such as carbon disulfide and solutions of dimethylacetamide with lithium chloride. When crosslinked, cellulose has even less tendency to swell and is therefore a good candidate for a solvent stable NF membrane. To date no commercial membrane has been produced because of the difficulties involved in making a porous NF membrane from cellulose.

[0008] Rendall, in US Patent 3,864,289 A, describes a process for the preparation of a cellulosic semipermeable membrane from a formulation containing a cellulosic membrane material, a cellulosic crosslinking agent and a blocking agent. The use of a "blocking agent" is undesirable because it adds unnecessary complexity to the process and an additional chemical change to the nature of the membrane material. Such blocking agents can also add to undesirable extractable material which can contaminate the purified permeate.

[0009] Wan, in US Patent 4,853,129 A, describes regenerated cellulose membranes for separating organic liquids, such as ketone dewaxing solvents from dewaxed oil. Reacting regenerated cellulose membranes with a bifunctional reagent results in improvement of the membrane's selectivity in organic liquid separations applications. Wan states that the process also serves to reduce the hydrophilicity of the membranes, and that by use of the crosslinking agents no unreacted hydroxy groups are left after reaction, nor are any hydroxy groups introduced by the crosslinking agent. Such membranes would not be suitable for use with water solutions, or solutions with appreciable amounts of water.

[0010] The membranes in the Wan patent have rejection values for oils of molecular weights in the range of from about 300-600 Daltons of 55%-90%. (Molecular weight data from concurrent patent US 4,510,047 A). These rejections are not suitable for the high value added products of pharmaceutical manufacturers.

[0011]  Tuccelli et al., in US Patent 5,522,991 A, disclose a back-pressure resistant cellulosic ultrafiltration membrane comprising a preformed nonfibrous polymeric microporous base resistant substrate and an ultrafiltration membrane layer formed from a polymer selected from the group consisting of cellulose, a cellulose ester and mixtures thereof. The polymeric microporous base resistant substrate has a pore size of from 0.05 to 10 µm and is formed from a polyolefin, polysulfone, polyethersulfone, polyarylsulfone, polytetrafluoroethylene or cellulose, the use of ultrahigh molecular weight polyethylene being especially preferred.

[0012] Beer et al., in US Patent 5,739,316 A, claim a process for making a cross-linked cellulose hydrate ultrafiltration membrane comprising contacting a cellulose hydrate membrane with an aqueous alkaline solution of a water soluble diepoxide. Besides being limited to water soluble diepoxides, Beer teaches away from the use of organic solvents in the reactions as being technically difficult and expensive. Moreover, Beer states as an objective of his invention a process that does not modify the high flux of the membrane. This means that the membranes so produced would not have increased rejection from the initial ultrafiltration membrane.

[0013]  Charkoudian et al., in US Patent Applications 2005/272925 A1 and 2004/206693 A1 teach crosslinked and crosslinked and charged cellulose ultrafiltration membranes that retain the ultrafiltration structure of the membranes. According to US 2005/272925 A1, crosslinked and charged cellulose ultrafiltration membranes can be obtained by reacting a crosslinked cellulose ultrafiltration membrane with an agent capable of forming a negatively or positively charged ionic group upon combination with residual hydroxyl groups of the cellulose or reactive groups at the crosslinkages.

[0014] US Patent 6,113,794 A describes a nanofiltration composite membrane comprising a substrate ultrafiltration membrane formed from non-cross-linked ethylenically unsaturated nitrile polymer, and a porous coating of a cross-linked hydrophilic polymer having a molecular weight of 20,000 to 2,000,000 and containing reactive functional groups, formed from an aqueous solution of the polymer containing 1.5-2.5% w/w of the polymer. The patent is directed to chitosan coated membranes that are completely dried before being crosslinked. This will produce a dense film rather than a porous membrane.

[0015] The US 6,113,794 patent cannot be used with dipolar aprotic solvents such as N-methyl pyrrolidone or dimethylacetamide because such solvents will dissolve the support layer and destroy the composite membrane.

[0016] Guo et al., in Chinese Chemical Letters Vol. 5#10 (1994), pp 869-872, reports on crosslinking large pore cellulose membranes with DMSO aqueous alkaline solutions of epoxyl propane chloride (epichlorohydrin). These membranes were used for affinity separations. Such large pore membranes would not be suitable for small molecule separations, and there is no teaching that the method could be used to make ultrafiltration or NF membranes.

[0017] Several patent applications and articles have been published by authors primarily associated with GKSS Research Center. These all appear to be based on the same technology. This method (WO 97/20622 A1) coats a substrate membrane with a low solids solution of cellulose-hydroxyether, such as hydroxyethyl cellulose or hydroxypropyl cellulose, and then crosslinks the coating with aldehyde, preferably a dialdehyde to the point of water insolubility. In an article in JAOCS Vol. 76#1 (1999), pp 83-87, Zwijnenberg et al. report on nanofiltration of vegetable oils in acetone using composite membranes with a "cellulose-type top-layer". In Membrane Technology #107 (1999), pp 5-8, Ebert et al. report on nanofiltration of vegetable oils in solvents with "cellulose-type" membranes in which the performance of the cellulose type membranes is influenced by the crosslinking conditions. Cellulose hydroxyethers are a different class of material from regenerated cellulose, as can be seen by the referenced authors describing the material as cellulose-like. Cellulose hydroxyethers are water soluble and can be expected to behave differently from regenerated cellulose membranes in operation. The membranes made from cellulose hydroxyethers are formed from thin dense layers and will have a different structure than the regenerated cellulose made by phase separation methods.

[0018] Nußbaumer et al., in German Patent Application DE 10 2004 053 787 A1, disclose a method of producing cellulose hydrate ultrafiltration membranes, the method comprising the steps of (a) tempering a cellulose ester ultrafiltration membrane in a tempering medium so as to provide a tempered cellulose ester ultrafiltration membrane, (b) saponifying the tempered cellulose ester ultrafiltration membrane so as to provide a cellulose hydrate ultrafiltration membrane, and optionally (c) crosslinking the cellulose hydrate ultrafiltration membrane using a multifunctional crosslinking agent dissolved in an aqueous solvent, an organic solvent, or a mixture of water and an organic solvent. According to the publication, the tempering step unexpectedly has a significant influence on the cutoff value of the cellulose hydrate ultrafiltration membranes obtained after saponification. The inventors of the present invention have found that by using a porous ultrafiltration membrane as a precursor, and carefully controlling reaction conditions so as to maintain sufficient hydrophilic nature of the membrane, they can produce a solvent stable cellulose nanofiltration membrane capable of operating at satisfactory flux in aqueous solutions, including aqueous-solvent mixtures or blends, which is also low binding to organic biomaterials. The invention is defined by the claims.

Summary of the Invention

[0019] The present invention relates to a method of forming an organic solvent resistant nanofiltration hydrophilic membrane capable of operation in dipolar aprotic solvents, capable of retaining solutes of greater than about 200 Daltons (D), and having a porous support integral with a crosslinked cellulose ultrafiltration membrane, the method comprising the steps of:

providing a microporous support made from a polymer selected from polyethylene, polypropylene, polyether ether ketone, polyolefins, polyethylene terephthalate, fluorinated polymers, and ultrahigh molecular weight polyethylene;

forming an integral hydrophilic cellulose ultrafiltration membrane having molecular weight cutoff (MWCO) values of 10,000 Daltons (D) or less on said microporous support;

providing a crosslinking solution comprising a multifunctional crosslinking agent and a charge modifying agent dissolved in an aqueous solvent, an organic solvent or an aqueous-organic solvent mixture, said multifunctional crosslinking agent being selected from butanediol diglycidyl ether, ethylene glycol diglycidyl ether and polyethylene glycol diglycidyl ethers; and

crosslinking said hydrophilic cellulose ultrafiltration membrane on said microporous support by reacting said multifunctional crosslinking agent through hydroxyl groups in the cellulose of the hydrophilic cellulose ultrafiltration membrane while simultaneously attaching said charge modifying agent to said hydrophilic cellulose ultrafiltration membrane so as to provide a crosslinked cellulose nanofiltration hydrophilic membrane having a negative surface charge or a positive surface charge attached to its surfaces,

wherein the crosslinking reaction is carried out at a temperature of between 25 to 50°C for a time of 4 to 24 hours under basic conditions such that sufficient hydroxyl groups that are present in the cellulose of the hydrophilic cellulose ultrafiltration membrane are left unreacted.

[0020] The nanofiltration hydrophilic membrane produced by the method of the invention is capable of filtering solutes from organic solvents, including dipolar aprotic solvents, aqueous solutions, and mixtures of water and organic solvents.

[0021] The method of the invention comprises obtaining a preformed porous support capable of operation in dipolar aprotic solvents, forming a cellulose ultrafiltration membrane on said support, and crosslinking the cellulose ultrafiltration membrane in a controlled manner so as to render the resultant nanofiltration membrane capable of retaining solutes of greater than about 200 Daltons. A preferred embodiment has a microporous membrane as the support. A more preferred embodiment has a microporous membrane support made from ultrahigh molecular weight polyethylene as the support. In an embodiment, the cellulose ultrafiltration precursor membrane has a molecular weight cutoff of less than about 5000 Daltons.

[0022] Further disclosed is a method of removing organic solutes from organic - aqueous or aqueous - organic solvent solutions comprising passing the solution through the nanofiltration hydrophilic membrane produced by the method of the invention.

[0023] The nanofiltration hydrophilic membrane produced by the method of the invention has controlled amounts of either negative or positive charge. Charge added to the membrane's internal and external surfaces has been shown to provide improved retention of similarly charged molecules.

[0024] The membrane is used to remove or concentrate organic or inorganic solutes of from about 200 D to 1000 D from the feed solution by sealing the membrane in a pressure holding device, such as a spiral wound module, a pleated cartridge, or a plate and frame type cassette, or other device, so that one side faces the higher pressure feed side and the other side of the membrane is at the lower pressure permeate stream. A pressurized feed solution stream is introduced to the cellulose side of the membrane and the permeate liquid collected from the lower pressure downstream side of the membrane. Solutes greater than about 200 D are retained (rejected) on the upstream side of the membrane. Lower molecular weight solutes, such as solvents pass through the membrane. Additionally, other low molecular weight solutes, such as salts and ions also pass through the nanofiltration membrane providing a concurrent desalting of the solute.

[0025] In some applications, after concentration of the desired solute, one or more other solutes may be added to the upstream side to exchange solvents. Also, pure solvent of the kind used in the original solution may be added to the concentrated solute to produce a purer solution relative to the original feed, now that low molecular impurities have been removed by passage through the membrane.

Detailed Description of the Invention

[0026] The nanofiltration hydrophilic membrane produced by the method of the invention comprises a crosslinked cellulosic membrane integral with a support layer. The cellulosic membrane is made from a cellulosic ultrafiltration membrane preferably made by the process of US Patent 5,522,991 A. The change in the membrane caused by the crosslinking reaction is from a membrane that separates primarily by size (ultrafiltration) to one where other interactions between the pore materials and the solutes play an important role in rejection of solutes. In nanofiltration, the forces on the solute molecule that retard entrance of solute into the pores, or transport through the porous nature of the membrane derive from the nature of the membrane material and the intimacy of solute to the pore surface. Charge and dielectric constant effects on the solute and solvent in the pores affect transport through the pores in a manner absent in the larger pores of ultrafiltration membranes. Therefore, when making a nanofiltration membrane by the process of the present invention, the pore size was reduced to obtain a porous structure in which solute-membrane material interactions were important, and where rejection simply by size was not the only mechanism.

[0027] Supports suitable for use in the method of the invention are made from a polymercapable of operation in dipolar aprotic solvents (e.g. DMSO, DMF, NMP), examples of which comprise polyethylene, polypropylene and polyether-ether ketone (PEEK). Supports need to combine porosity for flow, mechanical strength and flexibility and resistance to swelling or dissolution by organic solvents. Supports may be non-woven or woven fabrics made from, for example, polyolefins, polyethylene terephthalate, or fluorinated polymers such as polytetrafluoroethylene. A preferred support is a microporous membrane. A more preferred support is a microporous membrane made from ultrahigh molecular weight polyethylene (UPE) produced by the process described in US Patent 4,778,601 A.

[0028] Cellulose membranes can be formed by immersion casting of a cellulose acetate or other cellulose ester polymer solution onto a support. The cellulose ester is then hydrolyzed to cellulose by using a strong base such as 0.5N NaOH. A preferred method of making a cellulose ultrafiltration membrane is described in US patent 5,522,601 A wherein a solution of cellulose acetate is coated onto a UPE microporous membrane and coagulated into a membrane. The membrane is then hydrolyzed with sodium hydroxide to form the cellulose membrane.

[0029] Alternatively, cellulose can be dissolved in solutions of solvents such as dimethylacetamide (DMAC) or N-methyl pyrrolidone (NMP) with the addition of a salt such as lithium chloride. This cellulose solution can be used to form the membrane and subsequently eliminate the need for base hydrolysis.

[0030] Cellulose ultrafiltration hollow fiber membranes can be made by spinning a cuprammonium solution of cellulose into an acetone-water coagulating solution as described in US Patent 4,604,326 A. A similar process can be used to produce flat sheet membranes.

[0031] These examples are not to limit the methods possible to make cellulose ultrafiltration membranes, but as examples of some of the various methods available to a practitioner of this art.

[0032] A cellulose ultrafiltration membrane to be used in the method of the invention has a molecular weight cutoff (MWCO) value of 10,000 Daltons (D) or less, and preferably has a MWCO of less than 5000 D. A preferred membrane is PLCCC, produced by Millipore Corporation of Billerica, Massachusetts.

[0033] Crosslinking comprises a heterogeneous reaction between the dissolved crosslinking reactant and a membrane. The reaction solution can be based on an aqueous or an organic solvent, or an aqueous-organic mixture. Preferred organic solvents are N-methyl pyrrolidone, dimethyl acetamide, dimethyl sulfoxide, dimethyl formamide or similar solvents.

[0034] Crosslinkers to be used in the method of the invention are multifunctional epoxides, namely butandiol diglycidyl ether (BUDGE), ethylene glycol diglycidyl ether (EDGE) and polyethylene glycol diglycidyl ethers.

[0035] Crosslinker concentration in the reaction solution is about 5% by weight to about 60 % by weight, with a preferred range of about 10% to about 40% by weight.

[0036] A skilled practitioner will determine the reaction based on reaction temperature and reaction conditions. Generally, the reaction will take place at a faster rate at higher temperatures. A larger reaction vessel will require more time to reach the reaction temperature and to cool down. Higher pressures may be used to increase reaction rate. Depending on the reaction vessel, the practitioner may use a continuous flow, stirred tank or other means to improve contact of reactants to the membrane and thereby control the reaction. Higher concentrations will increase reaction rate. Crosslinker type as well as solvent will also play a role in determining reaction time. Hydroxyl ion activity is another important reaction condition.

[0037] According to the invention, the reaction time is from 4 to 24 hours, and the reaction is run at a temperature of from 25°C to 50°C. One of ordinary skill in the art will be able to modify or reduce this time by increasing for example the mass transfer rates, by using a continuous web or by further increasing reaction rates by adjusting temperature, concentrations and other like parameters.

[0038] Since a multifunctional epoxy is used, the reaction is run at basic conditions. Sodium or potassium hydroxides are generally used. Typically, about 0.1M to about 1M hydroxide solutions are used. The skilled practitioner will be able to balance the reaction against alkaline deterioration of the cellulose. Higher hydroxide concentrations and higher reaction temperatures will accelerate alkaline deterioration, lower concentrations of hydroxide and lower temperatures will slow deterioration rate as well as crosslinking reaction rate.

[0039] The reaction between the cellulose membrane and the crosslinking reactants can be done in aqueous solutions, either 100% water or mixed with solvents such as methyl ethyl ketone, methyl pentanediol, acetone, other ketones. This list is not limiting. A skilled practitioner will be able to develop this method using convenient and solvents suitable to their requirements.

[0040] In the method of the invention, the surface charge is introduced through a one step process. In the one step process, the charge modifying reactant is added to the crosslinking solution. In a two step process, the charge adding reaction is conducted before or after the crosslinking reaction.

[0041] Suitable reactants for forming a negatively charged membrane include compounds of the structure X(CH₂)_mA or alkali metals salts thereof. X is a halogen, preferably chloride or bromide, A is carboxyl or sulfonate. Reaction time, reactant concentration, pH, and temperature are used to control the amount of negative charge added to the surfaces of the membrane.

[0042] Positive charge may be imparted to the membrane by the use of glycidyl quaternary ammonium compounds and quaternary ammonium alkyl halides. These molecules would have a structure of Y(CH₂)_mB where Y is a halogen and B is a positively charge moiety.

[0043] In the method of the invention, the crosslinking reaction is done while adding charged groups to the membrane, so as to crosslink and add charge simultaneously. For this purpose, the crosslinking reaction is controlled at a rate where the crosslinked membrane resulting can restrain potential swelling by the added charge.

[0044] Practitioners will be able, with routine laboratory work, using the teachings herein, to produce nanofiltration membranes with the proper balance of pore size, charge and other material properties to have a working and economically viable solvent resistant nanofiltration membrane.

Dextran Test

[0045] This test is based upon methods published by L. Zeman and M. Wales, "Separation Science and Technology" 16(3), pp 275-390 (1981).

[0046] A sample of wetted membrane is placed in a test cell. A feed solution containing a mixture of dextrans having nominal molecular weights from 10,000 to 2,000,000 Daltons is contacted in a continuous flow mode or in a stirred cell with the upstream side of the membrane. The permeation rate is controlled by a peristaltic pump in order to run at low flux, and thereby eliminate concentration polarization on the feed side.

[0047] Samples of the permeate are examined for their molecular weight distribution (MWD) by size exclusion chromatography. The resulting distribution is compared to the MWD of the feed solution. A rejection at any elution volume can be calculated from R₂=(h(f)_v - h(p)_p)/ h(f)_v where h(f)_v is the height of the feed solution chromatograph at elution volume v, and h(p)_v is that of the permeate solution at volume v. In this way a distribution of rejections as a function of v can be found. The relation between elution volume and molecular weight of the solute is determined from the known MWD supplied by the manufacturer of the dextran. Molecular size can be calculated from the molecular weights by the relation of Granath and Kuist, J. Chromatography 28 (1967), pp 69-81. In this way a rejection vs. size distribution curve is generated.

[0048] A measure of MWCO is to determine the molecular weight at 90% rejection (R90) and consider that as the MWCO of the membrane.

Retention Test

[0049] Membrane discs were placed in a pressure cell having an inlet for the feed stream and to allow pressure to be applied, and an outlet for permeating liquid. Tests were done with dilute magnesium sulfate and raffinose solutions at 50 psi. Raffinose concentration in feed and permeate were determined by HPLC with refractive index detection. Magnesium sulfate concentrations were determined by conductivity.

Examples

A. Aqueous Solutions

[0050] PLCCC is a cellulose ultrafiltration membrane made by Millipore Corporation of Billerica, Massachusetts. It has a rated molecular weight cutoff as specified in the manufacturer's literature of 5000 Daltons.

[0051] BUDGE is butane diol diglycidyl ether used as a crosslinking agent.

[0052] EDGE is ethylene glycol diglycidyl ether used as a crosslinking agent.

Example 1 (not according to the invention)

[0053] A piece of PLCCC membrane 85 mm x 165 mm, is treated with a solution of 40 grams of ethyleneglycol diglycidylether(EDGE) dissolved in 60 grams 0.1M NaOH for 6 hours at 40 degrees C by rolling the membrane with the EDGE solution in a glass jar placed in a temperature controlled TECHNE HB1D hybridizer. The membrane is washed three times with 200 cc of Milli-Q® water. It is stored until use in 200 cc of Milli-Q® water containing .01% sodium azide to prevent bacterial contamination (Membrane #1).

[0054] Membrane 1 was tested for its rejection of neutral dextrans and its buffer flux according to the Dextran Test described above. The molecular weight at which 90% of the dextrans are rejected (R90) is tabulated in Table 1 along with the value for the PLCCC control. Also shown in Table 1 is the buffer flux for Membrane 1 and the PLCCC control.

[0055] Membrane 1 was tested for its ability to reject MgSO4 according to the Retention Test described above. A 0.2% aqueous MgSO4 solution was prepared and its conductivity measured to give 2.34 milliSiemens (mS). The membrane was placed in a high pressure filtration stirred cell. The 0.2% feed solution was passed through Membrane 1 at a pressure of 50 psi and a stirring rate of 150 rpm. The conductivity of the filtrate was 0.68 mS which corresponds to a concentration of 0.04% MgSO4. This is a reduction of about 80% of the feed MgSO4. The flux of this membrane during the nanofiltration experiment was 0.24 lmh/psi. This data is given in Table 2.

[0056] Membrane 1 was also tested for its ability to reject raffinose according to the Retention Test described above. Raffinose is a small sugar molecule with a molecular weight of 594 Daltons. A 0.1% aqueous raffinose solution was prepared a processed using the same cell and settings as for the MgSO4 experiment above. The feed solution and the filtrate were analyzed for their raffinose concentration by HPLC using a refractive index (RI) detector. A 91% reduction in raffinose concentration was recorded after being processed with membrane 1. This data is shown in Table 2.

B. Organic Solutions

Example 2 (not according to the invention)

[0057] A piece of PLCCC membrane, 85 mm x 165 mm, is treated with a solution of 20 grams of butanediol diglycidylether(BUDGE) dissolved in 40 grams N-methylpyrrolidone and 40 grams of 0.5M NaOH for 90 hours at 24 degrees C by rolling the membrane with the BUDGE solution in a glass jar placed in a temperature controlled hybridizer. The membrane is washed once with 200 cc of methanol and twice with 200 cc of Milli-Q® water. It is stored until use in 200 cc of Milli-Q® water containing .01% sodium azide to prevent bacterial contamination (Membrane #2).

[0058] Membrane 2 was tested for its rejection of neutral dextrans and its buffer flux according to the Dextran Test described above; these values are given in Table 1.

[0059] Membrane 2 was tested for its ability to reject raffinose in isopropyl alcohol (IPA) according to the Retention Test described above. A 0.1% solution of raffinose in IPA was processed with Membrane 2 at 50 psi. After passing through Membrane 2, the concentration was reduced to 0.029%. This is a decrease of 71% relative to the feed concentration. These data along with the flux and stir rate are shown in Table 3.

[0060] The dramatic difference in rejection seen for raffinose in DMAC compared to isopropyl alcohol demonstrates that pore size alone does not control rejection, but that the interaction of solute/membrane is important.

Example 3 (not according to the invention)

[0061] A piece of PLCCC membrane, 85 mm x 165 mm, is treated with a solution of 40 grams of butanediol diglycidylether(BUDGE) dissolved in 40 grams N-methylpyrrolidone and 40 grams of 0.5M NaOH for 40 hours at 24 degrees C by rolling the membrane with the BUDGE solution in a glass jar placed in a temperature controlled hybridizer. After this period of time this solution was discarded and a fresh solution with the same composition was introduced for 5 hours at 40 degrees C. The membrane is washed once with 200 cc of methanol and twice with 200 cc of Milli-Q® water. It is stored until use in 200 cc of Milli-Q® water containing .01% sodium azide to prevent bacterial contamination (Membrane #3).

[0062] Membrane 3 was tested for its rejection of neutral dextrans and its buffer flux according to the Dextran Test described above; these values are given in Table 1.

[0063] Membrane 3 was tested for its ability to reject raffinose in N-methylpyrollidone (NMP) according to the Retention Test described above. A 0.1% solution of raffinose in IPA was processed with Membrane 3 at 50 psi. After passing through Membrane 3, the concentration was reduced to below the detection limit of the HPLC equipment which is 0.005%. This corresponds to a decrease of at least 95% relative to the feed concentration. These data are listed in Table 3.

Example 4 (not according to the invention)

[0064] A piece of PLCCC membrane, 85 mm x 165 mm, is treated with a solution of 40 grams of ethyleneglycol diglycidylether(EDGE) dissolved in 60 grams 0.25M NaOH for 4 hours at 40 degrees C by rolling the membrane with the EDGE solution in a glass jar placed in a temperature controlled hybridizer. The membrane is washed three times with 200 cc of Milli-Q® water. It is stored until use in 200 cc of Milli-Q water containing .01 % sodium azide to prevent bacterial contamination (Membrane #4).

[0065] Membrane 4 was tested for its rejection of neutral dextrans and its buffer flux according to the Dextran Test described above.

[0066] Membrane 4 was tested for its ability to reject raffinose in N-methylpyrollidone (NMP) according to the Retention Test described above. A 0.1% solution of raffinose in IPA was processed with Membrane 4 at 50 psi. After passing through Membrane 4, the concentration was reduced to below the detection limit of the HPLC equipment which is 0.005%. This corresponds to a decrease of at least 95% relative to the feed concentration. These data are listed in Table 3.

TABLE 1: Membrane Characteristics Before and After Crosslinking to Form Nanofiltration Membrane

Membrane Number	Crosslinking	R90 (Daltons)	Buffer Flux (lmh/psi)
PLCCC	control	2645	3.8
1	EDGE	544	0.2
2	BUDGE	1113	0.2
3	BUDGE	886	0.1
4	EDGE	602	0.2

TABLE 2: Aqueous Nanofiltration

Membrane Number	Crosslinking	Feed	% before Nanofiltration	% after Nanofiltration	% Reduction	Flux (1mh/psi)
PLCCC	control	0.2% MgSO4	0.2	0.18	10	0.65
1	EDGE	0.2% MgSO4	0.2	0.04	80	0.2
PLCCC	control	0.1% raffinose	0.1	0.08	20	0.65
1	EDGE	0.1% raffinose	0.1	0.009	91	0.24

TABLE 3: Organic Solution Nanofiltration

Membrane Number	Crosslinking	Feed	% before Nanofiltration	% after Nanofiltration	% Reduction	Flux (1mh/psi)
PLCCC	control	0.1% Raffinose/IPA	0.1	0.09	10	0.008
2	BUDGE	0.1% Raffinose/IPA	0.1	0.01	90	0.008
3	BUDGE	0.1% Raffinose/NMP	0.1	<0.005	>95	0.01
1	EDGE	0.1% Raffinose/NMP	0.1	<0.005	>95	0.01

Prophetic Charged Nanofiltration Membranes

Example 1 - Negatively Charged 1 (not according to the invention)

[0067] A piece of Membrane #1, 85 mm x 165 mm, is treated with a solution of 22.5 grams of bromopropylsulfonic acid sodium salt (BPSA) in 100 grams of 0.5M NaOH for 4 hours at 25 degrees C by rolling the membrane with the BPSA solution in a glass jar placed in a temperature controlled hybridizer. The membrane is washed three times with 200 cc of Milli-Q® water. It is stored until use in 200 cc of Milli-Q ®water containing .01% sodium azide to prevent bacterial contamination (Negatively Charged Membrane #1).

Example 2 - Negatively Charged 2 (not according to the invention)

[0068] The same BPSA reaction conditions as in Example 1 are employed except for reaction time which is allowed to proceed to 16 hours. This produces a sulfonic acid modified membrane with a higher amount of negative charge compared to 1 above (Negatively Charged Membrane #2).

Example 3 - Positive Charge 1 (not according to the invention)

[0069] A piece of Membrane #1, 85 mm x 165 mm, is treated with a solution of 15 grams of a 70-75% aqueous solution of glycidyltrimethylammonium chloride (GTMAC), 10 grams of 1M NaOH, and 75 grams of water for 3 hours at 25 degrees C by rolling the membrane with the GTMAC solution in a glass jar placed in a temperature controlled hybridizer. The membrane is washed three times with 200 cc of Milli-Q® water. It is stored until use in 200 cc of Milli-Q® water containing .01% sodium azide to prevent bacterial contamination (Positively Charged Membrane #1.)

Example 4 - Positive Charge 2 (not according to the invention)

[0070] The same GTMAC reaction conditions as in Example 3 is employed except for reaction time which was allowed to proceed to 16 hours. This produces a quaternary ammonium modified membrane with a higher amount of positive charge compared to 3 above (Positively Charged Membrane #2).

Claims

1. A method of forming an organic solvent resistant nanofiltration hydrophilic membrane capable of operation in dipolar aprotic solvents, capable of retaining solutes of greater than about 200 Daltons (D), and having a porous support integral with a crosslinked cellulose ultrafiltration membrane, the method comprising the steps of:

providing a microporous support made from a polymer selected from polyethylene, polypropylene, polyether ether ketone, polyolefins, polyethylene terephthalate, fluorinated polymers, and ultrahigh molecular weight polyethylene;

forming an integral hydrophilic cellulose ultrafiltration membrane having molecular weight cutoff (MWCO) values of 10,000 Daltons (D) or less on said microporous support;

providing a crosslinking solution comprising a multifunctional crosslinking agent and a charge modifying agent dissolved in an aqueous solvent, an organic solvent or an aqueous-organic solvent mixture, said multifunctional crosslinking agent being selected from butanediol diglycidyl ether, ethylene glycol diglycidyl ether and polyethylene glycol diglycidyl ethers; and

crosslinking said hydrophilic cellulose ultrafiltration membrane on said microporous support by reacting said multifunctional crosslinking agent through hydroxyl groups in the cellulose of the hydrophilic cellulose ultrafiltration membrane while simultaneously attaching said charge modifying agent to said hydrophilic cellulose ultrafiltration membrane so as to provide a crosslinked cellulose nanofiltration hydrophilic membrane having a negative surface charge or a positive surface charge attached to its surfaces,

wherein the crosslinking reaction is carried out at a temperature of between 25 to 50°C for a time of 4 to 24 hours under basic conditions.

2. The method according to claim 1, wherein said microporous support comprises a polymeric woven fabric, a polymeric non-woven fabric or a microporous polymeric membrane.

3. The method according to claim 1 or 2, wherein said crosslinking solution comprises said multifunctional crosslinking agent at a concentration of from 5% by weight to 60% by weight.

4. The method according to any one of claims 1 to 3, wherein said multifunctional crosslinking agent is butanediol diglycidyl ether.

5. The method according to any one of claims 1 to 3, wherein the molecular weight cutoff (MWCO) value of said hydrophilic cellulose ultrafiltration membrane is less than 5000 Daltons (D).

Ansprüche

1. Verfahren zur Herstellung einer gegenüber organischem Lösungsmittel resistenten, hydrophilen Nanofiltrationsmembran, welche in dipolaren aprotischen Lösungsmitteln eingesetzt werden kann, gelöste Substanzen mit mehr als etwa 200 Dalton (D) zurückhalten kann, und einen mit einer vernetzten Cellulose-Ultrafiltrationsmembran integral ausgebildeten porösen Träger aufweist, wobei das Verfahren die Schritte umfasst:

Bereitstellen eines mikroporösen Trägers, welcher aus einem Polymer ausgewählt aus Polyethylen, Polypropylen, Polyetheretherketon, Polyolefinen, Polyethylenterephthalat, fluorierten Polymeren, und Polyethylen mit ultrahohem Molekulargewicht gebildet ist;

Ausbilden einer integralen hydrophilen Cellulose-Ultrafiltrationsmembran mit Molekulargewichts-Ausschlussgrenzwerten (MWCO-Werten) von 10,000 Dalton (D) oder weniger auf dem mikroporösen Träger;

Bereitstellen einer Vernetzungslösung, welche ein multifunktionelles Vernetzungsmittel und ein Ladungsmodifizierungsmittel umfasst, die in einem wässrigen Lösungsmittel, in einem organischen Lösungsmittel, oder in einem Gemisch aus Wasser und organischem Lösungsmittel gelöst sind, wobei das multifunktionelle Vernetzungsmittel aus Butandioldiglycidylether, Ethylenglykoldiglycidylether und Polyethylenglykoldiglycidylethern ausgewählt ist; und

Vernetzen der hydrophilen Cellulose-Ultrafiltrationsmembran auf dem mikroporösen Träger durch Umsetzen des multifunktionellen Vernetzungsmittels mit Hydroxylgruppen der in der hydrophilen Cellulose-Ultrafiltrationsmembran enthaltenen Cellulose und gleichzeitiges Binden des Ladungsmodifizierungsmittels an die hydrophile Cellulose-Ultrafiltrationsmembran, um auf diese Weise eine vernetzte hydrophile Cellulose-Nanofiltrationsmembran bereitzustellen, auf deren Oberflächen eine negative Oberflächenladung oder eine positive Oberflächenladung gebunden ist,

wobei die Vernetzungsreaktion bei einer Temperatur von zwischen 25 bis 50°C für eine Dauer von 4 bis 24 Stunden unter basischen Bedingungen durchgeführt wird.

2. Verfahren gemäß Anspruch 1, wobei der mikroporöse Träger ein polymeres Gewebe, einen polymeren Vliesstoff oder eine mikroporöse Polymermembran umfasst.

3. Verfahren gemäß Anspruch 1 oder 2, wobei die Vernetzungslösung das multifunktionelle Vernetzungsmittel in einer Konzentration von 5 Gew.-% bis 60 Gew.-% umfasst.

4. Verfahren gemäß einem der Ansprüche 1 bis 3, wobei es sich bei dem multifunktionellen Vernetzungsmittel um Butandioldiglycidylether handelt.

5. Verfahren gemäß einem der Ansprüche 1 bis 3, wobei der Molekulargewichts-Ausschlussgrenzwert (MWCO-Wert) der hydrophilen Cellulose-Ultrafiltrationsmembran weniger als 5000 Dalton (D) beträgt.

Revendications

1. Procédé de formation d'une membrane hydrophile de nanofiltration résistant aux solvants organiques capable de fonctionner dans des solvants aprotiques dipolaires, capable de retenir des solutés supérieurs à environ 200 Daltons (D), et ayant un support poreux d'un seul tenant avec une membrane d'ultrafiltration en cellulose réticulée, le procédé comprenant les étapes consistant à :

fournir un support microporeux constitué d'un polymère choisi parmi le polyéthylène, le polypropylène, la polyétheréthercétone, les polyoléfines, le téréphtalate de polyéthylène, les polymères fluorés, et le polyéthylène à poids moléculaire ultrahaut ;

former une membrane d'ultrafiltration en cellulose hydrophile d'un seul tenant ayant des valeurs de coupure de poids moléculaire (MWCO) de 10 000 Daltons (D) ou moins sur ledit support microporeux ;

fournir une solution de réticulation comprenant un agent de réticulation multifonctionnel et un agent de modification de charge dissous dans un solvant aqueux, un solvant organique ou un mélange de solvant aqueux-organique, ledit agent de réticulation multifonctionnel étant choisi parmi l'éther diglycidylique de butanediol, l'éther diglycidylique d'éthylèneglycol et les éthers diglycidyliques de polyéthylèneglycol ; et

réticuler ladite membrane d'ultrafiltration en cellulose hydrophile sur ledit support microporeux par réaction dudit agent de réticulation multifonctionnel par l'intermédiaire des groupes hydroxyle dans la cellulose de la membrane d'ultrafiltration en cellulose hydrophile avec fixation simultanée dudit agent de modification de charge à ladite membrane d'ultrafiltration en cellulose hydrophile de façon à obtenir une membrane hydrophile de nanofiltration en cellulose réticulée portant une charge de surface négative ou une charge de surface positive fixée sur ses surfaces,

dans lequel la réaction de réticulation est effectuée à une température comprise entre 25 et 50°C pendant une durée de 4 à 24 heures dans des conditions basiques.

2. Procédé selon la revendication 1, dans lequel ledit support microporeux comprend une étoffe tissée polymère, une étoffe de type non-tissé polymère ou une membrane polymère microporeuse.

3. Procédé selon la revendication 1 ou 2, dans lequel ladite solution de réticulation comprend ledit agent de réticulation multifonctionnel à une concentration de 5 à 60 % en poids.

4. Procédé selon l'une quelconque des revendications 1 à 3, dans lequel ledit agent de réticulation multifonctionnel est l'éther diglycidylique de butanediol.

5. Procédé selon l'une quelconque des revendications 1 à 3, dans lequel la valeur de coupure de poids moléculaire (MWCO) de ladite membrane d'ultrafiltration en cellulose hydrophile est inférieure à 5 000 Daltons (D).