High throughput membrane emulsification using a single-pass annular flow crossflow membrane

Membrane emulsification has the potential to revolutionize the energy-efficient production of uniform emulsions and dispersions, relevant to diverse fields from pharmaceutical active ingredient controlled release particles to Fast Moving Consumer Goods. A novel highly robust single-pass continuous phase crossflow system has been developed providing dispersed phase concentrations up to 40% vol/vol and dispersed phase fluxes up to 5,730 L m(-2) hr(-1), from a single 100 mm long membrane tube. Extensive results of two oil-in-water systems (vegetable oil and PolyCaproLactone dissolved in DiChloroMethane) and one water-in-oil system (sodium silicate solution) are reported, using hydrophilic and hydrophobic membranes respectively. Mathematical models are validated enabling comprehensive engineering analysis of processes including predicted droplet size, membrane pressure drops, and energy requirement for dispersion production. Surfactant depletion, pore utilization, and droplet interaction at the membrane surface were investigated to provide a comprehensive analysis of the capabilities of novel annular-flow membrane emulsification for high throughput emulsion generation.