Application of a pore-blockage--cake-filtration model to protein fouling during microfiltration

Although protein fouling is a critical factor governing the performance of microfiltration systems, there have been relatively few studies comparing the fouling behavior of different proteins. Flux-decline data were obtained for the filtration of bovine serum albumin, lysozyme, pepsin, immunoglobulin G, and myoglobin through polycarbonate track-etch membranes. The data were analyzed using a recently developed model that accounts for simultaneous pore blockage and cake formation. The model was in very good agreement with the data for all five proteins, demonstrating the general applicability of this new theoretical framework. The initial fouling due to pore blockage is directly related to the concentration of protein aggregates in solution, which was measured independently by quasi-elastic light scattering. The results provide important insights into the mechanisms of protein fouling during microfiltration.     

Influence of fermentation conditions and microfiltration processes on membrane fouling during recovery of glucuronane polysaccharides from fermentation broths.

We have investigated the recovery of exopolysaccharides produced by Sinorhizobium meliloti M5N1 CS bacteria from fermentation broths using different membrane filtration processes: cross-flow filtration with a 7 mm i.d. tubular ceramic membrane of 0.5-microm pores under fixed transmembrane pressure or fixed permeate flux and dynamic filtration with a 0.2 microm nylon membrane using a 16-cm rotating disc filter. With the tubular membrane, the polysaccharide mass flux was mainly limited by polymer transmission that decayed to 10% after 90 min. The mass flux of polymer produced under standard fermentation conditions (70 h at 30 degrees C) stabilized after 70 min to 15 g/h/m(2). This mass flux rises to 36 g/h/m(2) when the mean stirring speed during fermentation is increased and to 123 g/h/m(2) when fermentation is extended to 120 h. In both cases, the mean molecular weight of polysaccharides drops from 4.0 10(5) g/mol under standard conditions to 2.7 10(5) g/mol. A similar reduction in molecular weight was observed when the fermentation temperature was raised to 36 degrees C without benefit to the mass flux. These changes in fermentation conditions have little effect on stabilized permeate flux, but raise significantly the sieving coefficient, due probably to molecular weight reduction and the filamentous aspect of the polymer as observed from SEM photographs. The polymer-mass flux was also increased by reducing transmembrane pressure (TMP) and raising the shear rate by inserting a rod in the membrane lumen. Operation under fixed permeate flux instead of constant TMP inhibited fouling during the first 4 h, resulting in higher sieving coefficients and polymer mass fluxes. The most interesting results were obtained with dynamic filtration because it allows operation at high-shear rates and low TMP. Sieving coefficients remained between 90 and 100%. With a smooth disc, the polysaccharide mass flux remained close to 180 g/h/m(2) at 1500 rpm and cell concentrations from 1 to 3 g/L. When radial rods were glued to the disc to increase wall shear stress and turbulence, the mass flux rose to 275 g/h/m(2) at the same speed and cell concentration.     

Properties of microfiltration membranes: flux loss during constant pressure permeation of bovine serum albumin

An experimental study of permeation of dilute BSA solutions (filtration) at microfiltration membranes has been carried out. Most measurements were made with capillary pore aluminum oxide membranes, with some comparative measurements with tortuous and capillary pore polymeric membranes. In all cases, a continuous and substantial decrease in the rate of permeation with time was observed. This decrease in permeation with time was observed. This decrease in permeation rate was due neither to concentration polarization nor to protein adsorption alone. However, it could be quantified using the standard blocking filtration law, which describes a decrease in pore volume due to deposition of protein on the walls of the pore. The maximum calculated thickness of the deposited layers was 55nm on the walls of 200-nm diameter pores. This phenomenon is quite different to adsorption of protein at such surfaces, this latter giving only sub-monolayer or monolayer protein coverage under the conditions studied.     

Effect of membrane morphology on system capacity during normal flow microfiltration

Understanding the effects of membrane fouling on system capacity is critical for the successful design and scale-up of microfiltration systems. The underlying morphology and structure of the microfiltration membrane can have a significant effect on system capacity by altering the rate and extent of fouling. Experimental data were obtained for system capacity during protein microfiltration using several model membranes with both homogeneous and composite structures. Data were compared with predictions of a new model that can account for both pore blockage and cake formation, and also includes the effects of membrane morphology on internal flow profiles within the membrane. Membranes with highly interconnected pores have a significantly higher capacity due to the reduction in flux decline arising from the fluid flow under and around any surface blockage. The model calculations are in good agreement with the flux decline data, allowing far more accurate predictions of system capacity than for the commonly used V(max) analysis.     

Albumin denaturation during ultrafiltration: effects of operating conditions and consequences on membrane fouling

Ultrafiltration of high-purity grade bovine serum albumin has been carried out under various temperature between 5 and 30 degrees C and at various cross-flow velocities, pressures, and concentrations with the aim of studying protein denaturation and its consequences on the process. Three different pump heads have been tested. Denaturation of proteins in solution has been monitored by laser light scattering and size exclusion chromatography. The rate of protein denaturation increases with temperature, cross-flow, and time. It is observed that membrane fouling is different whether denaturation has occurred or not. Under high-concentration polarization, denaturation can occur in the boundary layer if the wall concentration exceeds 400 g/L. It is shown how the residence time, operating temperature, and pressure play an important part in membrane fouling. This can provide guidelines for process design and control.     

Properties of microfiltration membranes: Mechanisms of flux loss in the recovery of an enzyme

The transmission and rate of filtration of the enzyme yeast alcohol dehydrogenase (YADH) has been studied at capillary pore microfiltration membranes. Photon correlation spectroscopy (PCS) with nanometer resolution showed that the enzyme existed as discreate molecules only for a narrow range of pH and ionic strength. Under such conditions, the transmission of the enzyme was high. However, the rate of filtration still decreased continuously with time. Analyssis of the time dependence of the rate of filtration indicated that this decrease was due to in-pore enzyme deposition at low concentration ("standard blocking model") and suface depositon at high concentration ("cake filtration model"). Use of atomic force microscopy (AFM) gave unequivocal and quantitative confirmation of these inferences. The work shows the great advantage of using advanced physical characterization techniques, both for the identification of the optimum conditions for filtration (PCS) and for the elucidation of mechanisms giving rise to inefficiencies in the filtration process (AFM). (c) 1995 John Wiley & Sons, Inc.     

Effect of protein fouling on filtrate flux and virus breakthrough behaviors during virus filtration process

Virus filtration process is used to ensure viral safety in the biopharmaceutical downstream processes with high virus removal capacity (i.e., >4 log₁₀). However, it is still constrained by protein fouling, which results in reduced filtration capacity and possible virus breakthrough. This study investigated the effects of protein fouling on filtrate flux and virus breakthrough using commercial membranes that had different symmetricity, nominal pore size, and pore size gradients. Flux decay tendency due to protein fouling was influenced by hydrodynamic drag force and protein concentration. As the results of prediction with the classical fouling model, standard blocking was suitable for most virus filters. Undesired virus breakthrough was observed in the membranes having relatively a large pore diameter of the retentive region. The study found that elevated levels of protein solution reduced virus removal performance. However, the impact of prefouled membranes was minimal. These findings shed light on the factors that influence protein fouling during the virus filtration process of biopharmaceutical production.     

Surfactant pretreatment of a polysulfone ultrafilter for reduction of antifoam fouling

Effectiveness of surfactant precoat treatment of the polysulfone ultrafilter was first investigated for reduction of membrane fouling in ultrafiltration of antifoam. Fifteen different surfactants, including alcohols and synthetic nonionic surfactants, were tested. In general, pretreatment with nonionic surfactant gave a larger flux than that with alcohol did. The flux increase by pretreatment with nonionic surfactant depended on a hydrophile lipophile balance (HLB) value and type of hydrophobic tail. The most effective surfactant for reducing antifoam fouling among the 15 surfactants was Brij-58 which has an HLB value of 16 and a straight alkyl hydrophobic chain. The ultrafiltration flux of the membrane treated with Brij-58 was almost three times larger than that of untreated membrane. The precoat treatment with Brij-58 was the most effective for reducing antifoam fouling in terms of rejection properties.Furthermore, flux was also improved by the surfactant pretreatment in ultrafiltration of model process streams, such as fermentation media, broth, and yeast suspension with or without antifoam. The surfactant Brij-58 was found to be more effective for reducing membrane fouling in ultrafiltration of model stream YG compared with ethanol or Brij-35. The mean flux increase by the pretreatment with Brij-58 was about 80% in ultrafiltration of the model stream without antifoam. When antifoam was added to the model stream, flux was almost doubled by the pretreatment with Brij-58. The effectiveness of surfactant precoat treatment for reducing membrane fouling was also confirmed in terms of rejection properties. (c) 1994 John Wiley & Sons, Inc.     

Investigation of fouling mechanisms of virus filters during the filtration of protein solutions using a high throughput filtration screening device

The downstream process development of novel antibodies (Abs) is often challenged by virus filter fouling making a better understanding of the underlying mechanisms highly desirable. The present study combines the protein characterization of different feedstreams with their virus filtration performance using a novel high throughput filtration screening system. Filtration experiments with Ab concentrations of up to 20 g/L using either low interacting or hydrophobically interacting pre-filters indicate the existence of two different fouling mechanisms, an irreversible and a reversible one. At the molecular level, size exclusion chromatography revealed that the presence of large amount of high molecular weight species—considered as irreversible aggregates—correlates with irreversible fouling that caused reduced Ab throughput. Results using dynamic light scattering show that a concentration dependent increase of the mean hydrodynamic diameter to the range of dimers (17 nm at 20 g/L) together with a negative DLS interaction parameter k_D (−18 mL/g) correlate with the propensity to form reversible aggregates and to cause reversible fouling, probably by a decelerated Ab transport velocity within the virus filter. The two fouling mechanisms are further supported by buffer flush experiments. Finally, concepts for reversible and irreversible fouling mechanisms are discussed together with strategies for respective fouling mitigation. © 2019 American Institute of Chemical Engineers Biotechnol. Prog., 35: e2776, 2019.     

Hydraulic resistance and fouling of microfilters by Candida utilis in fermentation broth

The hydraulic resistance and membrane fouling effects of Candida utilis in fermentation broth were investigated using Millipore PVDF 0.22-mum membranes (GVWP and GVHP) in a stirred-cell system at 50 kPa and 700 rpm. With the various components of broth, spent medium, which contains colloidal particles and macromolecules having sizes (0.32 to 2.67 mum) comparable with the membrane pores (actual range 0.26 to 0.63 mum), was found to be the major contributing factor to the membrane fouling by broth through pore plugging. This led the spent medium to exhibit the highest hydraulic resistance (R(sm) of 5.8E + 12 m(-1)) and percentage flux loss (81.0%) when compared with either intact cells alone in buffer or to whole broth. Intact cells appeared to physically block and protect the pores without significant adhesion, because of the relatively hydrophilic nature of their cell walls (hydrophobicity of 5.9% at hour 36), resulting in the lowest hydraulic resistance (Rsbc of 7.5E + 11m(-1)) and percentage flux loss (19.3%).However, the hydraulic resistance and percentage flux loss of broth increased as cells aged. This was attributed to the increase in particle loading (intact cells by 15.37%, released cell contents and cell fragments) and in the hydrophobicity of cell walls. Autoclaved broth, lysed broth and aged broth, which contained a larger portion of colloidal particles and released cell contents caused a more pronounced fouling effect. This was revealed by the absence of flux recovery after depressurization with continuous stirring, even when a hydrophilic membrane was used. Furthermore, the hydrophobicity of C. utilis was found to increase with yeast extract present in medium, and use of hydrophobic membranes helped enhance the fouling effect. Overall, the degree of irreversible membrane fouling could be revealed by the value of R(sm)/R(t') and the hydraulic resistance, which resulted from concentration polarrzation, could be revealed by the value of R(c)/R(t') where R(t) = R(m) + R(sm) + R(c') and R(m) is the clean membrane resistance. (c) 1995 John Wiley & Sons, Inc.     

Properties of microfiltration membranes: the effects of adsorption and shear on the recovery of an enzyme

An experimental study of the interaction of the enzyme yeast alcohol dehydrogenase (YADH) with microfiltration membranes has been carried out. Most measurements were made with capillary pore inorganic membranes (Anopore) with some comparative measurements being made with polymeric membranes of low protein affinity (Durapore). It has been shown that the prolonged exposure of the enzyme to the inorganic membrane under low-shear conditions (slow recycle) resulted in a loss of enzyme activity. Under filtration conditions, the membrane permeation rate decreased continuously with time. This decrease could be quantified using the standard blocking filtration law, which describes a decrease in pore volume due to deposition of enzyme on the walls of the pore. No significant loss in activity of permeating enzyme occurred under solution conditions where the enzyme was stable. However, a significant loss of such activity occurred under solution conditions where the enzyme was slightly unstable. The experiments indicate that the likely mechanism for activity loss is a membrane/enzyme interaction resulting from a shear induced deformation of the enzyme structure. Two conclusions of practical importance are drawn from the work. (c) 1992 John Wiley & Sons, Inc.     

Comparison of intramolecular and intermolecular reactions in protein folding

The intrinsic component of the standard free energy change for the formation of a disulfide bond in a protein molecule is compared to that for an analogous chemical reaction. The former reaction, which represents theintramolecular formation of a disulfide bond in a protein molecule from a cysteine group containing a mixed disulfide bond with glutathione, and a free cysteine residue, is a unimolecular reaction. In contrast, its chemical analogue is a bimolecular reaction, and corresponds to theintermolecular disulfide interchange between a mixed disulfide-bonded compound between a cysteine residue and glutathione, and a free cysteine molecule. The difference in the intrinsic free energy of the above two reactions is estimated by two different approaches. First, a theoretical estimate of the magnitude of the difference in free energy of the two reactions (for a standard state of 1 M) is obtained using a gas-phase statistical thermodynamic approach, which indicates that the intramolecular reaction is energetically favored over its intermolecular counterpart by as much as 15.6 kcal/mole. For comparison, an experimentally derived value is also obtained, using experimental data from a study by Konishi et al. of the regeneration of the protein ribonuclease A (RNase A) from its reduced form by reduced and oxidized glutathiones. The intrinsic component of the free energy change of the intramolecular reaction, as it occurs in the protein molecule, is obtained from such experimental data by accounting explicitly for the free energy change (assumed to be solely an entropy change) pertaining to the conformational changes (ring closure) that the protein molecule undergoes in the course of the reaction. On the basis of the value derived from such an experimental approach, the intramolecular reaction is also energetically more favorable as compared to its intermolecular analogue, but only by a difference of 2.3 kcal/mole (for a standard state of 1 M). The large apparent discrepancy between the two values estimated from the theoretical and experimental approaches is rationalized by the postulation of several additional factors not inherent in the gas-phase theoretical estimate, such as dehydration and intramolecular hydrogen-bonding effects, which can largely compensate for the otherwise favorable energetics of the intramolecular reaction.     

Evaluation of membranes for use in on-line cell separation during mammalian cell perfusion processes

In this study two microporous hollow fibre membranes were evaluated for their use as cell retention device in continuous perfusion systems. A chemically modified permanent hydrophillic PTFE membrane and a hydrophilized PP membrane were tested. To investigate the filtration characteristics under process conditions each membrane was tested during a long term perfusion cultivation of a hybridoma cell line. In both cultivations the conditions influencing membrane filtration (e.g. transmembrane flux) were kept constant. Filtration behaviour was investigated by monitoring transmembrane pressure and protein permeability. Transmembrane pressure was measured on-line with an autoclavable piezo-resistive pressure sensor. Protein permeability was determined by quantitative evaluation of unreduced, Coomassie stained SDS-PAGE. The membrane fouling process influences the filtration characteristics of both membranes in a different way. After fermentation the PP membrane was blocked by a thick gel layer located in the big outer pores of the asymmetric membrane structure. The hydraulic resistance was higher but the protein permeability was slightly better than of the PTFE membrane. For this reason the PP membrane should be preferred. On the other hand, transmembrane pressure decreases slower when the PTFE membrane is used, which favours this membrane for long term cultivations, especially when low molecular weight proteins (<30 KD) are produced.Abbreviations PP Polypropylene - PTFE Polytetrafluoroethylene     

粘杆菌素发酵液微滤膜分离处理过程研究

粘杆菌素由于其药性强、残留低、对人畜无害被认为是最安全的畜禽抗生素之一。利用微滤对粘杆菌素发酵液进行预处理,根据发酵液的特性,选择孔径为0．2μm、膜面积为0．06M。的管式陶瓷膜为微滤膜,研究了操作参数的适宜值：压力为0．2MPa,流量为20L／min,在浓缩倍数达到3．5倍时连续两次加入与浓缩液体等量的水,得率为96％。经微滤处理后,滤液的吸光度Abs（470nm）为0．394,N-NH,含量为115mg／100mL,有效地去除了菌体、胶体蛋白及部分色素等,效果优于工业生产中板框过滤滤液的质量标准。     

Purification of an elastin-like fusion protein by microfiltration

This article describes a simple and potentially scalable microfiltration method for purification of recombinant proteins. This method is based on the fact that when an elastin-like polypeptide (ELP) is fused to a target protein, the inverse phase transition behavior of the ELP tag is imparted to the fusion protein. Triggering the phase transition of a solution of the ELP fusion protein by an increase in temperature, or isothermally by an increase in salt concentration, results in the formation of micron-sized aggregates of the ELP fusion protein. In this article, it is shown that these aggregates are efficiently retained by a microfiltration membrane, while contaminating E. coli proteins passed through the membrane upon washing. Upon reversing the phase transition by flow of Milli-Q water, soluble, pure, and functionally active protein is eluted from the membrane. Proof-of principle of this approach was demonstrated by purifying a fusion of thioredoxin with ELP (Trx-ELP) with greater than 95% recovery of protein and with greater than 95% purity (as estimated from SDS-PAGE gels). The simplicity of this method is demonstrated for laboratory scale purification by purifying Trx-ELP from cell lysate using a syringe and a disposable microfiltration cartridge. The potential scalability of this purification as an automated, continuous industrial-scale process is also demonstrated using a continuous stirred cell equipped with a microfiltration membrane.     

Effects of low-concentration Cr(VI) on the performance and the membrane fouling of a submerged membrane bioreactor in the treatment of municipal wastewater

The effects of low-concentration Cr(VI) (0.4 mg?l^?1) on the performance of a submerged membrane bioreactor (SMBR) in the treatment of municipal wastewater, as well as membrane fouling were investigated. Compared with the SMBR for control municipal wastewater, the SMBR for Cr(VI)-containing municipal wastewater had a higher concentration of soluble microbial products (SMP) with lower molecular weights, and smaller sludge particle sizes. Furthermore, low-concentration Cr(VI) induced membrane fouling, especially irreversible membrane pore blocking, which markedly shortened the service life of the membrane.     

重组毕赤酵母产华根霉脂肪酶的陶瓷膜微滤除菌工艺研究

在重组毕赤酵母生产脂肪酶的提取中,应用并优化了陶瓷膜微滤除茵工艺,确定了最佳条件为膜截留分子量500kDa、膜操作压力0．3Ⅷa、温度20℃、湿菌体含量35％,先对发酵液稀释1．5倍后再进行洗滤。40L处理量的小试结果显示,在5h处理时间内,能获得高达92．70％的酶活回收率。560L处理量的中试放大,酶活回收率为89．91％,耗时5．5h。在膜的清洗与再生中,采用2％NaC10和2％NaOH在60℃、0．3MPa膜压力下进行清洗40min,清水膜通量恢复率为98．14％。陶瓷膜与板框除菌的比较试验发现,两种方法都获得了微生物限量合格的产品和较高的酶活回收率,但陶瓷膜微滤的滤液微生物检出量更低,处理时间较短,动力能耗更低,易与超滤膜耦合提取,废水产生量更少,菌体废渣易于回收,是一种节能减排、清洁环保的新型除茵工艺。     

Selective precipitation-assisted recovery of immunoglobulins from bovine serum using controlled-fouling crossflow membrane microfiltration

Efficient and economic recovery of immunoglobulins (Igs) from complex biological fluids such as serum, cell culture supernatant or fermentation cell lysate or supernatant, represents a substantial challenge in biotechnology. Methods such as protein A affinity chromatography and anion exchange chromatography are limited by cost and selectivity, respectively, while membrane chromatography is limited by low adsorptive area, flow distribution problems and scale-up difficulties. By combining the traditional salt-assisted precipitation process for selective removal of Igs from serum followed by constant-permeate flux membrane microfiltration for low fouling, we demonstrate an exciting new, efficient and economic hybrid method. The high selectivity of an ammonium sulfate-induced precipitation step was used to precipitate the Igs leaving the major undesirable impurity, the bovine serum albumin (BSA), in solution. Crossflow membrane microfiltration in diafiltration mode was then employed to retain the precipitate, while using axial flow rates to optimize removal of residual soluble BSA to the permeate. The selectivity between immunoglobulin G (IgG) and BSA obtained from the precipitation step was approximately 36, with 97% removal of the BSA with diafiltration in 5 diavolumes with resulting purity of the IgG of approximately 93% after the membrane microfiltration step. Complete resolubilization of the IgG was obtained without any aggregation at the concentrations of ammonium sulfate employed in this work. Further, membrane pore size and axial Reynolds number (recirculation rate) were shown to be important for minimizing fouling and loss of protein precipitate.     

Effects of colloidal fouling and gas sparging on microfiltration of yeast suspension

Cross-flow microfiltration is an important step in separating Baker’s yeast (Saccharomyces cerevisiae) from aqueous suspension in many processes. However the permeate flux often declines rapidly due to colloidal fouling of membranes and concentration polarisation. The present work explores the possibility of maintaining acceptable permeate flux by co-current sparging of gas along with the feed, which would scour away colloidal deposits and reduce concentration polarisation of membranes. In this work, both washed and unwashed yeast were used to study the effect of washing to reduce protein fouling of membranes. It was found that permeate flux increased by 45% for liquid throughput of 75 kg/h for a feed concentration of 2.0 kg/m³ of washed yeast as compared with unwashed yeast suspension without gas sparging. For washed yeast suspension, the increase in gas flow rate from 0.5 lpm to 1.5 lpm (30 l/h to 90 l/h) had beneficial effect on permeate flux. It is concluded that in the present case, the gas flow rate should be less than or equal to the liquid flow rate for enhancement of permeates flux.     

Modeling the influence of slurry concentration on Saccharomyces cerevisiae cake porosity and resistance during microfiltration

Filtration of an isotonic suspension of baker's yeast through a 0.45‐μm membrane was studied at two different pressures, 40 and 80 kPa, for yeast concentrations ranging from 0.14 to 51 kg/m³ (dry weight). For a yeast volume fraction above 0.06 (～21.8 kg/m³), the porosity of the yeast cake is less dependent on the suspension concentration. For highly diluted suspensions, the specific cake resistance approaches a minimum that depends on the filtration pressure. Correlation functions of cake porosity and specific cake resistance were obtained for the concentration range investigated showing that the Kozeny–Carman coefficient increases when the applied pressure increases. Both filtration pressure and slurry concentration can be process controlled. In the range of moderate yeast concentration, the filtrate flux may be increased by manipulating the filtration pressure and the slurry concentration, thereby improving the overall process efficiency. The complex behavior of yeast cakes at high slurry concentration can be described by a conventional model as long as part of yeast cells are assumed to form aggregates, which behave as single bigger particles. The aggregation effect may be accounted for using a binary mixture model. © 2012 American Institute of Chemical Engineers Biotechnol. Prog., 2012