Plasma Polymerized Coatings on Hollow Fiber Membranes-Applications and Their Aging Characteristics in Different Media.

In the past 30 years, plasma polymerization has emerged as a versatile technique for depositing ultrathin nanocoating on a variety of substrates for applications that range from providing lubricity to the substrate, protection from harsh environments, promoting adhesion, surface modification to applications of coating in ultrafiltration and gas separation membranes. Applications in the field of volatile organic compound (VOC) recovery and membrane distillation have also gained importance in recent years. Most of these applications use silicone and fluorosilicone-based plasma polymers that provide versatility, good separation characteristics, and long-term stability to the membrane. However, plasma polymers are known to age with time. The current study focuses on the aging behavior of silicone and fluorosilicone plasma polymers in different environments that include air, ionized air, heat, aqueous solutions of inorganic chemicals, as well as harsh solvents such as hexane, dichloromethane (DCM), and toluene. Membrane gas permeance and gas selectivity were used to quantitatively measure the aging behavior of the coatings on gas separation membranes, while water and VOC flux were used to measure the effect of aging for membranes designed for membrane distillation and VOC separation. It was found that while all plasma polymers of this study showed changes in membrane gas permeance on exposure to air, they fundamentally retained their membrane separation characteristics in all the studied environments. Significant changes in gas permeability characteristics were observed on exposure of the membranes to organic solvents like dichloromethane, 2-propanol, hexane, and toluene, which are attributed to dimensional changes in the hollow fiber substrate rather than changes in plasma polymer characteristics. Ionized air was also found to have a significant effect on the gas permeability characteristic of the membranes, reducing the gas permeance by as much as 50% in some cases. This is attributed to accelerated oxidation and crosslinking of the polymer in ionized air. XPS studies showed an increase in the oxygen content of the polymer on aging. Differences were found in the aging behavior of polymer coatings made from different monomers with long-chain monomers such as hexamethyltrisiloxane offering more stable coatings. The cross-link density of the polymer also influenced the aging behavior, with the more cross-linked polymer showing a lesser influence on aging in a chemical environment. No significant effect of aging was found on applications of these polymer coatings in the field of membrane distillation, pervaporation, and VOC removal, and a stable performance was observed over a long period of time. It was also noted that the selection of co-monomers played a significant role in membrane distillation, with polymers forming fluoro co-monomers giving better results. The current study also demonstrated the usefulness of plasma polymers in controlling the pore size of microporous membranes that can find useful applications in bio-filtration and VOC recovery.

Graphene Oxide and Metal-Organic Framework-Based Breathable Barrier Membranes for Toxic Vapors.

Garments protective against chemical warfare agents (CWAs) or accidently released toxic chemicals must block the transport of toxic gases/vapors for a substantial time and allow moisture transport for breathability. These demands are challenging: either the barriers block CWAs effectively but have poor breathability or barriers have excellent breathability but cannot block CWAs well. Existing protective garments employ large amounts of active carbon, making them quite heavy. Metal-organic framework (MOF)-based adsorbents are being investigated as sorbents for CWAs. Breathable laminate of graphene oxide (GO) flakes supported on a porous membrane reduces permeation rates of CWA simulants substantially. We developed a multilayered membrane-based flexible barrier: GO laminate-based membrane over a MOF nanocrystal-filled expanded polytetrafluorethylene (ePTFE) membrane having submicrometer pores. The GO laminate-based layer developed a steady breakthrough concentration level almost 2 orders of magnitude below the usual breakthrough level. This highly reduced level of CWA was blocked by the MOF nanocrystal-filled membrane substrate layer over a highly extended period. We demonstrated the blocking of CWAs, mustard (HD), soman (GD), a sarin simulant [dimethyl methyl phosphonate (DMMP)], and ammonia for an extended period while the moisture transmission rate was substantial. The times for complete blockage of ammonia, HD, GD, and DMMP were 2750 min, 1075 min, 176 min, and 7 days, respectively. This remarkable performance resulted from a very low steady-state penetrant permeation through GO-laminate membrane and substantial penetrant sorption by MOF nanocrystals; furthermore, both layers show high moisture vapor transmission.

Porous Hydrophobic-Hydrophilic Composite Hollow Fiber and Flat Membranes Prepared by Plasma Polymerization for Direct Contact Membrane Distillation.

High water vapor flux at low brine temperatures without surface fouling is needed in membrane distillation-based desalination. Brine crossflow over surface-modified hydrophobic hollow fiber membranes (HFMs) yielded fouling-free operation with supersaturated solutions of scaling salts and their precipitates. Surface modification involved an ultrathin porous polyfluorosiloxane or polysiloxane coating deposited on the outside of porous polypropylene (PP) HFMs by plasma polymerization. The outside of hydrophilic MicroPES HFMs of polyethersulfone was also coated by an ultrathin coating of porous plasma-polymerized polyfluorosiloxane or polysiloxane rendering the surface hydrophobic. Direct contact membrane distillation-based desalination performances of these HFMs were determined and compared with porous PP-based HFMs. Salt concentrations of 1, 10, and 20 wt% were used. Leak rates were determined at low pressures. Surface and cross-sections of two kinds of coated HFMs were investigated by scanning electron microscopy. The HFMs based on water-wetted MicroPES substrate offered a very thin gas gap in the hydrophobic surface coating yielding a high flux of 26.4-27.6 kg/m2-h with 1 wt% feed brine at 70 °C. The fluxes of HFMs on porous PP substrates having a long vapor diffusion path were significantly lower. Coated HFM performances have been compared with flat hydrophilic membranes of polyvinylidene fluoride having a similar plasma-polymerized hydrophobic polyfluorosiloxane coating.

Graphene Oxide-Based Membrane as a Protective Barrier against Toxic Vapors and Gases.

Traditional protective garments loaded with activated carbons to remove toxic gases are very bulky. Novel graphene oxide (GO) flake-based composite lamellar membrane structure is being developed as a potential component of a garment for protection against chemical warfare agents (CWAs) represented here by simulants, dimethyl methyl phosphonate (DMMP) (a sarin-simulant), and 2-chloroethyl ethyl sulfide (CEES) (a simulant for sulfur mustard), yet allowing a high-moisture transmission rate. GO flakes of dimensions 300-800 nm, 0.7-1.2 nm thickness and dispersed in an aqueous suspension were formed into a membrane by vacuum filtration on a porous poly(ether sulfone) (PES) or poly(ether ether ketone) (PEEK) support membrane for noncovalent π-π interactions with GO flakes. After physical compression of such a membrane, upright cup tests indicated that it can block toluene for 3-4 days and DMMP for 5 days while exhibiting excellent water vapor permeation. Further, they display very low permeances for small-molecule gases/vapors. The GO flakes underwent cross-linking later with ethylenediamine (EDA) introduced during the vacuum filtration followed by physical compression and heating. With a further spray coating of polyurethane (PU), these membranes could be bent without losing barrier properties vis-à-vis the CWA simulant DMMP for 5 days; a membrane not subjected to bending blocked DMMP for 15 days. For the PEEK-EDA-GO-PU-compressed membranes after bending, the separation factors of H2O over other species for low gas flow rates in the dynamic moisture permeation cell (DMPC) are: αH2O-He is 42.3; αH2O-N2 is 110; and αH2O-ethane is 1800. At higher gas flow rates in the DMPC, the moisture transmission rate goes up considerably due to reduced boundary layer resistances and exceeds the threshold water vapor flux of 2000 g/(m2·day) that defines a breathable fabric. This membrane displayed considerable resistance to permeation by CEES as well. The PES-EDA-GO-PU-compressed membrane shows good mechanical property under tensile strength tests.

Continuous synthesis of drug nanocrystals by solid hollow fiber cooling crystallization.

Size reduction of drug with poor water solubility to nanoscale is an effective way to help improve the efficacy of drug delivery to the human body. A solid hollow fiber cooling crystallization technique has been adopted to continuously produce griseofulvin drug nanoparticles under modest conditions with accurate controllability. In the solid hollow fiber cooling crystallization device, drug solution flowed through the bores of solid hollow fibers while the cooling liquid was circulated counter-currently in the shell side of the device to cool down the drug solution in the tube side. Due to intense heat exchange between the cooling liquid and the drug solution through the thin fiber walls, the temperature of drug solution decreased rapidly so that drug nanoparticles were precipitated out from the solution by sudden reduction of solubility. Through variation of the experimental conditions and parameters, the mean size of the produced nanoparticles was regulated and controlled. The nanoparticles were dispersed uniformly, the chemical structure and bonds of prepared nanoparticles was the same with as-received griseofulvin. Both raw material and NPs the polymorph(s) present form I, the melting point was 220 °C. Drug dissolution testing was also executed to verify that nanocrystals have a higher dissolution profile.

Membrane-Based Technologies in the Pharmaceutical Industry and Continuous Production of Polymer-Coated Crystals/Particles.

BACKGROUND: Membrane technologies are of increasing importance in a variety of separation and purification applications involving liquid phases and gaseous mixtures. Although the most widely used applications at this time are in water treatment including desalination, there are many applications in chemical, food, healthcare, paper and petrochemical industries. This brief review is concerned with existing and emerging applications of various membrane technologies in the pharmaceutical and biopharmaceutical industry. METHODS: The goal of this review article is to identify important membrane processes and techniques which are being used or proposed to be used in the pharmaceutical and biopharmaceutical operations. How novel membrane processes can be useful for delivery of crystalline/particulate drugs is also of interest. RESULTS: Membrane separation technologies are extensively used in downstream processes for bio-pharmaceutical separation and purification operations via microfiltration, ultrafiltration and diafiltration. Also the new technique of membrane chromatography allows efficient purification of monoclonal antibodies. Membrane filtration techniques of reverse osmosis and nanofiltration are being combined with bioreactors and advanced oxidation processes to treat wastewaters from pharmaceutical plants. Nanofiltration with organic solvent-stable membranes can implement solvent exchange and catalyst recovery during organic solvent-based drug synthesis of pharmaceutical compounds/intermediates. Membranes in the form of hollow fibers can be conveniently used to implement crystallization of pharmaceutical compounds. The novel crystallization methods of solid hollow fiber cooling crystallizer (SHFCC) and porous hollow fiber anti-solvent crystallization (PHFAC) are being developed to provide efficient methods for continuous production of polymer-coated drug crystals in the area of drug delivery. CONCLUSION: This brief review provides a general introduction to various applications of membrane technologies in the pharmaceutical/biopharmaceutical industry with special emphasis on novel membrane techniques for pharmaceutical applications. The method of coating a drug particle with a polymer using the SHFCC method is stable and ready for scale-up for operation over an extended period.

Continuous preparation of polymer coated drug crystals by solid hollow fiber membrane-based cooling crystallization.

A facile way to continuously coat drug crystals with a polymer is needed in controlled drug release. Conventional polymer coating methods have disadvantages: high energy consumption, low productivity, batch processing. A novel method for continuous polymer coating of drug crystals based on solid hollow fiber cooling crystallization (SHFCC) is introduced here. The drug acting as the host particle and the polymer for coating are Griseofulvin (GF) and Eudragit RL100, respectively. The polymer's cloud point temperature in its acetone solution was determined by UV spectrophotometry. An acetone solution of the polymer containing the drug in solution as well as undissolved drug crystals in suspension were pumped through the tube side of the SHFCC device; a cold liquid was circulated in the shell side to rapidly cool down the feed solution-suspension in the hollow-fiber lumen. The polymer precipitated from the solution and coated the suspended crystals due to rapid temperature reduction and heterogeneous nucleation; crystals formed from the solution were also coated by the polymer. Characterizations by scanning electron microscopy, thermogravimetric analysis, laser diffraction spectroscopy, X-ray diffraction, Raman spectroscopy, and dissolution tests show that a uniformly coated, free-flowing drug/product can be obtained under appropriate operating conditions without losing the drug's pharmaceutical properties and controlled release characteristics.

Continuous synthesis of polymer-coated drug particles by porous hollow fiber membrane-based antisolvent crystallization.

Using porous hollow fiber membranes, this study illustrates a novel technique to continuously synthesize polymer-coated drug crystals by antisolvent crystallization. The synthesized polymer-coated drug crystals involve crystals of the drug Griseofulvin (GF) coated by a thin layer of the polymer Eudragit RL100. The process feed, an acetone solution of the drug GF containing the dissolved polymer, was passed through the shell side of a membrane module containing many porous hollow fibers of Nylon-6. Through the lumen of the hollow fibers, the antisolvent water was passed at a higher pressure to inject water jets through every pore in the fiber wall into the shell-side acetone feed solution, creating an extremely high level of supersaturation and immediate crystallization. It appears that the GF crystals are formed first and serve as nuclei for the precipitation of the polymer Eudragit, which forms a thin coating around the GF crystals. The polymer-coated drug crystals were collected by a filtration device at the shell-side outlet of the membrane module, and the surface morphology, particle size distribution, and the polymer coating thickness were then characterized by scanning electron microscopy (SEM), scanning transmission electron microscopy (STEM), laser diffraction spectroscopy (LDS), and thermogravimetric analysis (TGA). To study the properties of the coated drug crystals, X-ray diffraction (XRD), Raman spectroscopy, and dissolution tests were implemented. These results indicate that a polymer-coated, free-flowing product was successfully developed under appropriate conditions in this novel porous hollow fiber antisolvent crystallization (PHFAC) method. The coated drug particles can be potentially used for controlled release. The molecular and the crystal structures of GF were not affected by the PHFAC method, which may be easily scaled up.

Continuous polymer nanocoating on silica nanoparticles.

Continuous polymer coating of nanoparticles is of interest in many industries such as pharmaceuticals, cosmetics, food, and electronics. Here we introduce a polymer coating/precipitation technique to achieve a uniform and controllable nanosize polymer coating on nanoparticles in a continuous manner. The utility of this technique is demonstrated by coating Aerosil silica nanoparticles (SNPs) of diameter 12 nm with the polymer Eudragit RL 100. Both hydrophilic and hydrophobic SNPs were successfully coated. After determining the cloud point of an acetone solution of the polymer containing a controlled amount of the nonsolvent water, the solid hollow fiber cooling crystallization (SHFCC) technique was employed to continuously coat SNPs with the polymer. A suspension of the SNPs in an acetone-water solution of the polymer containing a surfactant was pumped through the lumen of solid polypropylene hollow fibers in a SHFCC device; cold liquid was circulated on the shell side. Because of rapid cooling-induced supersaturation and heterogeneous nucleation, precipitated polymers will coat the nanoparticles. The thickness and morphology of the nanocoating and the particle size distribution of the coated SNPs were analyzed by scanning transmission electron microscopy (STEM) with electron energy loss spectroscopy (EELS), thermogravimetric analysis (TGA), and dynamic light scattering (DLS). Results indicate that uniformly polymer-coated SNPs can be obtained from the SHFCC device after suitable post-treatments. The technique is also easily scalable by increasing the number of hollow fibers in the SHFCC device.

A new integrated membrane filtration and chromatographic device.

To improve protein separation, a novel integrated device combining membrane filtration and chromatography has been developed. The device basically consists of a hollow fiber filtration module whose shell side is filled with chromatographic resin beads. However, there is an essentially impermeable coated zone near the hollow fiber module outlet. The integrated device enjoys the advantages of both membrane filtration and chromatography; it also allows one to load the chromatographic media directly from the fermentation broth or lysate and separate the adsorbed proteins through the subsequent elution step in a cyclic process. Interfacial polymerization was carried out to coat the bottom section of the hollow fiber membrane; the rest of the hollow fiber membrane remained unaffected. Myoglobin (Mb) and alpha-lactalbumin (alpha-LA) were primarily used as model proteins in a binary mixture; binary mixtures of Mb and bovine serum albumin (BSA) were also investigated. Separation behaviors of binary protein mixtures were studied in devices having either an ultrafiltration (UF) or a microfiltration (MF) membrane. Experimental results show that the breakthrough time and the protein loading capacities were dramatically improved after introducing the impermeable coating in both UF and MF modules. For a synthetic yeast fermentation broth feed, four loading-washing-elution-reequilibration-based cyclic runs for separation of Mb and alpha-LA were performed in the device using a MF membrane with a coated zone without cleaning in between. The Mb and alpha-LA elution profiles for the four consecutive runs were almost superimposable. Due to lower transmembrane flux in this device plus the periodical washing-elution during the chromatographic separation, fouling was not a problem, unlike in conventional microfiltration.

In vitro delivery of doxycycline hydrochloride based on a porous membrane-based aqueous-organic partitioning system.

This work investigated the controlled release of an antibiotic drug, doxycycline HCl, from its solution/suspension in an organic solvent in a reservoir through a porous membrane employing aqueous-organic partitioning with or without a mouse skin to simulate a skin patch. The reservoir contained the agent in solution in the solvent 1-octanol or its dispersion/solution in the solvent mineral oil with or without an enhancer. The porous membranes employed with water-in-pores were hydrophobic Celgard 2400 of polypropylene and hydrophilized polyvinylidene fluoride (PVDF). Conventional Franz diffusion cells as well as a skin patch were used. The transport rates of the agent observed through both Celgard and PVDF membranes could be successfully described by Fickian diffusion through the water-filled pores when the appropriate organic-aqueous partition coefficient was incorporated. The light mineral oil-based system yielded much higher permeability due to the much lower organic-aqueous partition coefficient of the antibiotic in light mineral oil. The optimized skin patch systems yielded drug flux and permeability values similar to their relevant membrane systems. The addition of a mouse skin beneath the patch drastically reduced the drug transfer rate. Among a number of enhancers used to correct this deficiency, linoleic acid at 10% level in the reservoir solution was found to yield a flux of 2.7 +/- 0.5 microg/cm(2) h and a permeability of 2.7e - 04 +/- 5.0e - 05 cm/h. These values are higher than the values available in literature obtained with full thickness human cadaver skin.

Highly selective membranes in protein ultrafiltration.

A new ultrafiltration technique based on a multimembrane stack has been developed to fractionate solutes closer in size than conventionally possible. The technique is illustrated here by obtaining a pure protein product from a binary protein mixture. By employing membranes in series without any gaskets or spacers in-between, ultrafiltration is carried out to separate two proteins relatively close in molecular weight or size. Flat YM30 regenerated cellulose membranes, all of the same molecular weight cut-off (MWCO) 30,000, are stacked together in the desired number, and ultrafiltration takes place. The membrane rejection of a protein is amplified with each additional membrane, ultimately resulting in a completely rejected species. Complete purification of the more permeable protein may be achieved regardless of the physicochemical condition that may be optimal or suboptimal for selective separation by a single membrane. Two systems, myoglobin and beta-lactoglobulin, as well as myoglobin and alpha-lactalbumin were studied, under various operating conditions. The solvent flux reduction encountered when each membrane is added may also be avoided, by operating at increased pressure, while still achieving the desired purification. Cleaning in situ is achievable with reproducible experimental results before and after on-line cleaning. The results clearly demonstrate that multimembrane stacks can be used for fractionation of proteins that are quite close in molecular weight/size.

Stable liquid membranes: recent developments and future directions.

Immobilized liquid membranes offer the advantages of high selectivity and species flux in separation of species from either gaseous or liquid streams. Despite these advantages, they are not yet commercially viable because of their instabilities and limited lifetime. This paper presents recent advances made in developing stable immobilized liquid membranes for gas separation with high fluxes and selectivities for the species of interest. Some of the recent approaches being studied for development of stable liquid membranes for liquid separation are also discussed.

Protein loading, elution, and resolution behavior in a novel device that integrates ultrafiltration and chromatographic separation.

Hollow fiber membranes and chromatographic resin beads are commonly employed in a variety of bioseparation processes. A new class of integrated separation devices is being studied in which the shell side of a hollow fiber device is filled with adsorbents/chromatographic resin beads. Such devices and the corresponding separation methods integrate feed broth clarification by the microfiltration/ultrafiltration membrane with bioproduct purification by the shell-side resin beads either as an adsorbent or as beads in elution chromatography. A mathematical model has been developed for the prediction of the chromatographic behavior of such an integrated device. Simulations have been done to study the effects of axial dispersion, feed flow rate, water permeation rate, fiber packing density, and void fraction. Numerical solutions were obtained by solving the governing equations. This model can reasonably describe the concentration profiles as well as the breakthrough and elution behaviors in the integrated device.