Ultrasonic assisted ultrafiltration process for emulsification of oil field produced water treatment

Ultrafiltration has been proven to be very effective in the treatment of oil-in-water emulsions, since no chemical additives are required. However, ultrafiltration has its limitations, the main limits are concentration polarization resulting to permeate flux decline with time. Adsorption, accumulation of oil and particles on the membrane surface which causes fouling of the membrane. Studies have shown that the ultrasonic is effective in cleaning of fouled membrane and enhancing membrane filtration performance. But the effectiveness also, depends on the selection of appropriate membrane material, membrane geometry, ultrasonic module design, operational and processing condition. In this study, a hollow and flat-sheet polyurethane (PU) membranes synthesized with different additives and solvent were used and their performance evaluated with oil-in-water emulsion. The steady-state permeate flux and the rejection of oil in percentage (%) at two different modes were determined. A dry/wet spinning technique was used to fabricate the flat-sheet and hollow fibre membrane (HFMs) using Polyethersulfone (PES) polymer base, Polyvinylpyrrolidone (PVP) additive and N, N-Dimethylacetamide (DMAc) solvent. Ultrasonic assisted cross-flow ultrafiltration module was built to avoid loss of ultrasonic to the surrounding. The polyurethane (PU) was synthesized by polymerization and sulphonation to have an anionic group (–OH; –COOH; and –SO₃H) on the membrane surface. Changes in morphological properties of the membrane had a significant effect on the permeate flow rate and oil removal. Generation of cavitation and Brownian motion by the ultrasonic were the dominant mechanisms responsible for ultrafiltration by cracking the cake layers and reducing concentration polarization at the membrane surface. The percentage of oil after ultrafiltration process with ultrasonic is about 90% compared to 49% without ultrasonic. Ultrasonic is effective in enhancing the membrane permeate flux and controlling membrane fouling.