Guiding the design of hollow fiber membrane modules for gas separation using computational fluid dynamics

Abstract Hollow fiber membranes hold considerable promise for gas separation across a range of industrial applications. However, the transition from laboratory-scale membrane performance to plant-scale module operation remains challenging, primarily due to the complex and poorly understood relationship between intrinsic membrane properties and module-level behavior. In this study, a computational fluid dynamics (CFD) model is developed to investigate the performance of hollow fiber membrane modules (HFMMs) for post-combustion carbon capture. The effects of key module design parameters, including port positioning, fiber packing patterns, and module length, on separation efficiency are systematically analyzed. Results reveal that maldistribution of fluid flow, particularly that induced by non-ideal fiber packing, can reduce module performance by up to 50 %, and that longer modules are more effective in minimizing entrance effects. Additionally, the influence of membrane permeance, selectivity, and operating conditions on module performance was evaluated. Overall, the developed CFD model offers a robust framework for understanding flow and mass transfer phenomena within HFMMs, indicates a need for greater effort in module design, and provides valuable insights for more accurate process simulations.