Numerical study of energy consumption in spacer-filled feed channels through 3D inverse modeling and computational fluid dynamics

Abstract

This project employs advanced Computational Fluid Dynamics (CFD) simulations to investigate the complex flow field dynamics within the channel of membrane module featuring a commercially available feed spacer. Utilizing Micro-CT scanning, the intricate three-dimensional (3D) structure of the spacer is accurately captured, enhancing the precision of the simulation models. The project focuses on the effects of varying Reynolds number (Re) and Aspect Ratio (AR) on the energy consumption within the feed channel of membrane module, analyzing streamline patterns, vorticity, and flow separation angles in detail. Findings indicate that the total enstrophy identification method effectively pinpoints areas of high energy consumption, especially at lower Re levels where flow separation significantly contributes to hydraulic losses. As Re increases, the separation vortex shifts rearward, resulting in a marked decrease in the energy consumption coefficient. Furthermore, the flow separation angle consistently declines with increasing Re, stabilizing at higher levels. Significantly, a reduction in AR from 1.015 to 0.725 more than doubles the decrease in flow separation angle, highlighting substantial potential energy savings through spacer design optimization. These insights are crucial for improving the design and efficiency of spiral wound membrane modules and for refining feed spacer configurations to enhance performance.