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JECT.

2012;44:139–144
The Journal of ExtraCorporeal Technology

Development of a New Arterial-Line Filter Design Using


Computational Fluid Dynamics Analysis
Daniel P. Herbst, MSc, CCP, CPC; Hani K. Najm, MD, MS, FRCSC, FRCSC UK

King Abdullah International Medical Research Center, King Saud bin Abdulaziz University for Health Sciences, King Abdulaziz
Cardiac Center, Cardiac Science Department, Riyadh, Kingdom of Saudi Arabia

Abstract: Arterial-line filters used during extracorporeal circula- to define the inputs needed for numerical modeling of a new filter
tion continue to rely on the physical properties of a wetted micro- design. Flow patterns, pressure distributions, and velocity profiles
pore and reductions in blood flow velocity to affect air separation predicted with computational fluid dynamics software were used to
from the circulating blood volume. Although problems associated inform decisions on model refinements and how to achieve initial
with air embolism during cardiac surgery persist, a number of design goals of £225 mL prime volume and £500 cm2 of screen
investigators have concluded that further improvements in filtra- surface area. Predictions for optimal model geometry included a
tion are needed to enhance air removal during cardiopulmonary screen angle of 56 from the horizontal plane with a total surface
bypass procedures. This article reviews theoretical principles of area of 293.9 cm2 and a priming volume of 192.4 mL. This article
micropore filter technology and outlines the development of a describes in brief the developmental process used to advance a
new arterial-line filter concept using computational fluid dynamics new filter design and supports the value of numerical modeling
analysis. Manufacturer-supplied data of a micropore screen and in this undertaking. Keywords: arterial-line filter, filtration, CPB
experimental results taken from an ex vivo test circuit were used equipment, patient safety. JECT. 2012;44:139–144

Since their introduction more than five decades ago, filtration and describes in brief the development of a new
arterial-line filters used for extracorporeal circulation arterial-line filter design aimed at improving filtration effi-
(ECC) have relied on principles related to the physical ciency using computational fluid dynamics (CFD) analy-
properties of a wetted micropore and reductions in blood sis. The use of CFD analysis for ECC component design
flow velocity to aid air separation from the circulating has been widely accepted as a development tool for this
blood volume. Although current designs have undoubt- field in a broad range of applications (15–18).
edly affected patient outcomes positively (1,2), ECC filters
remain unable to remove all air bubbles effectively from Theoretical Background of Extracorporeal
circulation (3). The relationship between cognitive dys- Circulation Filtration
function and cerebral embolic load during cardiac surgery Because microembolic events continue to plague com-
has been well studied, affecting as much as 60% of this plications associated with ECC, the call to advance filter
patient population (4–10). With annual open-heart proce- technology is growing. A recurring theme to this call for
dures reaching in excess of one million cases globally improvement is the conclusion that although micropore
(11,12), a sizable patient population could therefore diameter remains an important factor in filter mechanics,
potentially benefit from improvements in perfusion inter- by itself it does not correlate well with filtration efficiency
ventions and techniques related to the development and suggesting that other factors such as the blood flow
application of extracorporeal filter technology (13,14). path may also impact the air-handling ability of these
This article reviews theoretical principles of micropore devices (19–23). Industry leaders continue to address these
challenges with varied results, having introduced several
innovations that either alter the configuration of common
Received for publication September 17, 2011; accepted August 4, 2012. features or go beyond the theoretical principles guiding
Address correspondence to: Daniel P. Herbst, MSc, CCP, CPC, Department
of Cardiac Sciences, Mail Code 413, King Fahad National Guard conventional filter designs (24–26).
Hospital, PO Box 22490, Riyadh, Kingdom of Saudi Arabia. E-mail: In recognizing common principles underpinning the use
d_hebrst@me.com of micropore filters, most commercially available designs
The senior author has stated that authors have reported no material,
financial, or other relationship with any healthcare-related business or incorporate a large-volume chamber to decrease flow
other entity whose products or services are discussed in this paper. velocity and allow more time for any air bubbles to rise

139
140 D.P. HERBST AND H.K. NAJM

up and out of circulation through an appropriately located Fick’s law of diffusion states that the rate of diffusion
purge port. Additionally, the wetted pores of a micron for a gas is directly proportional to the partial pressure
screen interposed between the inlet and outlet of the filter gradient in the direction of diffusion and is described by
are used to form a physical barrier to prevent the passage the following formula:
of bubbles and further enhance air separation. In theory
J = D  dp=dx ð3Þ
there are at least two ways that free gases in a liquid can
pass through a wetted micropore, first by exceeding the where J is equal to the rate of diffusion (mol/m2s), –D is
bubble-point pressure (BPP) of the micropore itself or equal to the diffusion coefficient of the gas down its con-
alternatively by crossing the screen barrier as dissolved centration gradient from high to low pressure (m2/s), dp is
gases (27–29). equal to the partial pressure gradient of the gas (mol/m3),
and dx is equal to the distance through which the gas must
Bubble-Point Pressure
diffuse (m).
The BPP can be defined as the amount of pressure
In theory, as bubbles become trapped on the proximal
required to eject air across a wetted pore and is described
surface of a screen filter, the gases they contain can diffuse
by the following formula:
into solution according to the principles described. Dis-
P = 4g  cosq=d ð1Þ solved gases traversing the micropore are exposed to a
pressure drop at the distal surface of the screen that would
where P is equal to the BPP (mmHg), g is equal to the
allow them to re-emerge again in accordance with Henry’s
surface tension (dynes/cm), q is equal to the contact or
law (27). As a result, free gas bubbles may exist distal to
wetting angle ( ), and d is equal to the micropore diameter
the micropore screen filter capable of entering the fluid
(cm). The surface tension (g) of a given liquid is a measure
stream returning to the patient.
of the strength of attractive forces between the molecules
These theoretical principles hold obvious implications
that make up that liquid, whereas the wetting angle (q) is
for perfusion practice and standard of care closely tied to
defined by the degree of attraction between the molecules
the setup and use of micropore filter devices. Extra efforts
of a given liquid–solid interface (27–29). Together, the
and attention given to ensure that priming of the micro-
surface tension and wetting angle can be used to describe
pore screen is complete afford optimal filter performance
the force needed to raise a column of liquid in a capillary
and patient safety at the start of the ECC procedure. Per-
tube (capillary force) or, similarly in this case, to fill the
fusion strategies that incorporate use of the filter purge
micropore of a screen filter (27–29). It is the anchoring
port should also be routine because the effective filtration
effects of these surface active forces that are breached
of free gases can only be realized when they are perma-
when the BPP is exceeded. Although it is clear that bub-
nently removed from circulation. Avoiding use of the filter
bles smaller than the diameter of a micropore are able to
purge port limits the device to function simply as a bubble
pass through a wetted filter, bubbles larger than the micro-
trap where under certain circumstances the filter itself
pores of the filter screen will accumulate on its proximal
can become a source of air. Inline monitoring equipment
surface and partially obstruct fluid flow, causing a rise in
used to help maintain an adequate oxygen content while
the prescreen pressure. As bubble accumulation con-
avoiding excessive amounts of dissolved gas may also be
tinues, the prescreen pressure builds until a sufficient
considered a part of routine perfusion practice and stan-
force exists to overcome the opposing capillary forces
dard of care to limit the diffusion flow of gas across the
maintaining the wetted pore, allowing air to be ejected
filter screen as a source of free gas transfer to the patient.
through (27–29).
Gas Diffusion in a Liquid Limitations in Extracorporeal Circulation Filter Design
The amount and rate of gas diffusion into a liquid is Common methods used in ECC filters call for designs
dependent on the principles described by Henry’s law and that require a pleated micropore screen to be placed
Fick’s law of diffusion (30). nearly perpendicular to the fluid path. Pleating of the
Henry’s law states that the amount of gas dissolved screen allows the filter housing to be packed more densely,
in a liquid is directly proportional to its partial pres- increasing surface area and the number of pores available
sure in equilibrium with that liquid and can be des- to limit flow-through resistance and avoid exceeding the
cribed as: BPP. This nearly perpendicular orientation however
may hinder filter performance by promoting both trap-
P=K  C ð2Þ
ping and fragmentation because bubbles can be held
where P is equal to the partial pressure of the gas (atm), K against the screen by the force of fluid flowing through
is equal to Henry’s law constant (Latm/mol), and C it and more easily break apart as a result of the abrupt
is equal to the molar concentration of the gas in solu- angle of collision. Both of these events could increase
tion (mol/L). the risk of free gas transfer to the patient as a result of

JECT. 2012;44:139–144
DEVELOPMENT OF A NEW ARTERIAL-LINE FILTER DESIGN 141

confidence in CFD model predictions. Used in this con-


text, porosity represents a measure of the screens open
area, whereas permeability defines the ease at which a
given fluid can pass through.
Porosity Setting
To define a porosity value, manufacturer-supplied data
of a 38-mm polyester screen, which included the screen
fabric density (1350 kg/m3), thickness (70 mm)m and mass
(4.5E-2 kg/m2)m were first taken to calculate the void
volume (7.33E-8 m3) of a known sample area (2.0E-3 m2)
using the following formula:
M=r  v ð4Þ
where M is equal to mass (kg), r is equal to density (kg/m3),
and v is equal to volume (m3).
Once the void volume and solid volume of the filter
screen was known (Appendix A), a porosity value could
then be determined and set as a model parameter using:

Figure 1. New arterial-line filter design with sequential filter


porosity (e) = void volume (vv )=void volume (vv ) ð5Þ
screen arrangement. + solid volume (vs )
Porosity is a dimensionless term representing a ratio
between variables with the same units of measure.
an increasing pressure drop across the screen resulting
Permeability Setting
from bubble accumulation, an increase in the diffusion
To define a permeability value, a simple filter model
flow of gas, or an increased incidence in microembolic
ex vivo test circuit was used to assess pressure loss
showers as larger bubbles impacting on the screen break
across a known micropore screen. The test circuit consisted
apart. Pleating of the screen itself may also be counter-
of a BP50 centrifugal pump with DP38 flow probe
productive to filtration efficiency because it provides an
(Medtronic, Minneapolis, MN), 3/8-inch polyvinylchloride
added physical structure between which gas bubbles can
(PVC) tubing (total length 220 cm), 1/4-inch PVC tubing
become lodged to further promote trapping and the pos-
(total length 20 cm), a sample of 38-mm screen fabric (Sefar
sible re-emergence of bubbles beyond the intended pro-
AG, Heiden, Switzerland), two 3/8-inch 3/8-inch luered

+
tection of the micropore barrier. Moreover, the densely
polycarbonate connectors, two 3/8-inch 1/4-inch polycar-

+
packed pleats may make priming the filter device more
bonate connectors, a dual-port Digitron 2088p pressure
difficult, reducing its practical value, especially in emer-
manometer (Digitron, Torquay, England, UK), and a saline-
gent situations.
filled container used to prime and recirculate the system.
To address these limitations, a new filter design was
A sample of 38-mm screen fabric was placed evenly over
developed to include multiple screens placed in a sequen-
one end of a 3/8-inch luered connector and then inserted
tial arrangement (31,32). The new design shown in
into a 5-cm piece of 3/8-inch PVC tubing. Once seated,
Figure 1 was adapted so that fluid passes from the inlet
the screen was visually inspected to ensure a smooth flat
through multiple screens to the outlet following a unique
placement and the connection was then secured with a tie-
up-and-down flow path, whereas the nonpleated filter
band to avoid screen displacement and fluid leakage. A
screen angle better uses the fluid flows rising momentum
second 3/8-inch luered connector was inserted into the
to ease priming and help direct any air bubbles up and
opposite end of the 5-cm piece of tubing, which together
away from the fluid stream returning to the patient.
comprised a simple filter model with pre- and postscreen
pressure sampling ports as depicted in Figure 2.
MATERIALS AND METHODS Height differences between the pump and circuitry were
minimized to reduce the effects of hydrostatic pressure,
Defining Boundary Conditions for Computational Fluid while filter model placement was set 150 cm from the
Dynamics Analysis pump outlet to aid the development of laminar flow at the
Before starting with CFD analysis, porosity and perme- screen. The test circuit as shown in Figure 3 was then primed
ability values for the micropore surfaces contained in the with saline .9% solution at room temperature (23.1 C) and
new filter model first needed to be defined to establish pump output was zeroed according to the manufacturer’s

JECT. 2012;44:139–144
142 D.P. HERBST AND H.K. NAJM

Table 1. Experimental results for pressure drop measurements


across a 38-mm screen fabric.
Pump Flow Rate (L/min) Pressure Drop (Pa) Pressure Drop (mmHg)

.01 50 .4
.02 110 .8
.03 170 1.3
.04 240 1.8
.05 310 2.3

Kpa, kilopascals.

(ANSYS, Canonsburg, PA) and prepared for analysis


using a mesh of approximately 2.0 106 cells. Meshing

+
refers to the process of splitting the model surfaces and
volume into smaller discrete blocks of cells or areas and
assigning attributes to those areas to mathematically
define the models behavior under CFD processing. Flow,
Figure 2. Simple filter model assembly (3/8-inch). velocity, and pressure characteristics of the computational
geometry were then predicted and analyzed using ANSYS
CFX software Version 11 (ANSYS, USA).

RESULTS

Along with manufacturer-supplied technical specifica-


tions of a screen fabric, experimental results taken from an
ex vivo test circuit were used to theoretically define a poros-
ity (e = .34) and permeability (k = 4.16E-12 m2) value for
CFD modeling methods. Results from numerical modeling
of the new filter device were used to examine flow patterns,
pressure distributions, velocity profiles as well as inform
decisions on how to achieve initial design goals of £225 mL
prime volume and £500 cm2 screen surface area while
maintaining an acceptable flow-through resistance and
pressure drop. The consecutive model refinements derived
Figure 3. Test circuit diagram with simple filter model. from several CFD analyses resulted in the predicted dimen-
sions and performance values shown in Table 2.

operating instructions. Special attention was given to ensure


deairing of the filter screen and entire circuit was complete, Table 2. Computational fluid dynamics predicted model dimen-
sions and performance values.
and both pressure ports of the Digitron 2088p manometer
were fluid-filled and calibrated to measure gauge pressure. CAD Model
To simulate the expected flow range for the new filter design Dimension Predicted Performance Variable Predicted
in L/min/cm2 of screen surface area based on 7 L/min Internal 192.4 mL Mean inlet velocity 1.4 m/sec
(smallest single stage filter = 134.2 cm2), pump flow rate in volume (based on 6 LPM
flow rate)
the test circuit was initially set at .01 L/min and adjusted in Outer screen 159.7 cm2 Mean outlet velocity 1.2 m/sec
increments of .01 L/min to a maximum flow rate of .05 L/min area (based on 6 LPM
with pressure drops (Dp) recorded at each flow setting as flow rate)
shown in Table 1. An average of the recorded pressure Inner screen 134.2 cm2 Mean velocity range .15–.65 m/sec
angle/area (across both
drops was then taken to determine the permeability con- filter screens)
stant used as an input for the CFD analysis. Total screen 293.9 cm2 Total pressure drop 32.5 mmHg
A complete three-dimensional CAD model of the new area (.9% saline, 23.1 C,
6 LPM)
filter design was then imported into ANSYS software

JECT. 2012;44:139–144
DEVELOPMENT OF A NEW ARTERIAL-LINE FILTER DESIGN 143

Empirically testing a physical prototype of the new filter ACKNOWLEDGMENTS


design based on this numerical model is needed to confirm
these findings and further determine whether any perfor- Official approval and financial support for this research was
mance gain in filtration efficiency can actually be realized obtained from the Research Committee and Institutional Review
Board at the King Abdullah International Medical Research
with its use. Additional research would also be required to Center (KAIMRC) in collaboration with the King Saud bin
determine the blood handling capabilities of a sequential Abdulaziz University for Health Sciences (KSAUHS) and the
screen arrangement with smaller surface area. King Abdulaziz Cardiac Center (KACC).

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APPENDIX A: NOTES ON CALCULATING THE
VOID VOLUME AND SOLID VOLUME OF A 38-m volume (v) = Mass (M)=density (r)
MSCREEN FABRIC HAVING A 2.0E-3 M2
volume of void spacesolid = 9:9E-5 kg=1350 kg=m3
SURFACE AREA
= 7:33E-8 m3
Manufacturer-supplied data: fabric density (1350 kg/m3), (Note: volume of void spacesolid is the mass of void
thickness (70 mm), and mass (.045 kg/m2) (Sefar AG, spacesolid/density to give the total volume occupied by the
Heiden, Switzerland). pores in the sample.)

JECT. 2012;44:139–144

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