Downloaded from SAE International by University of New South Wales, Monday, August 20, 2018

SAE TECHNICAL
PAPER SERIES 2001-01-2357

Development of a Membrane Based Gas-Liquid

Separator for the Space Station Water Processor
Catherine Thibaud-Erkey, Anthony Lanzarone, Adam Lurie and Doug Snowdon
Hamilton Sundstrand Space Systems International, Inc.

KS Cheng
Millipore Corp.

31st International Conference

on Environmental Systems
Orlando, Florida
July 9-12, 2001

400 Commonwealth Drive, Warrendale, PA 15096-0001 U.S.A. Tel: (724) 776-4841 Fax: (724) 776-5760
 Downloaded from SAE International by University of New South Wales, Monday, August 20, 2018

The appearance of this ISSN code at the bottom of this page indicates SAE’s consent that copies of the
paper may be made for personal or internal use of specific clients. This consent is given on the condition,
however, that the copier pay a $7.00 per article copy fee through the Copyright Clearance Center, Inc.
Operations Center, 222 Rosewood Drive, Danvers, MA 01923 for copying beyond that permitted by Sec-
tions 107 or 108 of the U.S. Copyright Law. This consent does not extend to other kinds of copying such as
copying for general distribution, for advertising or promotional purposes, for creating new collective works,
or for resale.

SAE routinely stocks printed papers for a period of three years following date of publication. Direct your
orders to SAE Customer Sales and Satisfaction Department.

Quantity reprint rates can be obtained from the Customer Sales and Satisfaction Department.

To request permission to reprint a technical paper or permission to use copyrighted SAE publications in
other works, contact the SAE Publications Group.

All SAE papers, standards, and selected

books are abstracted and indexed in the
Global Mobility Database

No part of this publication may be reproduced in any form, in an electronic retrieval system or otherwise, without the prior written
permission of the publisher.

ISSN 0148-7191
Copyright © 2001 Society of Automotive Engineers, Inc.

Positions and opinions advanced in this paper are those of the author(s) and not necessarily those of SAE. The author is solely
responsible for the content of the paper. A process is available by which discussions will be printed with the paper if it is published in
SAE Transactions. For permission to publish this paper in full or in part, contact the SAE Publications Group.

Persons wishing to submit papers to be considered for presentation or publication through SAE should send the manuscript or a 300
word abstract of a proposed manuscript to: Secretary, Engineering Meetings Board, SAE.

Printed in USA
 Downloaded from SAE International by University of New South Wales, Monday, August 20, 2018

2001-01-2357

Development of a Membrane Based Gas-Liquid Separator for the

Space Station Water Processor

Catherine Thibaud-Erkey, Anthony Lanzarone, Adam Lurie and Doug Snowdon

Hamilton Sundstrand Space Systems International, Inc.

KS Cheng
Millipore Corporation

Copyright © 2001 Society of Automotive Engineers, Inc.

ABSTRACT during the development of this device.

The Water Processor developed for the INTRODUCTION

International Space Station includes a high
temperature catalytic reactor that utilizes
oxygen gas to oxidize dissolved chemicals.
The effluent from the reactor is a mixture of
gases (O2, CO2, N2) and hot water. Since
the crew has requested that drinking water
does not contain any free gas at body
temperature (37.8 °C or 100 °F), a phase
separator operating at elevated
temperatures is required downstream of the
catalytic reactor.
For this application, Hamilton Sundstrand
Space Systems International (HSSSI) has
developed a passive Gas Liquid Separator
(GLS) that relies on a positive barrier - a
membrane - to extract the free gas from the
inlet two-phase mixture. The membrane
selected is a hollow fiber hydrophobic
asymmetric membrane with pore size in the
ultra-filtration range.
NASA and HSSSI have been developing a
number of enabling systems for long-
duration space missions. Among the
systems under development is the Potable
Water Processor for the International Space
Station. This system produces potable
water from a variety of wastewater sources
such as humidity condensate, urine distillate
and hygiene wash waters. The Water
Processor uses a number of unit operations
to purify the feed water including filtration,
adsorption, ion exchange, catalytic oxidation
and gas/liquid phase separation. Gas/liquid
phase separation in a microgravity
environment is particularly challenging when
coupled with the constraints of an integrated
water processor. This paper describes the
design and the technology employed for the
final Gas-Liquid Separator (GLS) in the
Water Processor.

This paper outlines the challenges in both

design and operation that were overcome
 Downloaded from SAE International by University of New South Wales, Monday, August 20, 2018
BACKGROUND
NASA’s specification for potable water
includes the typical technical requirements
for ground-based systems (Metals,
Microbial, pH etc.) and some requirements
unique to operation in the Space Station
environment. One key requirement is that
potable water must not contain any free gas
at a temperature of 38°C (100 °F) and a
pressure of 101.3 kPa (14.7 psia). This
requirement is for crew comfort when
drinking the water.
Due to the operating pressure of the system
(2 psig, 14 kPa), the final gas/liquid phase
separation must be performed at elevated
temperature to meet the “no free gas”
requirement. In addition, the GLS must
remove the excess oxygen injected as part
of the operation of the catalytic reactor.
Translating these requirements into an
operation specification, the GLS must
remove 99.75 % of the free gas when
operating at a temperature range of 17 °C to
88 °C (63 °F to 190 °F). Based on the
design conditions this requires the removal
of approximately 5.5 gm/hr (0.012 lb/hr) of
gas. A further requirement is the GLS must
Heater
Sweep Port
Flow Direction
Two-Phase
Inlet
Module
Common Gas Exit
End Plate
Water Outlet
Figure 1. Gas Liquid Separator assembly
vent less than 14 gm/hr (0.03 lb/hr) of water
vapor in the Water Processor rack
environment. This latter requirement
effectively controls the amount of sweep gas
that is used to manage condensation inside
the device. The Water Processor operating
schedule is dictated by the amount of water
to be processed and is expected to be 10 hr
in an Operational mode (processing water)
and 14 hr in Standby mode (not processing
water).
PRODUCT DESCRIPTION
The GLS (Figure 1) consists of four hollow
fiber modules, containing a minimum of
1300 hydrophobic hollow fiber membranes
each. The hollow fiber modules are installed
into Inconel housings that are sealed at
each end with O-rings. The two-phase flow
travels through each module in series.
Permeate gases are collected from each
module in parallel. Each Inconel housing is
wrapped with a heater. The modules are
mounted against an end plate that includes
the common permeate outlet port. For
condensation control, each module is
equipped with a central sweep gas port.
Sweep gas is equally distributed to the
Sweep Manifold
 Downloaded from SAE International by University of New South Wales, Monday, August 20, 2018

modules by placing an orifice in each completely fluorinated, it has extremely good

distribution leg. heat and chemical resistance, which is a
characteristic of Teflon products. The
The GLS assembly is mated with other membrane is made from Thermo-Inversion-
hardware to form the Gas Separator Orbital Phase-Separation (TIPS) process, which is
Replacement Unit (GS ORU) (Figure 2). commonly known as the melt-spun hollow
The GS ORU is mounted on a tray and fiber process. The hollow fiber is completely
enclosed by a fiberglass cover internally asymmetric with a relatively open
insulated with Pyropel . The GLS microporous structure on the outside surface
performance is monitored with a gas as well as the bulk of the hollow fiber. The
detector placed in the downstream water inner surface has a skin structure with much
stream. A liquid sensor monitors the tighter pore sizes (see Figures 3 and 4). The
membrane integrity by detecting water in the thickness of the skin is less than one micron.
outlet gas stream. The pore size of the skin is in the
ultrafiltration (UF) range and we have
DESIGN FEATURES demonstrated that it has the ability to filter
macromolecules.
MEMBRANE CHARACTERISTICS - The
GLS development and flight devices are For degassing applications, the purpose of
hollow fiber modules that contain membrane forming a skin in the lumen (inside) of a
fibers. The membrane is a microporous hollow fiber is to maintain a very phobic
hollow fiber made from perfluoro-alkoxyl surface, which serves as a barrier to prevent
(PFA) polymer. PFA, like polytetra- penetration of the process fluid into the
fluorethylene (PTFE) and fluorinated membrane matrix. If this barrier is broken
ethylene propylene (FEP), belongs to the and the process fluid is allowed to penetrate
Teflon family. Since the polymer is into the microporous membrane matrix, the

Figure 2. Complete Gas Separator Orbital Replacement Unit

 Downloaded from SAE International by University of New South Wales, Monday, August 20, 2018
Figure 3. Cross-section of membrane
near inside of fiber (skin layer at
bottom)
degassing efficiency of the membrane will
drop drastically. The phobic nature of a
“Teflon” surface and the very small pore size
of the skin create an efficient barrier to liquid
penetration. Although the surface is very
tight, it is still porous. In fact, the surface is
still open enough that it does not impede
diffusion of gas molecules. Degassing tests
(i.e. removal of dissolved gas) of this fiber
shows that the skin has negligible
membrane mass transfer resistance. It is
this combination of porosity and phobicity
that gives this fiber its unique degassing and
debubbling properties.
In the GLS devices, PFA is used both as the
potting compound and the fiber material.
The membrane and membrane modules
were manufactured by Millipore Corporation
(Bedford, MA).
In normal operation, the two-phase flow runs
through the lumen of the fibers and the
permeate (water–saturated gas that
permeated the membrane) is recovered in
the shell side. The two-phase flow is
pressured to 2 psig (14 kPa) to provide a
driving force for gas transport.
Modeling - To gain insight into the operation
of the flight modules, a simplified model was
developed and benchmarked against the
operation of the development modules. The
model assumes that the removal of free gas
occurs in two consecutive steps: (a) the
diffusion of the gas through the liquid layer
inside the lumen and (b) the diffusion of the
gas through the hydrophobic membrane.
The overall resistance to mass transfer is
Figure 4. Lumen skin surface
therefore, the addition of the membrane
resistance and of the liquid resistance that
are inversely proportional to the membrane
and liquid permeabilities, respectively.
Typical permeability in liquids is between
100 to 1000 Barrers [1]. The membrane
permeability was determined experimentally
6
to be around 1x10 Barrers.
GAS-PHASE OPERATION - The membrane
oxygen permeability was measured using a
dead-end method as shown in Figure 5. All
outlet ports were left open to prevent
pressure build-up in the shell side.
The gas permeance -P- is given by the
relation:
Q = PS ( ph − pl )
where Q is the permeate flow rate, S is the
membrane surface area, and ph and pl are
respectively the partial pressures of the gas
of interest at the feed (high) and permeate
(low) sides of the membrane. Since the
incoming gas is pure, its partial pressure in
the tube side is equal to the total pressure.
In the shell side, the same holds as long as
the shell has been properly evacuated. The
shell side is assumed to be at atmospheric
pressure. Therefore, the driving force is
simply equal to the measured gauge
pressure in the lumen side.
The results obtained for four development
modules are plotted in Figure 6. The scatter
in oxygen permeance is due to the normal
variability in the porosity of the membrane
 Downloaded from SAE International by University of New South Wales, Monday, August 20, 2018

and is of no consequence in the current surface area. Therefore, the nominal

application since membrane resistance is challenge for the development modules was
not controlling the process. defined as removing twice the specified
amount of oxygen at twice the specified
TWO-PHASE OPERATION - The water flow rate.
development modules contain about twice
as many fibers as the later-designed flight The setup shown in Figure 7 was used to
modules and therefore about twice the evaluate the removal efficiency of the

Permeance=slope/membrane area
Mass flow
controller
F
l
o
w
r
a
P t
G e

A
S Pressure

Figure 5. Test Setup for pure gas permeation measurement and permeance relation

100

10
oxygen flow rate (l/min)

0.1

0.01

0.001
0.1 1 10
average delta pressure across membrane (psid)

Figure 6. Pure oxygen permeation through membranes and through an equivalent

water layer.
 Downloaded from SAE International by University of New South Wales, Monday, August 20, 2018
module in a two-phase flow configuration.
In all testing, the gas-liquid mixture was in
slug flow and was flowing inside the fibers
under slight pressure. The modules were
positioned vertically with upward flow to
ensure that gravity did not help separation.
Figure 8 shows the data obtained for
development modules tested individually at
various two-phase pressures. As expected,
the efficiency increases as the two-phase
flow pressure increases, although not in a
linear way as was found in the gas phase
case. The decreasing trend of the slope
indicates that the average mass transfer
coefficient actually decreases as the
removal efficiency increases. The amounts
of gas removed in two-phase operation are
on the order of 100 cc/min, which is much
less than the amounts removed in dry gas
phase operation. These observations are
consistent with the resistance in series
model.
Figure 8 also shows that, as expected, the
spread between the modules was greatly
reduced due the presence of the water
Soap
Bubble
Meter
Rota -
meter
Pump
Mass flow
controller
P
Control
H2O O2 box
Figure 7. Two phase Test Set-Up
layer.
The model was used to simulate the
experimental results obtained with the
development units and yielded good results.
For example, for development module 4 at
nominal development conditions, the
predicted permeate flow rate was within 2%
of the experimental flow rate.
The model could then be used to predict the
behavior of four flight modules in series. The
model predicts that, at the beginning of life
conditions, complete free gas removal
should be achieved within the first two
modules (see Figure 9).
CONDENSATION MANAGEMENT -To meet
the requirement of no free gas at 100 °F (38
°C) in the product water, the separator must,
at its operating pressure, operate at
elevated temperatures to ensure the release
of an adequate amount of free gas. The high
temperature capability of the membrane
material allows the GLS to operate with inlet
water temperatures in the range of 159 °F to
190 °F (70C to 88C).
Back
Pressure
P
Regulator
H
F
M
 Downloaded from SAE International by University of New South Wales, Monday, August 20, 2018

In operation, the gas permeate will contain modules. This air has a dew point as high as
water vapor due to the nature of the 60 °F. To not exceed the allowed amount of
membrane. The relative amount of water water vapor exhausted into the cabin, the
vapor present in the permeate (saturation) sweep air is limited to a flowrate of 0.03 lb/hr
will depend on the given inlet fluid (175 scc/min).
temperature. Controlling the saturation of
the permeate stream is important in THERMAL ISOLATION - The GLS is
ensuring that no water condenses in the sensitive to thermal gradients since heat
shell side possibly causing loss of leaks create the potential for condensation.
performance. This situation can be managed Therefore, the package design must provide
by ensuring that the permeate stream never an isothermal environment for the GLS.
encounters a surface having a temperature Radiation and conduction must be
lower than its dew point temperature, or by controlled. This has been accomplished
decreasing the dew point temperature of the through numerous design features. First,
permeate stream to a lower value. The the GLS operates in a fiberglass enclosure,
design of the GLS employs a careful which isolates the GLS from the rack
balance of both techniques. environment. Taped to the inside of the
To ensure that the permeate gases only fiberglass cover is a 1-inch layer of
encounter hot surfaces, each of the insulation. Second, to control radiation, a
low emmissivity tape is attached to both the
membrane modules is wrapped in a blanket
heater. The heater is controlled so that the inside of the insulation (facing the GLS
shell-side temperature is always higher than component) and the GLS. In order to control
conduction, the GLS is mounted to a frame
the inlet water temperature.
with thermal isolation mounts. The isolation
To lower the dew point temperature of the mounts are made of a phenolic material that
has a low thermal conductivity. These
permeate gases, a cabin air sweep gas is
introduced to the shell-side of the membrane design features help to thermally isolate the

120
with diffuser plate
without diffuser plate
100
removal efficiency (%)

80

60

40
module 2
module 3
20 module 4
module 1

0
0 2 4 6 8 10
average delta pressure across the membrane (psid)

Figure 8. Two-phase test results with and without diffuser plate.

 Downloaded from SAE International by University of New South Wales, Monday, August 20, 2018

GLS. Processor. However, this concept may be

useful in other systems where a gas-free
FLOW DISTRIBUTION - As in many
liquid is required. Such systems include the
capillary systems, the optimal utilization of
production of ultrahigh purity water for the
all parallel fibers is vital to ensuring the best
semi-conductor industry or the medical field.
possible performance. The GLS
For space applications, The GLS could be
incorporates a diffuser plate within the
adapted to separate gas and liquid
header to help distribute the inlet flow to as
downstream of a Sabatier reactor when
many fibers as possible. The effect of the
such a process becomes an integral part of
diffuser plate is clearly shown in Figure 8
the Space Station environmental control
and was also seen during flow visualization
system.
tests using a see-through end-cap.
SUMMARY AND CONCLUSIONS
FUTURE EFFORT
Working in conjunction with Millipore
Membranes are susceptible to loss of
Corporation, a membrane and potting
performance due to fouling. The chemical
technology was identified that is well-suited
compatibility and skinned nature of the
to the requirements of a Water Processor
membrane in conjunction with the flow-
phase separator. Excellent chemical
through design were selected to minimize
inertness, high temperature compatibility, a
this effect. Long-term testing is planned to
hollow-fiber configuration and a skinned
assess the effects of operating a flight-like
inner layer are key features of this
GLS component downstream of an
technology. By carefully controlling
operating flight configuration catalytic
temperatures, minimizing heat loss and
reactor.
using the smallest amount of sweep gas in a
tightly packaged design, the GLS
OTHER POSSIBLE APPLICATIONS component and ORU design make the best
use of the available resources to passively
The GLS design is specific to the Water remove 99.75% of the free gas present in a
module 1 module 2

100
Removal efficiency
Permeance
overall permeance (cc/(min.psi.cm2)

80
gas removal efficiency (%) or

60

40

20

0
0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6
dimensionless distance from first module inlet
Figure 9. Predictive model of flight gas liquid separator
 Downloaded from SAE International by University of New South Wales, Monday, August 20, 2018

two-phase inlet stream within a microgravity

environment.

ACKNOWLEDGEMENTS

The authors of this paper would like to thank

Millipore Corporation for its interest in
developing this technology. Special thanks
to T. Dean Gates of Millipore and Pete
Keilich of Hamilton Sundstrand for their
efforts and suggestions.

REFERENCES

[1] - "Polymeric gas separation

membranes", p 156, Paul, D. R.; Yampolski,
Y. P. Eds, CRC Press, 1994