Grant: CCI Applied Research and Development Grants

Development of a metallic potting material for ethanol dehydration addresses inefficiencies and sustainability issues faced by the membrane separation industry. Traditional epoxy-based potting materials embed nanoporous polymer fiber membranes and integrate them into membrane separation modules. These materials encounter challenges such as wicking, swelling, and overall mechanical degradation during the ethanol dehydration process. The epoxies also have a limited lifespan of on average between six to 24 months depending on use. The combination of a short lifespan and their intricate agricultural composition results in significant limitations for Canada’s bioethanol industry and directly affects energy and environmental sustainability. The Centre for Innovation and Research in Advanced Manufacturing and Materials (CIRAMM) at the Southern Alberta Institute of Technology, working in collaboration with Whitefox Technologies Canada Limited, have proposed a solution that centers on developing low-melting-point metallic alloys as potting materials to replace traditional epoxy resins. To date this technology is largely unexplored due to the complexity of metallizing thin nanoporous polymer fiber membranes and ensuring adequate metal-to-polymer adhesion. The proposed approach uses low melting point alloys and expects to enhance durability and performance inherent in metals and seeks to address the challenges associated with using metals, such as increased weight and potential chemical reactions. The project’s objectives are to develop and characterize novel metallic potting low-melting point alloys based on their solidification temperatures, to assess those alloys resistance to corrosion using advanced metallurgical techniques, and to evaluate mechanical strength correlated with exposure to agricultural chemical inputs. Alloys meeting these objectives will be evaluated for their metallization and adhesion to the nanoporous polymer fiber membrane by monitoring unrestricted flow through the membranes while maintaining a tight seal. These experiments will be scaled to incorporate bundles of fibers ranging from 50 to 50,000, while noting capabilities and limitations. The knowledge gained from this project will contribute to understanding metal-polymer interactions and surface modification techniques that can be transferred to Canadian companies and foster innovation in membrane technology applications bridging academia and industry.