Fluid-permeable fibre matrix and a method of producing said matrix

A fluid-permeable fibre matrix having a large surface area and a method of making said matrix are described. The fibre matrix is characterized in that its fibres are oriented to a high degree in such a manner that the total matrix fibre length is substantially oriented in a main orientation plane, and that membranes are provided between the fibres. It is recommended that at least 60%, preferably at least 80% of the total fibre length of the matrix deviate by at most about 20.degree. from the main orientation plane. The matrix fibres suitably consist of mineral wool, preferably glass wool, while the membranes consist of a film-forming organic or inorganic material, such as synthetic or natural polymeric materials, glass, metals, ceramics, waxes, fats or oils. The membranes may be impermeable or porous, and active material, such as inorganic catalysts, biocatalysts or adsorbing materials, such as activated carbon and zeolites, may be affixed to or incorporated in the membranes. The fluid-permeable fibre matrix may be produced by arranging the main orientation plane of the original fibre matrix which has no membranes, substantially vertical, whereupon a film-forming liquid, such as gelatin, is supplied to the upper end of the fibre matrix. With suitable values of the viscosity and the surface tension of the film-forming liquid, membranes are formed between the matrix fibres, and these membranes are solidified, for example by polymerization, evaporation of solvent, or in some other manner.

The present invention relates to a fluid-permeable fibre matrix having a 
large surface area, and a method of making such matrix. 
In a number of processes, such as chemical and biological processes, 
adsorption processes etc. in which two or more substances interact with 
one another, it is a well-known fact that the available interface between 
the interacting substances is a factor determining the rate of the 
process. The larger the available interface, the quicker and more 
efficient the process will proceed. In order to increase the available 
interface, it therefore is common practice to dispose one of the 
substances on a carrier having a large surface area, the substance 
frequently being arranged in as thin a layer as possible on the carrier. 
Consequently, the area of the available interface will increase with an 
increasing surface area of the carrier, and this surface area in turn 
increases as the particle size of the carrier is reduced. To carry the 
desired process into effect, there are provided, in actual practice, a 
multiplicity of carrier particles, with the substance disposed thereon, in 
a bed to which is supplied the remaining substance or substances 
participating in the process. One disadvantage of reducing the particle 
size of the carrier, thereby to increase the interface available to the 
process, is in this connection that the energy required to bring the 
substances participating in the process into contact with each other, for 
example in the form of an applied pressure, will increase as the particle 
size of the carrier is reduced. In view hereof, a compromise must usually 
be made between the carrier particle size and the pressure drop caused by 
the carrier. 
Also for particles of microporosity, it is the outer available surface that 
is of interest, as will appear from the following first example of prior 
art technique. 
The present invention aims at eliminating these difficulties and providing 
a fluid-permeable matrix having a large surface area and useful as a 
carrier, said fibre matrix having, in spite of its large surface area, a 
low pressure drop when fluid passes through the matrix.

Before the present invention and its advantages will be discussed in more 
detail, the prior art technique and the difficulties encountered therein 
will be illustrated by means of two examples. 
The first example relates to the adsorption of a substance from a mixture, 
such as a gaseous or liquid mixture for the purpose of purification or 
recovery, such as the adsorption of a solvent from a spray-painting plant, 
the mixture to be treated being conducted through a bed of an adsorbing 
material, such as activated carbon, zeolite or a microporous polymer, such 
as polystyrene cross-linked with divinyl benzene. In order to maintain the 
adsorption capacity of the bed, the bed normally is regenerated 
periodically, and the periodicity is determined by the maximum content 
(the breakthrough content) of the substance in question, which emanates 
from the filter bed and which may be tolerated on grounds of purification 
or loss. 
If the adsorbent is a bed of equally large spherical particles, the solvent 
content in the particles of the bed, at a given air flow through the bed 
and a given solvent concentration in the air supplied thereto, will vary 
at breakthrough with the depth of the bed as illustrated diagrammatically 
in FIG. 1 wherein curve 1 relates to very small particles and curves 2, 3 
and 4 relate to particles having a gradually increasing diameter. The 
relationship between the surface below the respective curve and the 
surface of the rectangle having the corners A, B, C, D will thus be a 
measure of the average degree of utilisation of the adsorbing material. 
To economise on adsorption material and make the filter casing smaller and 
thus less expensive, a small particle diameter and, consequently, a higher 
degree of utilisation are desired. However, small particles will give a 
greater pressure drop through the bed and thus higher energy cost. 
Furthermore, if the filtrated gas or liquid contains particulate 
impurities, the tendency to clogging of the bed will increase with the 
reduction in particle size. 
An economically optimal filter will thus be a compromise as regards 
particle size. 
The reason for the incomplete degree of utilisation is that the adsorbing 
substance does not have time to diffuse from the outer surface through the 
pores into the centre of all particles before the maximally permissible 
output content has been attained, i.e. breakthrough has occurred. 
The conditions illustrated in FIG. 1 will prevail also when the particles 
are not spherical but of the same geometrical shape, or if they are a 
mixture of substantially uniform particles having a given average particle 
diameter but being of different sizes. The determining factor is the 
longest diffusion length required in the micropores, i.e. the geometrical 
distance from the outer surface of the particle to its centre. The smaller 
this distance is, the more completely will the adsorbent be utilised, i.e. 
the closer will the concentration curve concerned conform to the line A, 
B, C. 
The above analysis is completely correct only if the material transport via 
diffusion through the micropores is the rate-determining step, and the 
diffusion rate of adsorbed substance from the bulk of the gaseous or 
liquid phase to the particle surface and also the adsorption rate on the 
active surface thus are immaterial. However, these conditions prevail in 
almost every practical application. 
Thus, at a given volume flow and a given content of the substance or 
substances to be adsorbed, the selection of the particle dimension of the 
adsorbent will be a compromise between on the one hand the pressure drop 
and thus the energy cost involved in surmounting this pressure drop and, 
on the other hand, the degree of utilisation of the adsorbent bed and thus 
the cost of the adsorbent and the filter casing. A large particle 
dimension and thus a longer diffusion length will reduce the former cost 
but increase the latter. Besides, a bed of small particles will have 
higher clogging tendency in the presence of solid impurities in the 
gaseous or liquid flow, which is very common in actual practice. 
This means that it would be of great practical value if an adsorbent bed 
could be provided which has a small maximum diffusion length but a 
retained low pressure drop and comparatively low clogging tendency. 
The other example to illustrate prior art technique is the cultivation of 
microorganisms, such as cells etc., on the surface of a carrier material. 
In such processes it is desired that the layer of cells on the surface of 
the carrier material be as thin as possible, and preferably is but a 
monolayer. In this manner, the diffusion of the nutrients and, where 
applicable, of the oxygen to the microorganisms as well as the diffusion 
of metabolites away from the microorganisms will be facilitated. One 
example of this technique is the biological beds that are used in the 
purification of wastewater. In these prior art methods, it is difficult to 
achieve an optimally efficient addition of oxygen to the microorganism. In 
fact, in order that the microorganism should be able to utilise the 
oxygen, this must diffuse through the liquid phase of substrate solution 
surrounding the microorganism. Such diffusion through the liquid phase 
normally is very slow and is the step which determines the rate of the 
entire process. Therefore, several attempts have been made to facilitate 
and accelerate the oxygen transfer, for instance by agitation, fine 
division of the air, fine division of the substrate solution into 
droplets, etc. Although these measures give a certain improvement, they 
require relatively large amounts of energy. 
For instance, the cost of oxygenation often is, next to costs for raw 
material and equipment, the largest cost in industrial biological 
processes. Moreover, the fine division effected to increase the liquid-gas 
contact surface generally is not very efficient. Thus, even if the 
substrate solution is divided into fine droplets, each droplet has a 
substantial mass or bulk into which the air can diffuse entirely only 
after a relatively long period of time. 
It appears from the above that the oxygen transfer capacity of the system 
which is decisive of the rate of aerobic biological processes, is not 
optimal in prior art systems, which is a serious drawback, inter alia 
because it sets an upper limit to the final cell concentration or 
productivity in the substrate. In biological processes, it is desired 
almost without exception that this concentration or productivity be as 
high as possible. 
It is against this background, and in order to eliminate the described 
drawbacks of prior art technique, that the present invention has been 
developed. As mentioned before, the invention relates to a fluid-permeable 
fibre matrix having a large surface area, an area that is achieved in the 
present invention by providing the matrix between the fibres with 
spaced-apart thin disks or membranes, the planes of which are 
substantially parallel to the direction of the fluid flow which is 
intended to pass through the fibre matrix. 
The characteristic features of the invention will appear from the appended 
claims. 
The invention primarily uses a fibre matrix of mineral wool, preferably 
glass wool. Such fibre matrices have all the properties which are required 
of a matrix according to the present invention, such as inertness, low 
resistance to gas and liquid flow, good dimensional stability, etc., and 
can also be manufactured at low cost. 
A matrix of glass wool with a density of 23 kg/m.sup.3 which is a normal 
value for a glass wool construction insulating panel consists of about 1% 
by volume of glass and 99% by volume of voids. 
The matrix fibres have an average diameter of about 1-500 .mu.m, preferably 
about 1-100 .mu.m, and most preferably about 1-20 .mu.m. 
According to the invention, the fibres in the mineral wool matrix have a 
main orientation plane, at least 60% of the total fibre length of the 
matrix deviating by at most 20.degree. from said main orientation plane. 
Preferably, the deviation is at most 20.degree. in at least 70%, and most 
preferably at least 80% of the total fibre length of the matrix. 
The main orientation plane of the fibres in the mineral wool matrix 
according to the invention is accomplished for example by increasing, 
during the preparation of the matrix, the rate of motion compared to the 
normal rate of motion of the substrate on which the fibres are laid, the 
plane of the substrate corresponding to the main orientation plane of the 
matrix fibres. However, the invention is not restricted to any special 
method of providing the dominant fibre orientation, and every matrix which 
has the main orientation plane here concerned and in which at least 60% of 
the total fibre length deviate by at most 20.degree. from the main 
orientation plane, is included, regardless of the production technique. 
As mentioned above, the matrix according to the present invention is 
three-dimensional, which means that it has an extent in each of three 
planes perpendicular to each other of at least 10 times the fibre 
diameter. In order to increase the self-supporting capacity of the 
three-dimensional fibre matrix, the fibres of the matrix may be linked 
together at their points of intersection by chemical or mechanical bonds. 
One example of chemical bonding is interconnecting the fibres at their 
points of intersection by means of polymer binders, for instance of the 
phenolic resin type. Another example of bonding is fusing the fibres at 
their points of intersection by heat or by means of a solvent. One example 
of mechanical bonding is needling the fibre material. A three-dimensional 
matrix thus bonded is substantially self-supporting, which means that a 
particular equipment for encapsulating the matrix is normally not 
required. It may, however, be desirable or suitable in some cases to 
provide the matrix element with external support means which may be 
designed in a simple and inexpensive manner as gas-permeable walls of, for 
example, wire netting or perforated metal sheets. 
In its simplest embodiment, the matrix consists of a homogeneous fibre 
body, i.e. of fibres having substantially the same size and properties. To 
counteract penetration of liquid from the downwardly flowing liquid at the 
vertical boundary walls of the matrix, the outer vertical surfaces of the 
matrix may be made hydrophobic by treating the fibres in these outer 
surfaces with hydrophobating oils, waxes or polymers in per se known 
manner. In these outer layers, the fibres are thus not wetted by the 
liquid, and the resistance to liquid penetration therefore is high, while 
the gas pressure drop is maintained low. This means that the outer layers 
constitute an outer boundary to the inner wetted layers of the matrix and 
allow the gas, but not the liquid, to pass therethrough. 
Further alternative embodiments of the matrix according to the invention 
include multilayer matrices in which the matrix body is composed of a 
plurality of different fibre layers which are distinct or continuously 
merging into each other and which differ by their fibre diameter, 
distribution of fibre diameter, fibre length, density, etc. These fibre 
layers are suitably arranged in parallel beside each other or 
concentrically around each other in the direction of flow of the liquid. 
In the case of distinct fibre layers, the layers may either engage each 
other directly or be separated by intermediate layers which preferably are 
hydrophobic. 
Although the structure and the material of the surface-enlarged membranes 
in the fibre matrix of the invention may vary, the membranes are all 
formed in situ in the fibre matrix by means of a film-forming material. 
The finished membrane may be polymeric, metallic, crystalline, amorphous 
or vitreous and extend between different fibres which, in addition, may be 
completely or partly covered by the membrane-forming substance. The 
membrane material consists of organic or inorganic materials which, under 
normal ambient conditions, are film-forming or may be made film-forming 
by, for example, heating to the softening or melting temperature of the 
membrane material. As examples of membrane material, mention may be made 
of glass, metals, ceramics, waxes, fats, oils and film-forming synthetic 
and natural polymeric materials. Membranes of organic materials may also 
be carbonated. 
The membranes in the fibre matrix may be either substantially impermeable, 
i.e. essentially impermeable to gases and liquids, or porous, such as 
microporous. 
The fibre matrix as defined by the present invention and provided with 
membranes may either be utilised as such, for example as an adsorbent, or 
it may be utilised as a carrier for fixing on the membrane an "active" 
material intended to interact with one or more other substances in a 
process. As examples of active materials that can be fixed to the fibre 
matrix according to the invention, mention may be made of functional 
groups which, by chemical aftertreatment, can be introduced into the 
membrane, or catalysts by which are meant both conventional inorganic and 
organic catalysts for influencing of chemical reactions, and so-called 
biological catalysts or biocatalysts by which are meant bacteria, yeast, 
fungi, algae, animal cells, human cells, plant cells, proteins and 
enzymes. Also adsorbing materials, such as activated carbon, zeolites and 
other porous materials having a large inner surface can be fixed to the 
fibre matrix according to the invention and are comprised by the 
above-mentioned active materials. 
Fixing the active material to the membrane in the fibre matrix according to 
the invention can be carried out in different ways. For example, the 
active material may be fixed on top of the membrane surface by means of 
physical adhesion forces, chemical bonds, or by means of binders, or the 
active material can be more or less enclosed by the membrane and fixedly 
anchored therein. Such enclosure of the active material in the membrane 
may be accomplished either by forming the membrane as a porous layer, in 
which case the active material is enclosed within the pores, or by 
supplying the active material during formation of the membranes, before 
these have solidified so that the active material to a greater or less 
extent is moulded into the membranes. 
As mentioned before, the invention also comprises a method of preparing a 
fluid-permeable fibre matrix of the type referred to above, and to 
illustrate this aspect of the invention, a typical production of a fibre 
matrix according to the invention will be described below. 
A porous three-dimensional mineral wool matrix of the type described above, 
having a high degree of fibre orientation such that the total fibre length 
is arranged substantially in one main orientation plane, as has also been 
mentioned before, is placed with the main orientation plane substantially 
vertical. To the upper end face of the fibre matrix arranged in this 
manner, a membrane-forming liquid is added which is allowed to flow 
downwardly through the matrix. The membrane-forming liquid wets the fibres 
of the matrix and has a suitable viscosity and surface tension to form 
membranes preferably between the fibres in the main orientation plane. The 
membrane-forming liquid is caused to solidify by polymerisation, 
evaporation of any solvent from the liquid, cooling or in some other 
manner. The solid membrane formed by this solidification process may be 
used either as it is or may be further treated to be made, for example, 
microporous and to form a microporous adsorbent. Since the fibre matrix is 
porous and readily permeable to both gas and liquid, it may be used as an 
adsorbent bed. Compared to a particle bed, this bed exhibits, besides the 
advantages of a low pressure drop and insignificant clogging tendency, 
also a self-supporting capacity whereby equipment expenditure can be 
reduced considerably. Furthermore, because of the reinforcing effect of 
the fibres, use may be made also of adsorbents having a very low 
mechanical strength. 
The thickness of the membranes may be controlled by suitable selection of 
the fibre diameter, the viscosity of the liquid, its surface tension and 
fibre wetting characteristics, the reaction rate, liquid flow, possibly 
renewed liquid throughflow of the solidification process etc. The 
adsorbent quantity per volume unit is determined by the average membrane 
thickness, the degree of fibre orientation and the original density of the 
fibre matrix. 
By using a membrane which swells in the presence of solvents, high 
absorption capacity can be combined with high accessibility to large 
molecules, which is of special interest in the separation and purification 
of biological materials. There is no restriction to the thickness of the 
membranes according to the invention, whether they are swelled or not. The 
increasing flow resistance resulting from an increasing membrane 
thickness, on the other hand, sets a limit to the thickness in actual 
practice. This limit varies considerably between and within different 
applications and depends entirely upon the pressure drops and flows that 
can be accepted in the individual case. 
To reduce the tendency to form membranes which are substantially transverse 
to the contemplated direction of flow during subsequent use of the 
fluid-permeable fibre matrix, air or some other suitable gas may be blown 
in the direction of flow during this solidification process. If it is 
desired to influence the rate of the solidification process by means of a 
gaseous catalyst or heat, use may preferably be made of air or some other 
gas as carrier. If the solidification process involves evaporation of 
solvent, the air or gas may furthermore be used for removing evaporated 
substance. 
As mentioned before, the three-dimensional fibre matrix of the invention 
has a high degree of orientation in that the total fibre length of the 
matrix is arranged substantially in one main orientation plane. Thus, the 
inventors have surprisingly found that an unexpected increase in the 
available surface of the fibre matrix, per unit of weight of 
membrane-forming substances, is obtained, i.e. an improved membrane 
formation, with increasing fibre orientation of the matrix. This increase 
is especially noticeable when at least 60% of the total fibre length 
deviate by at most 20.degree. from the main orientation plane. 
Furthermore, the flow resistance of the fibre matrix and the risk of 
clogging of the matrix by particles contained in the fluid supplied, such 
as impurities in a nutrient solution in the cultivation of microorganisms, 
are less in the case of an increased degree of fibre orientation. 
The invention will be illustrated by the following Example. 
EXAMPLE 
Glass wool matrices with different degrees of orientation are provided with 
gelatin membranes, and the relative outer surface is determined. Gelatin 
powder is dissolved in hot water to a concentration of 50 g/liter, Fibre 
matrices of mineral wool having a density of 40 g/dm.sup.3 and a fibre 
diameter of 4 .mu.m, and with different degrees of fibre orientation, are 
wetted with water, whereupon 1 liter of gelatin solution per liter of 
matrix is added. The solution is allowed to flow along the main 
orientation plane of the fibres. The matrix is then placed at 80.degree. 
C. for 6 hours to make the gelatin form membranes in the form of polymeric 
films between the fibres of the matrix. 
The outer surface of the matrix is determined by measuring the adsorbed 
quantity of the enzyme bovine pancreas ribonuclease (from Sigma Chemical 
Co.). Prior to use, the enzyme was dialysed and heat treated (62.degree. 
C.) whereupon the matrix was filled with an enzyme solution containing 2 g 
of enzyme and 0.05 M KNO.sub.3 per liter of water. Enzyme that had not 
been adsorbed, was then washed off, and the adsorbed enzyme quantity was 
measured and deposited in the form of a "relative outer surface" 
(increasing adsorbed enzyme quantity=increasing relative outer surface) as 
a function of the fibre orientation degree of the matrix, which was 
indicated by the percentage of the total fibre length that deviated by at 
most 20.degree. from the main orientation plane. The curve obtained in 
this respect is shown in FIG. 2, and it appears that a marked increase of 
the outer surface is obtained when the matrix fibres show a pronounced 
orientation in the main orientation plane, more particularly when at least 
60% of the total fibre length deviates by at most 20% from the main 
orientation plane of the fibres in the matrix.