Potting material for membrane separation modules

A header assembly for a housed membrane separation module, the header assembly comprising:

• a plurality of hollow fiber membranes which are bundled together longitudinally to form a bundle having a core axis and defining a first axial length;
• and
• a potting material provided as a cast having a second axial length parallel to the core axis of the bundle, wherein a ratio of the second axial length to the first axial length is from 1:5 to 1:50;
• wherein the potting material encases the bundle with a seal over the second axial length;
• and
• further wherein the potting material consists of a tin alloy having a melting point of from 210 to 230° C., wherein the tin alloy consists, on a metals basis, of:
• from 95 to 97 wt. % tin (Sn);
• and
• from 3 to 5 wt. % of a combination of Silver (Ag) with at least one of Nickel (Ni), Copper (Cu), or Germanium (Ge).

A method of forming a header assembly for a hollow fiber membrane separation module, said method comprising:

• preparing a molten potting material consisting of a tin alloy, wherein the tin alloy consists, on a metals basis, of:
• from 95 to 97 wt. % Tin (Sn), and from 3 to 5 wt. % of a combination of Silver (Ag) with at least one of Nickel (Ni), Copper (Cu), or Germanium (Ge);
• providing a plurality of hollow fiber membranes having a potting region;
• introducing the potting region of the plurality of membranes into a cavity of a mold having a volumetric capacity;
• introducing the molten potting material into the cavity of the mold at a temperature of from 225° C. to 250° C. such that the potting material flows around the membranes;
• solidifying the potting material in the cavity of the mold;
• removing the solidified potting material from the mold;
• and
• cutting a portion of the solidified potting material so that ends of the plurality of hollow fiber membranes are exposed.

A membrane separation module for withdrawing permeate from a multicomponent fluid feed, the module comprising:

• a housing;
• a plurality of hollow fiber membranes which are bundled together longitudinally to form a bundle having a core axis and defining a first axial length;
• a first header disposed within the housing, the first header comprising a first potting material which is provided as a cast having a second axial length, wherein a ratio of the first axial length to the second axial length is from 1:5 to 1:50;
• a second header disposed within the housing in a spaced apart relationship from the first header, the second header comprising a second potting material which is provided as a cast having a third axial length, wherein a ratio of the first axial length to the third axial length is from 1:5 to 1:50;
• wherein:
• the first potting material of the first header encases a first end of the bundle over the second axial length;
• the second potting material of the second header encases a second end of the bundle over the third axial length;
• and
• the first and second potting materials each consist of a tin alloy, the tin alloy consisting, on a metals basis, of:
• from 95 to 97 wt. % tin (Sn);
• and
• from 3 to 5 wt. % of a combination of Silver (Ag) with at least one of Nickel (Ni), Copper (Cu), or Germanium (Ge).