Commercial hemodialyzers are hollow-fiber cylindrical modules with dimensions and inlet–outlet configurations dictated mostly by practice. However, alternative configurations are possible, and one may ask how they would behave in terms of performance. In principle, it would be possible to depart from the standard counter-flow design, while still keeping high clearance values, thanks to the increase in the shell-side Sherwood number (Sh) due to the cross-flow. To elucidate these aspects, a previously developed computational model was used in which blood and dialysate are treated as flowing through two interpenetrating porous media. Measured Darcy permeabilities and mass transfer coefficients derived from theoretical arguments and CFD simulations conducted at unit-cell scale were used. Blood and dialysate were alternately simulated via an iterative strategy, while appropriate source terms accounted for water and solute exchanges. Several module configurations sharing the same membrane area, but differing in overall geometry and inlet–outlet arrangement, were simulated, including a commercial unit. Although the shell-side Sherwood number increased in almost all the alternative configurations (from 14 to 25 in the best case), none of them outperformed in terms of clearance the commercial one, approaching the latter (257 vs. 255 mL/min) only in the best case. These findings confirmed the effectiveness of the established commercial module design for the currently available membrane properties.
This work aims to explore the applicability of electrical resistance tomography (ERT) in the analysis of fluid distribution in haemodialysis modules, which is not straightforward due to the complex geometry of the hollow fibre bundles and the small sizes of the modules. On the other hand, ERT is potentially a suitable and convenient technique for investigation in this field due to its cost‐effectiveness and capacity to perform measurements in opaque systems. After a preliminary estimation of the fibre bundle local distribution, the assessment of the technique is performed by observing the time evolution of the measured conductivity maps during the module filling and emptying operations with water and air, which are alternatively fed inside or outside the fibre bundle. Reliable conductivity maps are obtained by placing the module vertically or horizontally. Additional experimental data collected by feeding liquid mixtures of different sodium chloride concentrations show that the technique is suitable for detecting concentration variations, due to the mass transfer through the fibres, and flow maldistribution, due to the specific geometry of the module. From the preliminary results collected in this work, the technique appears to be adequate for the collection of data that can support the optimization of the module geometry and computational model validation.
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