Cartridges useful in cleaning dialysis solutions

• US 9,867,918 B2
• Filed: 03/13/2015
• Issued: 01/16/2018
• Est. Priority Date: 03/17/2014
• Status: Active Grant

• Current Assignee: Fresenius Medical Care Holdings Incorporated (Fresenius Medical Care AG)
• Original Assignee: Fresenius Medical Care Holdings Incorporated (Fresenius Medical Care AG)
• Inventors: Merchant, Stephen A., Adams, Kerissa
• Primary Examiner(s): Kim, John
• Application Number:
  US14/656,729
• Publication Number:
  US 20150258266A1
• Time in Patent Office: 1,040 Days
• CPC Class Codes: A61M 1/1656 Apparatus for preparing dialysates
• CPC Class Codes: A61M 1/1666 by dissolving solids
• CPC Class Codes: A61M 1/1696 with dialysate regeneration
• CPC Class Codes: A61M 1/287 Dialysates therefor
• CPC Class Codes: A61M 2205/02 characterised by a particular materials
• CPC Class Codes: B01J 20/0211 Compounds of Ti, Zr, Hf
• CPC Class Codes: B01J 20/0292 Phosphates of compounds other than those provided for in B01J20/048
• CPC Class Codes: B01J 20/043 Carbonates or bicarbonates, e.g. limestone, dolomite, aragonite
• CPC Class Codes: B01J 20/06 comprising oxides or hydroxides of metals not provided for in group B01J20/04
• CPC Class Codes: B01J 20/08 comprising aluminium oxide or hydroxide; comprising bauxite
• CPC Class Codes: B01J 20/20 comprising free carbon; comprising carbon obtained by carbonising processes
• CPC Class Codes: B01J 20/28052 Several layers of identical or different sorbents stacked in a housing, e.g. in a column
• CPC Class Codes: B01J 2220/62 In a cartridge
• CPC Class Codes: B01J 39/12 Compounds containing phosphorus

Abstract

Cartridges useful in regenerating or purifying dialysis solutions are described as well as methods to regenerate or purify spent dialysis solutions. Dialysis methods using the sorbent cartridges of the present invention are further described.

Claims

1. A sorbent cartridge, comprising from inlet to outlet:

a) a first carbon-containing layer;

b) an enzyme-comprising layer that follows the first carbon-containing layer within the sorbent cartridge;

c) a second carbon-containing layer that follows the enzyme-comprising layer within the sorbent cartridge;

d) a zirconium phosphate-containing layer that follows the second carbon-containing layer within the sorbent cartridge;

e) a hydrous zirconium oxide layer that follows the zirconium phosphate-containing layer comprising hydrous zirconium oxide-chloride having an alkaline pH; and

f) a (bi)carbonate layer that follows the hydrous zirconium oxide layer comprising sodium (bi)carbonate.

2. The sorbent cartridge of claim 1, wherein the hydrous zirconium oxide-chloride has a pH greater than about 8.

3. The sorbent cartridge of claim 1, wherein the hydrous zirconium oxide-chloride has a pH greater than about 9.

4. The sorbent cartridge of claim 1, wherein the hydrous zirconium oxide-chloride has a pH of from about 9.5 to about 10.5.

5. The sorbent cartridge of claim 1, wherein the (bi)carbonate layer that follows the hydrous zirconium oxide layer comprising NaHCO₃.

6. The sorbent cartridge of claim 1, wherein the hydrous zirconium oxide layer is free of acetate.

7. The sorbent cartridge of claim 1, wherein the first carbon-containing layer is a layer of granular activated carbon or a carbon pad, and the second carbon-containing layer is a layer of granular activated carbon or a carbon pad.

8. The sorbent cartridge of claim 1, wherein the enzyme-comprising layer comprises a Jack Bean meal/alumina blend.

9. The sorbent cartridge of claim 1, further comprising an alumina-containing layer between the enzyme-comprising layer and the second carbon-containing layer.

10. A method to regenerate or purify dialysis fluid comprising passing dialysis fluid through the sorbent cartridge of claim 1.

11. The method of claim 10, wherein said (bi)carbonate layer is dissolved by the passing dialysis fluid.

12. A dialysis system to regenerate or purify spent dialysis fluid comprising the sorbent cartridge of claim 1.

13. The sorbent cartridge of claim 1 comprising:

a housing

defining a cartridge interior, the cartridge interior having a volume and configured to hold at least two layers of sorbent material, and

comprising a first end comprising a first port configured to permit entry of a fluid into the cartridge interior, and a second end distal to the first end and comprising a second port configured to permit exit of the fluid from the cartridge interior;

a first sorbent layer situated in the cartridge interior, the first sorbent layer having a first geometry and comprising a first sorbent material; and

a second sorbent layer situated in the cartridge interior, the second sorbent layer having a second geometry and comprising a second sorbent material;

wherein the first and second sorbent materials have equivalent chemical compositions, and (a) the first geometry differs from the second geometry in at least one dimension, (b) the first sorbent material differs from the second sorbent material in at least one physical characteristic, or (c) both, and

wherein the first and second sorbent materials are selected from said carbon-containing layer, said enzyme-comprising layer, said zirconium phosphate-containing layer, said hydrous zirconium oxide layer or any combination thereof.

14. The sorbent cartridge of claim 13, wherein the first geometry differs from the second geometry.

15. The sorbent cartridge of claim 14, wherein the first geometry differs from the second geometry in respect to size, shape, or both.

16. The sorbent cartridge of claim 14, wherein the first sorbent layer differs from the second sorbent layer in average height, average width, average length, or a combination thereof.

17. The sorbent cartridge of claim 14, wherein the sorbent cartridge has a central axis about which the first and second sorbent layers are centered, the first sorbent layer and the second sorbent layer are cylindrical, or frusto-conical in shape, and the first geometry differs from the second geometry in respect to average height, average radius, or both.

18. The sorbent cartridge of claim 14, wherein the first and second sorbent layers are concentric and positioned about a central axis along the axial dimension, the first sorbent layer having a width defined by a first radius extending from the central axis to the second sorbent layer, and the second sorbent layer having a width defined by the difference of the first radius and a second radius greater than the first radius.

19. The sorbent cartridge of claim 13, wherein the first sorbent layer and the second sorbent layer differ in volume.

20. The sorbent cartridge of claim 13, wherein the first sorbent layer and the second sorbent layer differ in average density.

21. The sorbent cartridge of claim 13, wherein the first sorbent layer and the second sorbent layer differ in surface area.

22. The sorbent cartridge of claim 13, wherein the first sorbent layer and the second sorbent layer differ in sorbent capacity for at least one species targeted for absorption, adsorption, or both.

23. The sorbent cartridge of claim 13, wherein the first and second sorbent materials comprise particles and average particle size of the first sorbent material differs from average particle size of the second sorbent material.

24. The sorbent cartridge of claim 13, wherein the first and second sorbent materials comprise particles and at least one of the first and second sorbent materials comprises a particle shape not present in the other layer.

25. The sorbent cartridge of claim 13, wherein the first sorbent layer at least partially surrounds the second sorbent layer, or vice versa.

26. The sorbent cartridge of claim 13, wherein the first and second sorbent layers have the same average height with respect to an axial dimension between the first and second ends, and differ in respect to average width, average length, or both.

27. The sorbent cartridge of claim 13 having at least one layer defined by a cross-sectional area with an inner region and outer region wherein the outer region surrounds the inner region, and the layer is defined by a height.

28. The sorbent cartridge of claim 13, wherein the first sorbent layer is adjacent to the second sorbent layer.

29. The sorbent cartridge of claim 13, wherein the first sorbent layer is proximal the first end and the second sorbent layer is proximal the second end.

30. The sorbent cartridge of claim 13, wherein the first sorbent layer has a greater sorbent capacity for at least one species targeted for absorption, adsorption, or both, compared to a sorbent capacity of the second sorbent layer for the at least one species.

31. The sorbent cartridge of claim 13, further comprising at least one additional sorbent layer comprising a sorbent material having a chemical composition differing from the chemical compositions of the first and second sorbent materials.

32. The sorbent cartridge of claim 13, wherein the at least one additional sorbent layer is located between the first end and first sorbent layer, between the first and second sorbent layers, or between the second sorbent layer and the second end.

33. The sorbent cartridge of claim 13, wherein the first sorbent layer and the second sorbent layer are separated from one another by at least one intervening layer comprising a third sorbent layer having a third geometry and comprising a third sorbent material, wherein the third sorbent material has a chemical composition non-equivalent to the chemical composition of the first and second sorbent layers.

34. The sorbent cartridge of claim 13, wherein first sorbent layer and the second sorbent layer are separated from one another by at least one intervening layer comprising a third sorbent layer having a third geometry and comprising a third sorbent material, wherein the first, second, and third sorbent materials have equivalent chemical compositions, and (a) the third geometry differs from the first and second geometries, (b), the third sorbent material differs from the first and second sorbent materials in at least one physical characteristic, or (c) the third geometry differs from either the first geometry or the second geometry and the third sorbent material differs from either the first sorbent material or the second sorbent material in at least one physical property.

35. The sorbent cartridge of claim 13, wherein the first and second sorbent materials have identical chemical compositions.

36. The sorbent cartridge of claim 13, wherein the first and second sorbent materials comprise at least one cation exchanger.

37. The sorbent cartridge of claim 36, wherein the first and second sorbent materials comprise the same cation exchanger.

38. The sorbent cartridge of claim 37, wherein the cation exchanger comprises zirconium phosphate.

39. The sorbent cartridge of claim 36, wherein the first sorbent layer has a greater cation exchange capacity than the second sorbent layer.

40. The sorbent cartridge of claim 13, wherein the first and second sorbent materials comprise at least one anion exchanger.

41. The sorbent cartridge of claim 40, wherein the first and second sorbent materials comprise the same anion exchanger.

42. The sorbent cartridge of claim 41, wherein the anion exchanger comprises hydrous zirconium oxide.

43. The sorbent cartridge of claim 42, wherein the anion exchanger further comprises zirconium carbonate.

44. The sorbent cartridge of claim 40, wherein the first sorbent layer has a greater anion exchange capacity than the second sorbent layer.

45. The sorbent cartridge of claim 13, wherein the first and second sorbent materials comprise urease.

46. The sorbent cartridge of claim 13, wherein the first and second sorbent materials comprise activated carbon.

47. The sorbent cartridge of claim 1 having an inlet and outlet comprising at least a first layer and a second layer, wherein the first layer and the second layer comprise particulate material having the same or substantially the same chemical composition and wherein the first layer is located closer to the inlet than the second layer and wherein the particulate material in the first layer has at least a greater/higher property then the particulate material in the second layer with respect to a) average particle size, b) average surface area, or c) adsorption capacity for at least one species, wherein the first layer and second layer are selected from said carbon-containing layer, said enzyme-comprising layer, said zirconium phosphate-containing layer, said hydrous zirconium oxide layer and the combination thereof.

48. A method of making the sorbent cartridge of claim 1, wherein said enzyme-comprising layer contains urease, said method comprising:

a) dissolving Jack Bean meal containing organic impurities in an organic solvent;

b) evaporating the organic solvent and at least a portion of the organic impurities as volatiles to separate the volatiles from a non-volatized residue comprising urease;

c) drying the residue comprising urease to provide dry urease-containing material; and

d) incorporating the dry urease-containing material between carbon-containing layers in a sorbent cartridge that includes zirconium phosphate without a layer of zirconium phosphate being between either of the carbon-containing layers and the dry urease-containing material.

49. A sorbent cartridge comprising from inlet to outlet:

a) a first carbon-containing layer;

b) an enzyme-comprising layer that follows the first carbon-containing layer within the sorbent cartridge;

c) a second carbon-containing layer that follows the enzyme-comprising layer within the sorbent cartridge;

d) a zirconium phosphate-containing layer that follows the second carbon-containing layer within the sorbent cartridge, wherein the zirconium phosphate-containing layer comprises sodium loading of greater than 55 mg Na/g zirconium phosphate;

e) a hydrous zirconium oxide layer that follows the zirconium phosphate-containing layer comprising hydrous zirconium oxide-chloride having an alkaline pH; and

f) a (bi)carbonate layer that follows the hydrous zirconium oxide layer comprising sodium (bi)carbonate.

50. The sorbent cartridge of claim 49, wherein the zirconium phosphate-containing layer comprises sodium loading of about 56 to about 58 mg Na/g zirconium phosphate.

51. The sorbent cartridge of claim 49, wherein the zirconium phosphate-containing layer comprises sodium loading of about 57 mg Na/g zirconium phosphate.

52. The sorbent cartridge of claim 49, wherein the hydrous zirconium oxide-chloride has a pH greater than about 8.

53. The sorbent cartridge of claim 49, wherein the hydrous zirconium oxide-chloride has a pH greater than about 9.

54. The sorbent cartridge of claim 49, wherein the hydrous zirconium oxide-chloride has a pH of from about 9.5 to about 10.5.

55. The sorbent cartridge of claim 49, wherein the (bi)carbonate layer comprising sodium bicarbonate.

56. The sorbent cartridge of claim 49, wherein the first carbon-containing layer is a layer of granular activated carbon or a carbon pad, and the second carbon-containing layer is a layer of granular activated carbon or a carbon pad.

57. The sorbent cartridge of claim 49, wherein the enzyme-comprising layer comprises a Jack Bean meal/alumina blend.

58. The sorbent cartridge of claim 49, further comprising an alumina-containing layer between the enzyme- comprising layer and the second carbon-containing layer.

59. A method to regenerate or purify spent dialysis fluid comprising passing spent dialysis fluid through the sorbent cartridge of claim 49.

60. A dialysis system to regenerate or purify spent dialysis fluid comprising the sorbent cartridge of claim 49.